Torque Converter Toothed Coupling for Blind Hybrid Assembly
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Solution Overview
Problem
Existing hybrid powertrain systems face challenges in efficiently connecting torque converters to actuators, particularly in ensuring secure and accessible assembly without requiring extensive worker access, which affects the reliability and efficiency of power transmission.
Innovation Solution
The implementation of a torque converter design featuring a front cover with an impeller and turbine supported for rotation about an axial centerline, coupled with a connecting assembly that includes axially extending teeth on the rotor shaft and hub portion, allowing for a toothed connection that facilitates blind assembly and secure engagement with the electric machine, enabling efficient power transmission without the need for extensive access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional torque converter connection design is used, then the structure is simple, but the assembly requires extensive worker access and is difficult to assemble securely
Solution Approach 1:
The rotor shaft is nested within the torque converter housing, with the connecting assembly integrated into the housing structure. The teeth on the rotor shaft engage with corresponding teeth in the housing, creating a nested connection that secures the rotor shaft within the torque converter without requiring external fasteners or extensive access.
Solution Approach 2:
The connecting assembly acts as an intermediary between the rotor shaft and the torque converter housing. It includes engagement features such as teeth or splines that mediate the connection, allowing secure power transmission while accommodating misalignment and reducing the need for precise manual assembly.
2Reliability
If a secure toothed connection is implemented, then power transmission reliability improves, but assembly complexity increases
Solution Approach 1:
The connecting assembly is merged with the torque converter housing, eliminating the need for separate connection components. The teeth for engagement are directly formed on the housing interior surface, combining the housing and connection features into a single integrated structure that reduces overall complexity.
Solution Approach 2:
The torque converter housing serves multiple functions: it contains the fluid coupling components (impeller, turbine), provides structural support, and incorporates the connecting assembly for rotor shaft engagement. This multi-functionality reduces the number of separate components needed while maintaining reliable power transmission.
3Ease of operation
If the rotor shaft is made removable for assembly, then assembly accessibility improves, but connection security and power transmission reliability deteriorate
Solution Approach 1:
The rotor shaft is pre-aligned with the torque converter housing using a pilot or alignment feature before the final engagement. This preliminary action ensures proper positioning of the teeth on the rotor shaft with the corresponding teeth in the housing, allowing for easy assembly while maintaining secure connection without requiring the shaft to be removable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the assembly process by allowing for secure and efficient connection of the torque converter to the electric machine, improving power transmission reliability and reducing assembly complexity, while maintaining accessibility for proper alignment and installation.
Implementation Method 1
a turbine adjacent the impeller and configured to fluidly couple with the impeller
Implementation Method 2
The hub portion has a second inner circumferential surface defining axially extending teeth configured to engage with a rotor shaft
Data Source
AI summary
A torque converter is configured to connect with an electric machine via a connecting assembly. The torque converter includes a front cover facing the electric machine. The connecting assembly is non-rotatably fixed to the front cover to be coaxial with a rotor shaft of the electric machine. The connecting assembly defines axially extending teeth configured to engage the electric machine.