Torque Converter Hub Weld Recess for Stronger Plate Joints
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Solution Overview
Problem
Existing welded connections between torque converter components, such as impeller or turbine hubs and shells, lack sufficient strength and durability, leading to failures and stress concentration issues, while also occupying excessive space.
Innovation Solution
A method of forming a welded connection between a hub and a plate component in a transmission assembly by creating a flare bevel with an axial extension that exceeds the thickness of the radially extending portion, allowing the weld to be placed in a recess between the flare bevel and the hub, and then removing part of the axial extension post-welding, which reduces stress concentration and allows for increased weld size and penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional welded connection is used between hub and plate component, then the assembly is simple to manufacture, but the weld strength is insufficient and stress concentration occurs
Solution Approach 1:
The invention transitions from a conventional planar weld to a three-dimensional recess weld. The flare bevel creates a recess that extends axially beyond the plate thickness, allowing the weld to be positioned in a new spatial dimension. This enables the weld gun to access and deposit weld material at greater thickness components, increasing weld size and penetration while distributing stress more effectively through the three-dimensional geometry.
Solution Approach 2:
The invention changes the geometric parameters of the connection by creating a flare bevel with a specific angle and depth. The recess is formed with controlled dimensions that allow the weld to sit within it, changing the weld position from the surface level to a recessed location. This parameter change enables increased weld penetration and size while reducing stress concentration at the connection interface.
2Strength
If the weld is placed at the surface level, then the connection is easier to access, but stress concentration contours increase and weld penetration is limited
Solution Approach 1:
The recess created by the flare bevel provides a new spatial dimension for weld placement. Instead of welding at the surface level, the weld is deposited within the recessed area, allowing the weld gun to be positioned at an optimal angle and depth. This dimensional change enables the weld to reach greater thickness components while the recess geometry facilitates proper weld gun alignment and material deposition.
3Reliability
If the axial extension is removed after welding, then the stress concentration is reduced, but an additional machining step is required
Solution Approach 1:
The flare bevel with axial extension is created as a preliminary action before welding. This pre-formed recess structure prepares the connection geometry to reduce stress concentration during the welding process itself. The axial extension is intentionally left protruding after welding, and its subsequent removal is a final finishing step that completes the stress reduction benefit already established by the recess geometry.
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 method enhances the strength and reliability of the welded connection by aligning the weld with the thicker components, reducing stress, and avoiding prior stress concentration issues, while maintaining compact dimensions.
Implementation Method 1
welding in a recess formed between the flare bevel and the hub to connect the plate component to the hub with the weld
Data Source
AI summary
A method of forming a welded connection between a hub and a plate component in a transmission assembly is provided. The method includes providing the plate component which includes a radially extending portion and an opening in a connection region to the hub, forming a flare bevel with an axial extension that extends beyond a projection of a thickness of the radially extending portion of the plate component at the opening, locating the plate component with the flare bevel and at least a portion of the axial extension on the hub, welding in a recess formed between the flare bevel and the hub to connect the plate component to the hub with the weld, and removing at least a portion of the axial extension after the welding.