Transmission Power Flow Module With Lightweight Clutch Drum Replacement
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Solution Overview
Problem
The existing OE THM400 transmission is not suitable for racing applications due to its heavy and massive direct clutch drum, which results in lost momentum, power, and speed during rotational starting, stopping, and changing directions, leading to stress failures and inefficiencies.
Innovation Solution
A modified transmission kit and power flow module that replaces the heavy direct clutch drum with lighter, smaller diameter components, including a forward piston housing, direct piston housing, and a sprag shaft, which are modularly designed to reduce mass and increase strength, incorporating a shared pressure plate and needle bearings for improved alignment and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heavy direct clutch drum is used in the OE transmission, then the transmission structure is robust and reliable, but the rotational mass causes lost momentum, power, and speed during starting, stopping, and direction changes
Solution Approach 1:
The patent divides the original direct clutch drum assembly into separate functional components: a direct clutch hub, sprag clutch mechanism, and drum. This segmentation allows each component to be optimized independently, reducing overall mass while maintaining structural integrity and reliability during rotational operations
Solution Approach 2:
The patent employs composite construction by combining different materials and component types (sprag clutch elements, hub structure, drum) to create an integrated assembly that achieves both high reliability and reduced weight. The composite design allows strategic placement of high-strength materials only where necessary
2Force
If the massive direct clutch drum is used, then the transmission can handle high torque, but stress failures occur during starting, stopping, and changing directions
Solution Approach 1:
The patent introduces dynamic elements including the sprag clutch mechanism and modular hub design that allow the transmission to adapt to varying torque loads. The dynamic configuration enables stress distribution across multiple components during starting, stopping, and direction changes, preventing stress concentration and failures
Solution Approach 2:
By segmenting the torque transmission path through separate hub, sprag, and drum components, the patent distributes stress across multiple interfaces and load paths. This segmentation prevents any single component from bearing excessive stress during transient operations
3Stability of the object's composition
If the heavy direct clutch drum is used, then the transmission structure is stable, but momentum is lost during rotational operations
Solution Approach 1:
The patent changes the mass parameter of the rotating components by reducing the drum weight while maintaining structural stability through optimized geometry and material distribution. This parameter change reduces the moment of inertia, minimizing momentum loss during starting, stopping, and direction changes while preserving structural integrity
Data Source
AI summary
A kit for modifying an OE vehicle transmission includes a replacement forward piston housing, forward clutch hub and a forward clutch and a replacement direct piston housing, direct clutch hub and a direct clutch. A drum extends between and operably connects the replacement forward piston housing and direct piston housing. The kit includes a replacement sprag shaft. The forward clutch hub and forward clutch and the direct clutch hub and direct clutch are positioned between the forward piston housing and the direct piston housing. At least a portion of the forward clutch and at least a portion of the direct clutch are operably mounted to the drum. The forward piston housing and direct piston housing do not counter rotate relative to one another. A power flow module for an OE vehicle automatic transmission is disclosed.