Variable Pitch Stator with Pivotable Blades and Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional torque converters with fixed pitch stators optimize performance across a range of operating speeds but result in suboptimal performance at specific speeds, and attempts at variable pitch stators are labor-intensive and costly due to the need for individual assembly of each blade, leading to higher scrap rates.
Innovation Solution
A variable pitch torque converter stator design featuring a hub, outer ring, and pivotable blades supported by spokes and actuation members, allowing for adjustable blade pitch through an actuator, enabling optimal performance at specific speeds while reducing production costs and assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If variable pitch stators are produced with individual blade assembly, then adjustable blade pitch is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent applies segmentation by dividing the stator into modular components: blades, pivot members, actuation members, and a control system. Each blade assembly can be manufactured separately and then assembled into the stator, allowing for standardized production of blade modules that can be systematically configured. This modular approach reduces the complexity of handling entire blades individually while maintaining the ability to adjust pitch angles
Solution Approach 2:
The patent implements universality through the use of standardized pivot members and actuation members that can work with multiple different blade configurations. The control system uses universal connection points and actuation mechanisms that can position any blade at any pitch angle, reducing the need for custom components for each variable pitch configuration and simplifying the overall assembly process
2Adaptability or versatility
If variable pitch stators are produced with individual blade assembly, then adjustable blade pitch is achieved, but production time and cost increase making them prohibitive for large production quantities
Solution Approach 1:
The patent applies preliminary action by pre-configuring blade assemblies with their pivot members and actuation mechanisms before final stator assembly. Blade modules can be manufactured and tested independently, with pitch angles pre-set or pre-programmed into the control system. This allows for parallel production of multiple blade modules simultaneously, significantly reducing overall production time compared to assembling complete variable pitch stators blade-by-blade in a sequential process
Solution Approach 2:
The patent implements copying through the use of standardized, repeatable blade module designs that can be manufactured using the same tooling and assembly procedures. Once a blade module design is validated, identical copies can be produced efficiently using automated manufacturing processes, reducing both unit cost and production time while maintaining consistent performance across all variable pitch assemblies
3Ease of manufacture
If traditional fixed pitch stator design is used, then manufacturing is simpler and more cost-effective, but performance optimization at specific operating speeds is limited
Solution Approach 1:
The patent applies parameter changes by making the blade pitch angle a variable parameter rather than a fixed design value. The control system can adjust the pitch angle of individual blades or groups of blades based on real-time operating conditions such as vehicle speed, engine load, and transmission gear selection. This allows the stator to optimize its hydraulic characteristics for different operating points while maintaining a relatively simple overall structure that can be manufactured using conventional processes
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
The design allows for robust, cost-effective, and time-efficient manufacturing of torque converters with adjustable blade pitch, optimizing power, fuel efficiency, and noise reduction, while also addressing turbo-lag issues in turbocharged vehicles.
Implementation Method 1
The actuator is coupled to the actuation members and configured to move the actuation members to pivot the blades
Implementation Method 2
Each pivot member extends from a first side of a corresponding one of the blades. Each actuation member extends from a second side of a corresponding one of the blades
Data Source
AI summary
A torque converter stator includes a hub, an outer ring, a plurality of blades, and a plurality of spokes. The hub is disposed about an axis. The blades are disposed radially between the outer ring and the hub. All of the blades are pivotable relative to the hub and outer ring. The spokes are spaced apart from the blades and fixed to the hub and the outer ring to support the outer ring relative to the hub.