Variable Pitch Stator Framework for Torque Converter Manufacturing
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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 previous attempts at variable pitch stators were labor-intensive and costly due to the need for individual assembly of stator blades, leading to high scrap rates.
Innovation Solution
A method for manufacturing a variable pitch torque converter stator involving a framework with an outer ring, blades, pivot members, and actuation members, where the pivot and actuation members are non-rotatably coupled to the blades, allowing for the adjustment of blade pitch through die casting or injection molding, and forming the framework as a single piece to reduce assembly errors and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed pitch stators are used to optimize performance across a range of operating speeds, then overall performance is improved, but performance at specific speeds becomes suboptimal
Solution Approach 1:
The stator blade pitch is made variable through a mechanical linkage system connected to a pivot member that can rotate. This allows the blade pitch angle to dynamically adjust based on operating conditions, enabling optimization at specific speeds while maintaining overall system performance across the full operating range.
Solution Approach 2:
The pitch angle parameter of the stator blades is changed by rotating the pivot member to different angular positions. This parameter variation allows the torque converter to adapt to different operating speeds and conditions, resolving the contradiction between fixed optimization and specific speed performance.
2Adaptability or versatility
If variable pitch stators are assembled with individual blade handling, then blade pitch can be adjusted, but manufacturing cost and labor intensity increase significantly
Solution Approach 1:
Multiple stator blades are merged into a single integrated framework structure where all blades are simultaneously supported and positioned by a common pivot member and linkage system. This merging eliminates the need for individual blade assembly, dramatically reducing manufacturing complexity and labor requirements while maintaining variable pitch capability.
Solution Approach 2:
The framework structure serves multiple functions simultaneously: it supports all stator blades, provides the pivot mechanism, contains the linkage system, and enables pitch adjustment for all blades through a single control input. This multi-functionality resolves the manufacturing complexity issue by consolidating what would otherwise require separate assembly operations.
3Manufacturing precision
If traditional assembly methods are used for variable pitch stators, then blade positioning is possible, but scrap rates increase due to assembly errors
Solution Approach 1:
The framework is pre-configured with all blade mounting positions, pivot locations, and linkage connections established during manufacturing. This preliminary action ensures that when blades are installed, they are automatically positioned with high precision, eliminating assembly errors and improving reliability.
Solution Approach 2:
By merging all blade support and positioning functions into a single pre-manufactured framework, the system eliminates multiple separate assembly operations that could introduce errors. The integrated structure ensures consistent, precise blade positioning across all installations, resolving the contradiction between positioning accuracy and error rates.
Data Source
AI summary
A method of manufacturing a variable pitch torque converter stator includes positioning a framework, including an outer ring, a plurality of blades, a plurality of pivot members, and a plurality of actuation members, so the pivot members are seated in a stator body and the actuation members are coupled to a stator piston, with the pivot and actuation members being non-rotatably coupled to opposite ends of corresponding blades. The method includes removing the outer ring from the framework.