WO2008049010A2 - Convertisseur de couple léger - Google Patents

Convertisseur de couple léger Download PDF

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Publication number
WO2008049010A2
WO2008049010A2 PCT/US2007/081655 US2007081655W WO2008049010A2 WO 2008049010 A2 WO2008049010 A2 WO 2008049010A2 US 2007081655 W US2007081655 W US 2007081655W WO 2008049010 A2 WO2008049010 A2 WO 2008049010A2
Authority
WO
WIPO (PCT)
Prior art keywords
turbine
pump
sheet
shell
ring
Prior art date
Application number
PCT/US2007/081655
Other languages
English (en)
Other versions
WO2008049010A3 (fr
Inventor
Dinesh C. Seksaria
John W. Cobes, Jr.
Original Assignee
Alcoa Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Inc. filed Critical Alcoa Inc.
Publication of WO2008049010A2 publication Critical patent/WO2008049010A2/fr
Publication of WO2008049010A3 publication Critical patent/WO2008049010A3/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H45/00—Combinations of fluid gearings for conveying rotary motion with couplings or clutches
    • F16H45/02—Combinations of fluid gearings for conveying rotary motion with couplings or clutches with mechanical clutches for bridging a fluid gearing of the hydrokinetic type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H41/00—Rotary fluid gearing of the hydrokinetic type
    • F16H41/24—Details
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H45/00—Combinations of fluid gearings for conveying rotary motion with couplings or clutches
    • F16H45/02—Combinations of fluid gearings for conveying rotary motion with couplings or clutches with mechanical clutches for bridging a fluid gearing of the hydrokinetic type
    • F16H2045/0273—Combinations of fluid gearings for conveying rotary motion with couplings or clutches with mechanical clutches for bridging a fluid gearing of the hydrokinetic type characterised by the type of the friction surface of the lock-up clutch
    • F16H2045/0294—Single disk type lock-up clutch, i.e. using a single disc engaged between friction members

Definitions

  • One embodiment of the present invention is directed toa hydrokinetic couplings, for example, including torque converters having a plurality of aluminum alloy components for use in automatic transmission powertrains of the type which are typically installed in, such as, automobiles and trucks. Further, the invention also includes a method of manufacturing torque converters.
  • Torque converters have traditionally been made from stamped-steel components.
  • steel components limits potential maximum output efficiency and reduced mass moment of inertia due to the weight of steel and the attachment structure of the steel components and incorporate coiled springs to dampen torsional vibrations.
  • Figure 1 is a cross section of one embodiment of the torque converter having a torsional damper according to the present invention
  • Figure Ia represents a perspective view of one embodiment of an assembled torque converter, in accordance with the present invention.
  • Figure Ib represents an exploded view of one embodiment of a torque converter, in accordance with the present invention.
  • Figure 2a represents a perspective view of exterior surface of one embodiment of a torque converter cover, in accordance with the present invention.
  • Figure 2b represents a perspective view of the interior surface of one embodiment of a torque converter cover, in accordance with the present invention.
  • Figure 3a represents a perspective view of one embodiment of a lockup clutch assembly for use in a torque converter, in accordance with the present invention
  • Figure 3b represents an exploded view of the lockup clutch assembly
  • FIGS. 3 c and 3d are illustrations of two embodiments of wave springs
  • Figures 3e and 3f are illustrations of one embodiment of a wave spring contracting/deflection and expanding/springing back;
  • Figure 3g is front view of one embodiment of the lockup clutch plate
  • Figure 4a depicts a perspective view of one embodiment of a turbine assembly, in accordance with the present invention
  • Figure 4b depicts an exploded view of the turbine assembly depicted in Figure 4a;
  • Figure 4c depicts a section view of one embodiment of the attachment of the turbine hub to the turbine shell, in accordance with the present invention
  • Figure 4d is a magnified view of Figure 4a turbine shell and unitary turbine vortex ring and blade array structure complimentary features;
  • Figure 5 depicts a elevated plan view of one embodiment of a stator, in accordance with the present invention.
  • Figure 6a depicts a perspective view of one embodiment of a pump assembly, in accordance with the present invention.
  • Figure 6b depicts a perspective view of a sectioned pump shell and a unitary pump vortex ring and blade array structure of one embodiment of a pump assembly, and further depicts the metallurgical braze joint connectivity of the unitary vortex ring and blade array structure to the pump shell, in accordance with the present invention
  • Figure 6c depicts an exploded view of the pump assembly depicted in Figure 6a;
  • Figure 6d is a magnified view of Figure 6b pump shell 37 and unitary pump vortex ring and blade array structure 38 complimentary features;
  • Figure 7 depicts a perspective view of a flexplate.
  • FIGS 1, 1a, and Ib depict one embodiment of a torque converter 10, in accordance with the present invention, including a cover assembly 15, lockup clutch assembly 20, turbine assembly 25, stator assembly 30, and pump assembly 35.
  • the cover assembly 15 may include a cover 16 can be formed of a metal sheet material, a pilot hub 17, and a plurality of engagement members 18 for attachment to a motor system (not shown), such as through a flexplate 60.
  • the lockup clutch assembly 20 may include a lockup clutch plate 21, a friction ring 22, a sealing member 23, and a gear ring 24.
  • the turbine assembly 25 may include a turbine hub 26, a turbine shell 27, and a unitary turbine vortex ring and blade array structure 28.
  • the stator assembly 30 may include a stator blade array 31, and a one-way clutch assembly 32 (Sprague).
  • the pump assembly 35 may include a pump hub 36, a pump shell 37, and a unitary pump vortex ring and blade array structure 38.
  • Figure 2a depicts the exterior face of the cover assembly 15 including a cover 16, can be formed of a metal sheet material composed of an aluminum alloy; a centrally positioned pilot hub 17, can be composed of a steel material; and a plurality of engagement members 18, can be composed of a steel material.
  • the cover 16 can be made from 6061 T4 plate by stamping and can be heat treated to high strength T6 temper. It can be machined to the final dimensions.
  • Cover 37 comprising a connector 36 adapted for fluid communication with a hydraulic system and is connected with the cover 16 to form an inner cavity 10a, wherein the inner cavity 10a is sized to house the lockup clutch plate 21, the monolithic blade structure 28, the monolithic pump structure 38, and the stator 31 therein.
  • the lockup clutch plate 21, the monolithic blade structure 28, the monolithic pump structure 38, and the stator 31 are operably connect and capable of fluid communication therebetween.
  • monolithic is defined to describe a component that is made or formed into or from a single item and not from multiple parts and integral is defined as consisting or composed of parts that together constitute a component.
  • the cover 16 is composed of an Aluminum Association 6xxx series aluminum alloy, in which the main alloying constituents include Si, Cu, Mg, and Cr, and can be Aluminum Association 6061 aluminum alloy, such as 0.40-0.8 wt. % Si, less than 0.7 wt. % Fe, 0.15-0.40 wt. % Cu, less than 0.15 wt. % Mn, 0.8-1.2 wt. % Mg, 0.04- 0.35 wt. % Cr, less than 0.25 wt % Zn, less than 0.15 wt. % Ti and a balance of Al with incidental impurities individually being less than 0.05 wt. % and totaling less than 0.15 wt %.
  • Cover 16 can be formed using a stamping operation and has a geometry providing an friction engaging surface 19 on the interior face 16i of the cover 16 for frictional engagement to the friction ring 22 of the lockup clutch assembly 20, as depicted in Figure Ib.
  • the pilot hub 17 can be composed of a steel material, is centrally positioned on the exterior face 16e of the cover 16 and joined to the aluminum alloy cover 16 by projection welding.
  • the plurality of engagement members 18, similar to the pilot hub 17 can be composed of a steel material and joined to the aluminum alloy cover 16 by projection welding.
  • One embodiment of the engagement members 18 are configured to provide for mechanical fastening to the flex plate 60 (Fig. 1), such as by nut and bolt arrangement, wherein the nut member is provided by the engagement members 18.
  • Projection welding is a form of resistance welding, which produces coalescence of metals with the heat obtained from resistance to electrical current through the work parts held together under pressure by electrodes.
  • the resulting welds are localized at predete ⁇ nined points by projections, embossments, or intersections. Localization of heating is obtained by a projection or embossment on one or both of the parts being welded. By localizing heating through projection welding minimizes, eliminating the formation of a heat effected zone between at the interface of the aluminum alloy cover 16 and the steel pilot hub 17 and/or the plurality of engagement members 18.
  • a heat effected zone typically results from being subjected to high temperatures resulting in the formation of mechanical property reducing intermetallics at the junction of the two materials being joined, which typically results in a substantial reduction in the mechanical properties of the structures being metallurgically joined.
  • the heat effected zone typically has decreased tensile strength, elongation, and hardness when compared to the base metal of the structures being joined, which are not subjected to the heat effect.
  • the mechanical properties of the aluminum alloy cover and the steel pilot and engaging member following joining is substantially equal to the mechanical properties of the components prior to joining due to the localized heating resulting from projection welding that minimizes the formation of the heat effected zone.
  • FIGS 3a and 3b depict one embodiment of a lockup clutch assembly 20, in accordance with the present invention.
  • the lockup clutch plate 21 is formed using a stamping operation and can be composed of an Aluminum Association 6xxx series aluminum alloy, in which the main alloying constituents include Si, Cu, Mg, and Cr, and representative of Aluminum Association 6013 aluminum alloy, including 0.40-0.8 wt. % Si, less than 0.7 wt. % Fe, 0.15-0.40 wt. % Cu, less than 0.15 wt. % Mn, 0.8-1.2 wt. % Mg, 0.04-0.35 wt. % Cr, less than 0.25 wt % Zn, less than 0.15 wt. % Ti, and a balance of Al with incidental impurities individually being less than 0.05 wt. % and totaling less than 0.15 wt %.
  • the clutch assembly 20 of the present invention utilizes the higher flexibility (i.e., lower elastic modulus) of aluminum along with the damping ability of a polymer seal 23 to provide torsional flexibility in providing a smooth engagement of the clutch during operation of the torque converter and for reducing the vibration for engine torque pulses without the use of a separate spring mechanism such as coil springs.
  • lockup clutch plate input torsional load is transmitted from friction ring 22 into lockup clutch plate 21 through rim portion 21d and substantially follows a torsional load path from rim portion 21d to outer extensions 21b to generally trapezoidal or wedge section 21a to arms 50 to inner extensions 21c to hub portion 21 e to ring gear 26 to the mating components of torque converter 10 and ultimately into the hydraulic system of the transmission (Fig. 3g).
  • the torsional loads and stresses are diminished in magnitude as it progresses along the lockup clutch plate torsional load path described above.
  • An exemplary embodiment of the lockup clutch plate 21 includes a plurality of integrally formed or monolithic arms 50.
  • the term "integrally formed” denotes that the arms 50 are formed from the same sheet or part as the lockup clutch plate 21 and not a separate part assembled to the lockup clutch plate 21. Any conventional manufacturing process to form the integral component is acceptable, for example, a stamping operation.
  • Arms 50 are configured to dampen vibration upon engagement of the torque converter systems with interfacing/mating dynamic systems and are illustrated and referred to hereinbelow as wave springs 50. Two examples of wave springs 50 are illustrated in Figures 3c and 3d.
  • wave springs 50 can be defined by post- formed or post-stamped deformation of surfaces 21 f and 21 g of lockup clutch plate 21, for example, by dimensional drops from surfaces 21f and 21g (such as X 1 , X 2 , X 3 , X 4 , and X 5 ), internal radius R x , and external radius R y .
  • Other geometric representations of wave springs 50 are also acceptable.
  • the torque converter systems engage motor systems that have a forcing frequency that causes a disturbing or resonant frequency.
  • the wave springs 50 result in the natural frequency of the clutch to be at a different natural frequency than the engine to minimize or eliminate resonant or otherwise to avoid resonant frequency.
  • the wave springs 50 can be tuned to set the lockup clutch plate natural frequency to a predetermined value, for example above the natural frequency of an engine, that varies from system-to-system but is determinable by conventional analytical and empirical methods.
  • Wave springs 50 can be tuned by adjusting one or more of the physical features of wave spring 50 including, but not limited to, dimensional drops from lockup clutch plate surfaces 21f and 21 g (such as X 1 , X 2 , X 3 , X 4 , and X 5 ), internal radius R x , external radius R y, inner radius (Ri), outer radius (R 2 ), width (W), gaps Gi and G 2 .
  • the plurality of wave springs 50 define a predetermined spring rate such that high and low frequency torsional forces generated between the engine and lockup clutch plate 21 are dampened through to contraction/deflection (Fig. 3e) and expansion/spring back (Fig. 3f) of wave springs 50.
  • the adjacently arranged wave springs 50 are interconnected at their respective ends 50a, 50b by the substantially flat section 21a.
  • the torsional load is transmitted from one wave spring to the direct adjacent wave spring through the substantially flat section 21a.
  • the directly adjacent wave spring expansion or springs back to original position.
  • This cooperative interaction between directly adjacent wave springs will dampen the oscillating frequency of the torsional load.
  • coiled springs of the conventional torsional damper can be eliminated.
  • the damping mechanism (arms or wave springs 50) does not interconnect or interact directly with adjacent or mating components of torque converter 10, such as turbine assembly 25, stator assembly 30, or pump assembly 35.
  • lockup clutch 21 includes a stamped aluminum part made from, for example, high strength 6013 aluminum alloy and takes advantage of the lower elastic modulus of aluminum compared to steel to obtain more springiness or resilience to operating torsional stresses and pulsations.
  • Lockup clutch plate 21 can be stamped in the T4 temper and can be heat treated to T6 for maximum strength and durability.
  • Lockup clutch plate 21 is illustrated having an integral series of eight tangential a ⁇ ns or wave springs 50, equally spaced around the centeiiine (CL) and located approximately at inner radius (Ri) and outer radius (R 2 ), wherein the radii difference (R 2 -Ri) defines the approximate width (W) of wave spring 50.
  • Wave springs 50 can be separated by a substantially flat and generally trapezoidal or wedge section 21a having a predetermined average width (P).
  • Wave springs 50 can be represented by a partial circular sector having angle ⁇ and an area (A) approximately equal to 0.5( ⁇ )(R 2 -Ri) 2 and arc length S approximately equal to ( ⁇ )(R n ), where R n is any radius including and between inner radius (Ri) and outer radius (R 2 ).
  • the width (W) of wave spring 50 may vary within the partial sector is adjustable be any conventional forming operation, such as trimming.
  • Lockup clutch plate 21 can also include outer extensions 21b and inner extensions 21c to secure substantially flat section 21 to either rim portion 21 d or hub portion 2 Ie, respectively.
  • One of ordinary skill in the art can size and shape the above features to tune-in the required torsional spring rate (k). It is within the contemplation of the invention that one or more of the above features can be eliminated depending on the desired dynamic response of the system.
  • Arms 50 have been illustrated as a specifically shaped profile and a series of wave- like form normal to it to tune the performance of the clutch. However, any shaped profile and partial sector having ⁇ , S, R 1 , R 2 , and W is acceptable.
  • clutch assembly 20 further includes polymer seal 23 configured to seal at least wave spring 50 portions of lockup clutch plate 21.
  • the polymer material maybe molded over the lockup clutch plate 21 filling the spaces between the arms 50 as well as forming the lip seal to the center shaft. This rubber like polymer material bonded to the arms 50 provides additional damping and can be tuned to obtain the desired damping characteristics.
  • the friction ring 22 may be a high f ⁇ ctional material, such as a ceramic material or other typically used brake material, and may be deposited on to the clutch assembly 20 or may be adhesively bound, providing the friction ring 22 is configured to engage the friction engaging surface 19 on the interior face 16i of the cover 16.
  • the gear ring 24 can be composed of hardened steel and configured for engagement to an exterior teeth 26e of the turbine hub 26 (Fig. 4b). hi one embodiment, gear ring 24 is centrally positioned to the lockup clutch plate 21 and is joined by friction welding. Friction welding involves the joining of metals without fusion or filler materials. The welds are created by the combined action of frictional heating and mechanical deformation. The maximum temperature reached is of the order of 0.8 of the melting temperature.
  • FIGS 4a-4d depict one embodiment of a turbine assembly 25, in accordance with the present invention.
  • Unitary or integral turbine vortex ring and blade array structure 28 includes a plurality of blades 28b and vortex ring 28a.
  • the term unitary turbine vortex ring and blade array structure 28 denotes that the vortex ring 28a and blades 28b that form the blade array are a produced in a singular casting.
  • Blade 28b can include an airfoil section 100 having a curved surface 100a that is complimentary to interior surface 27a of turbine shell 27, varying height 100b measured from root lOOd to curved surface 100a, and varying thickness 100c that varies along root lOOd and height 100b.
  • Blade thickness 100c increases from root lOOd to curved surface 100a.
  • Unitary or integral turbine vortex ring and blade array structure 28 is adjacently positioned with relationship to turbine shell 27 and heated to the melting temperature of the braze material.
  • Curved surface 100a can be positioned directly adjacent to interior surface 27a of turbine shell 27 such that the liquidous braze material will flow and fill the gap between curved surface 100a and interior surface 27a to form a fluid-tight seal to eliminate leakage between Unitary or integral turbine vortex ring and blade array structure 28 and shell 27, which causes turbulence.
  • the braze joint provides additional surface area to form a path to carry or transfer torsional load or stress.
  • the unitary turbine vortex ring structure and blade array 28 further includes at least one joining ring 51, wherein the at least one joining ring 51 includes a surface 51a complimentary with at least one annular groove 52 formed in the turbine shell 27 to provide a site for at least one of the braze joint metallurgical bond between the unitary turbine vortex ring and blade array structure 28 and the sheet turbine shell 27.
  • Unitary turbine vortex ring and blade array structure 28 can be cast from an aluminum alloy, for example, an Aluminum Association 3xx series aluminum alloy, such as Aluminum Association A356 and the alloy discussed in U.S. Patent No. 6,783,730.
  • 6,783,730 titled Al-Ni- Mn casting alloy for automotive and aerospace structural components, discloses another highly aluminum casting alloy for the unitary turbine vortex ring and blade array structure 28 and includes about 2-6 wt % Ni, about 1-3 wt. % Mn, less than about 1 wt. % Fe, and less than about 1 wt. % Si, with incidental elements and impurities, the disclosure of U.S. Patent No. 6,783,730 being incorporated in its entirety by reference.
  • the braze joint provides additional surface area to form a path to carry or transfer torsional load or stress.
  • the turbine shell 27 is formed in a spinning operation from an aluminum alloy sheet material, for example a brazing sheet material.
  • the turbine shell 37 further comprises a series of annular grooves 52 located circumferential at predetermined radii (Ri) from the center line along the interior surface 27a (Fig. 4b), wherein the at least one joining ring 51- of the unitary turbine vortex ring 28 compliments the at least one annular groove 52 to provide a site for at least one of the braze joint metallurgical bond between the unitary turbine vortex ring and blade array structure 28 and the sheet turbine shell 27.
  • the brazing sheet material of the turbine shell 27 can include a layered sheet composed of a prefluxed or non-prefluxed layer of Aluminum Association 4xxx series alloy, in which the prefluxed face of the brazing sheet is positioned to provide the surface for brazing engagement of the unitary turbine vortex ring and blade array structure 28.
  • the face of the brazing sheet from which the turbine shell 27 is formed is positioned to provide the surface for brazed engagement by braze joint metallurgical bond to the unitary turbine vortex ring and blade array structure 28.
  • This brazing operation is blind brazing of complex geometry without the intervention of an operator or technician to adjust the mating components for the desired match up or alignment of adjacent braze surfaces to produce the desire brazed joint.
  • the brazing sheet of the turbine shell 27 can be composed of at least one layer of Aluminum Association 4047 aluminum having a thickness that, for example, ranges from 0.1 to 0.3 mm thick, which can include 11.0-13.0 wt. % Si, less than 0.8 wt. % Fe, less than 0.30 wt. % Cu, less than 0.15 wt. % Mn, less than 0.1 wt. % Mg, less than 0.2 wt. % Zn, and a balance of Al with incidental impurities individually being less than 0.05 wt. % and totaling less than 0.15 wt %.
  • Brazing sheet can further includes an aluminum layer composed of 0.6- 0.84 wt.
  • turbine hub 26 can be formed of a steel material and heat treated to provide a high strength hardened material.
  • the turbine hub 26 includes a main body portion 26a having a bore 26b configured for engagement to the transmission system (not shown) and an exterior surface 26c providing the engagement to the ring gear 24 of the lockup clutch assembly 20, wherein an friction metallurgical bond is formed between the turbine hub 26 and the sheet turbine shell 27 and can be positioned at least between an annular ring 26d disposed around the bore 26b through the main body portion 26a of the turbine hub 26 and a surface of the turbine shell 27 ( Figure 1).
  • Inertia friction welding is a variation of friction welding in which the energy required to make the weld is supplied primarily by the stored rotational kinetic energy of the welding machine.
  • one of the work pieces for example the turbine hub 26
  • the flywheel is accelerated to a predetermined rotational speed, storing the required energy.
  • the drive motor is disengaged and the work pieces are forced together by the friction welding force. This causes the faying surfaces to rub together under pressure.
  • the kinetic energy stored in the rotating flywheel is dissipated as heat through friction at the weld interface as the flywheel speed decreases.
  • An increase in friction welding force (forge force) may be applied before rotation stops.
  • the forge force is maintained for a predetermined time after rotation ceases.
  • An inertia friction metallurgical bond results.
  • Figure 5 depicts one embodiment of a stator assembly 30 for use in the torque converter 10 of the present invention.
  • the stator assembly 30 includes a die cast and machined stator 31 including a plurality of blades, and a one direction directional Sprague clutch 32.
  • the stator 31 is die cast from an aluminum alloy and machined to it's final form.
  • FIGS 6a-6d depict one embodiment of a pump assembly 35, in accordance with the present invention.
  • the unitary pump vortex ring and blade array structure 38 includes a plurality of blades 38b and vortex ring 38 a.
  • the term unitary pump vortex ring and blade array structure 38 denotes that the vortex ring 38a and blades 38b that form the blade array are a produced in a singular casting.
  • the unitary pump vortex ring structure and blade array structure 38 further includes at least one joining ring 53, wherein the at least one joining ring 53 corresponds with at least one annular groove 54 formed in the pump shell 37 to provide a site for at least one of the braze joint metallurgical bond between the unitary pump vortex ring and blade array structure 38 and the metal sheet pump shell 37.
  • This brazing operation is blind brazing of complex geometry without the intervention of an operator or technician to adjust the mating components for the desired match up or alignment of adjacent braze surfaces to produce the desire brazed joint.
  • the braze joint provides additional surface area to form a path to carry or transfer torsional load or stress.
  • the unitary pump vortex ring and blade array structure 38 is cast from an aluminum alloy, for example being an Aluminum Association 3xx series aluminum alloy, such as Aluminum Association A356 or the alloy disclosed in U.S. Patent No. 6,783,730.
  • the pump shell 37 is formed in a spin forming operation from an aluminum alloy sheet material that can be made from a brazing sheet material, hi one embodiment the formed pump shell 37 further comprises a series of annular grooves 53, wherein the at least one joining ring of the unitary pump vortex ring 38 corresponds with the at least one annular groove 54 to provide a site for at least one of the braze joint metallurgical bond between the unitary pump vortex ring and blade array structure 38 and the sheet pump shell 37.
  • the brazing sheet material of the pump shell 37 includes a layered sheet composed of prefluxed or non-prefluxed layer of Aluminum Association 4xxx series alloy, which can have a thickness that ranges from 0.1 to 0.3 mm thick, in which the prefluxed face of the brazing sheet is positioned to provide the surface for brazing engagement of the unitary pump vortex ring and blade array structure 38.
  • the face of the brazing sheet from which the pump shell 37 is formed is positioned to provide the surface for brazed engagement by braze joint metallurgical bond to the unitary pump vortex ring and blade array structure 38.
  • the brazing sheet of the pump shell 37 can be composed of at least one layer of Aluminum Association 4047 aluminum.
  • One embodiment of the brazing sheet can further include an aluminum layer composed of 0.6-0.84 wt. % Si, 0.4-0.6 wt. % Fe, 0.4-0.64 wt. % Cu, 1.1 to 1.4 wt. % Mn, 0.2 -0.3 wt. % Mg, less than 0.05 wt % Zn, 0.10-0.20 wt. % Ti, and a balance of aluminum.
  • the brazing step can be conducted using a controlled atmosphere brazing (CAB) operation.
  • CAB controlled atmosphere brazing
  • a pump hub 36 can be centrally positioned and joined to the sheet pump shell 37 by an electromagnetic or inertia friction metallurgical bond.
  • the pump hub 36 includes a centrally positioned hollow shaft 36a having a shoulder 36b positioned at the base 36d of the hollow shaft 36a.
  • Shoulder 36b can have an annular ring 36c disposed about the centrally positioned hollow shaft 36a, wherein the inertia friction metallurgical bond between the pump hub 36 and the sheet pump shell 37 is positioned between at least a surface 36e of the annular ring 36c and a surface 37a of the sheet pump shell 37.
  • Figure 7 depicts one embodiment of a light weight flexplate 60 for use with the torque converter described above with respect to Figures 1-6.
  • the light weight flex plate 60 is provided having aluminum components for weight savings and steel components where required to meet higher strength components.
  • the light weight flex plate of the present invention includes a stamped aluminum plate 65 including a plurality of integral wave springs 61 ; and a steel ring gear 62 connected to the perimeter 60a of the stamped aluminum plate by a metallurgical bond having substantially no heat effected zone at the interface 66 of the stamped aluminum plate 65 and the steel ring gear 62.
  • the stamped aluminum plate 65 includes the same features as lockup clutch plate 21.
  • One embodiment of plate 65 is formed in a stamping operation and can be composed of an Aluminum Association 6013 series aluminum alloy, in which the main alloying constituents include Si, Cu, Mg, and Cr, and for example Aluminum Association 6013 aluminum alloy.
  • the stamped aluminum plate 65 can be stamped having holes 63 for engagement to the engagement members 18 of the torque converter 10 and also to the engine crank (not shown) and at holes 67.
  • the steel ring gear 62 is configured for engagement by the starter motor (not shown) of the engine system and is joined to the stamped aluminum plate by a weld formed by inertia friction welding.
  • the torque converter of the present invention results in a weight that is about 45%-50% lighter than its steel counter part (for example, 15.2 lbs vs 29 lbs). It has a mass moment of rotational inertia that is about 45%-50% less than that of the steel counterpart (for example, 215 lb-in 4 vs 425 lb-in 4 ) and can be produced using much fewer (for example, 20 vs 107) parts and uses a much simpler and more robust (for example, 16 vs 29) manufacturing steps.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Details And Applications Of Rotary Liquid Pumps (AREA)
  • Rotary Pumps (AREA)

Abstract

La présente invention concerne un convertisseur de couple (10) incluant un assemblage de pompe (35) incluant un anneau tourbillonnaire de pompe unitaire et une structure (38) en réseau de pales ainsi qu'une coque (37) de pompe de tôles métalliques, raccordé à la coque (37) de pompe en tôles grâce à une liaison métallurgique réalisée par brasage fort, un assemblage (20) de plaque d'embrayage de verrouillage incluant une pluralité de fonctions intégrées d'amortissement contre les vibrations et un anneau d'embrayage (24) positionné de manière centrale, un assemblage de turbine (25) incluant un anneau unitaire tourbillonnaire de turbine et une structure (28) en réseau de pales, une coque (27) de turbine en tôles métalliques, ainsi qu'un moyeu de turbine (26) configuré pour se mettre en prise avec l'anneau d'embrayage (24) de l'assemblage (20) de plaque d'embrayage de verrouillage et pour se mettre en prise avec l'arbre d'un système de transmission, ainsi qu'un stator (31) positionné entre l'assemblage de turbine (25) et l'assemblage de pompe (35).
PCT/US2007/081655 2006-10-17 2007-10-17 Convertisseur de couple léger WO2008049010A2 (fr)

Applications Claiming Priority (2)

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US82983406P 2006-10-17 2006-10-17
US60/829,834 2006-10-17

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WO2008049010A2 true WO2008049010A2 (fr) 2008-04-24
WO2008049010A3 WO2008049010A3 (fr) 2008-12-04

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010083245A3 (fr) * 2009-01-16 2010-09-10 Alcoa Inc. Alliages d'aluminium, produits en alliage d'aluminium et leurs procédés de fabrication
US11173568B2 (en) 2018-07-11 2021-11-16 GM Global Technology Operations LLC Composite metal flexplate

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US4135390A (en) * 1978-02-13 1979-01-23 General Motors Corporation Engine torque transducer using a spoked torque transmitting plate
US4540076A (en) * 1984-06-25 1985-09-10 Eaton Corporation Torque converter viscous bypass coupling with improved seal arrangement
EP0435358A2 (fr) * 1989-12-26 1991-07-03 General Motors Corporation Turbine de convertisseur de couple
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US6216837B1 (en) * 1997-04-06 2001-04-17 Luk Getriebe-Systeme Gmbh Hydrokinetic torque converter
DE19818749A1 (de) * 1997-04-25 1998-11-05 Exedy Corp Leitrad für einen Drehmomentwandler
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US6112869A (en) * 1998-02-17 2000-09-05 Luk Getriebe-Systeme Gmbh Force transmitting apparatus having an external damper
US6364777B1 (en) * 1999-06-07 2002-04-02 Mannesmann Sachs Ag Torque-transmitting connecting arrangement
EP1211438A2 (fr) * 2000-11-29 2002-06-05 Ford-Werke Aktiengesellschaft Convertisseur de couple hydrodynamique
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US20030173175A1 (en) * 2002-03-15 2003-09-18 Naoki Tomiyama Piston coupling mechanism and lockup device for fluid-type torque transmission device equipped with the same
US20040185940A1 (en) * 2003-03-18 2004-09-23 Kozo Yamamoto Damper mechanism and damper disk assembly
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Publication number Priority date Publication date Assignee Title
WO2010083245A3 (fr) * 2009-01-16 2010-09-10 Alcoa Inc. Alliages d'aluminium, produits en alliage d'aluminium et leurs procédés de fabrication
US8349462B2 (en) 2009-01-16 2013-01-08 Alcoa Inc. Aluminum alloys, aluminum alloy products and methods for making the same
US8950465B2 (en) 2009-01-16 2015-02-10 Alcoa Inc. Aluminum alloys, aluminum alloy products and methods for making the same
US11173568B2 (en) 2018-07-11 2021-11-16 GM Global Technology Operations LLC Composite metal flexplate

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