Analysis and Experimental Identification of Torsional Dynamic Characteristics of Hydrodynamic Torque Converter

The subsection linear torsional model of hydrodynamic torque converter was established and further simplified. According to the identification theory, the frequency characteristic was achieved with the Matlab/ Ident toolbox. Then parametric model was established by adopting the subsection linearization method, and the damp value was estimated. The curve and function of damp changing with speed ratio was also established by fitting. In order to validate the identification results, the experimental output was compared with the output of the model in which torque was chosen as input signal and speed as output signal in Matlab/Ident toolbox. It was shown that model output is in good agreement with experimental output.

Study on Blade Mould CAD/CAM for Hydrodynamic Torque COnverters

Aim To develop blade mould CAD/CAM system of torque converter. Methods The mouldconsisted of four parts and an interactive computer program was developed to design a blade mould of torque converter based on UG at workstation. Results As compar- ed to manual modeling, it is showed in the application that this means not only improves the accuracy of blade shape and manufacture efficiency of converter, but also reduces costs. Conclusion It is proved that this CAD/CAM system is successful, and it opens up widely prospects for design and manufacture of the blade elementsand their moulds.

Mathematical Model of Hydrodynamic Torque Converter and Analytic Description of Streamline

The mathematical model of a 3-element centripetal-turbine hydrodynamic torque converter and analytic description of fluid flow inside the hydrodynamic torque converter are investigated. A new torus coordinate system is proposed so as to quantitatively describe fluid movement inside the hydrodynamic torque converter. The particle movement inside the hydrodynamic torque converter is decomposed into meridional component movement and torus component movement, and a universal meridional streamline equation is derived. According to the relationship between the converter wheel velocity polygon and its blade angle, a torus streamline differential equation is established. The universal meridional streamline equation is approximated with square polynomials. The approximation error curve is given and the percentage error is not greater than 0.86%. Considered as a function of polar angle, the blade angle cotangent of each converter wheel varies linearly with polar angle. By using integral calculus, torus streamline equations are obtained. As a result, the problem of difficult flow description of the hydrodynamic torque converter is solved and a new analytic research system is established.

Performance Analysis and Improvement of Flat Torque Converters Using DOE Method

Automotive torque converters have recently been designed with an increasingly narrower profile for the purpose of achieving a smaller axial size and reducing weight. Design of experiment(DOE) and computational fluid dynamics(CFD) techniques are applied to improve the performance of a flat torque converter. Four torque converters with different flatness ratios(0.204, 0.186, 0.172, and 0.158) are designed and simulated first to investigate the effects of flatness ratio on their overall performance, including efficiency, torque ratio, and impeller torque factor. The simulation results show that the overall performance tends to deteriorate as the flatness ratio decreases. Then a parametric study covering six geometric parameters, namely, inlet and outlet angles of impeller, turbine, and stator is carried out. The results demonstrate that the inlet and outlet angles play an important role in determining the performance characteristics of a torque converter. Furthermore, the relative importance of the six design parameters is investigated using DOE method for each response(stall torque ratio and peak efficiency). The turbine outlet angle is found to exert the greatest influence on both responses. After DOE analysis, an optimized design for the flat torque converter geometry is obtained. Compared to the conventional product, the width of the optimized flat torque converter torus is reduced by about 20% while the values of stall torque ratio and peak efficiency are only decreased by 0.4% and 1.7%, respectively.The proposed new optimization strategy based on DOE method together with desirability function approach can be used for performance enhancement in the design process of flat torque converters.

SYSTEM FOR TORQUE CONVERTER DESIGN AND ANALYSIS BASED ON CAD/CFD INTEGRATED PLATFORM

A 3D torque converter design system is developed based on numerical investigation into flow field and CAD technology. The 3D steady-state flow field simulation is undertaken by using time averaged Reynolds equation and k-epsilon turbulence model, with mixing-plane boundary conditions at three section interfaces. The blades are designed according to the flow field characteristics by using a reverse design method in the system. The accurateness of numerical analysis and the validity of design system are verified by the fluid field experiment of desingn example of the torque converter. This kind of design and analysis system for torque converter based on integration of comput ationol fluid dynamics （CFD） and CAD is a powerful tool for torque converter manufacturing, but also a prettg important significance for research and development.

Numeric Simulation of Single Passage Ternary Turbulence Model in Hydraulic Torque Converter

Based on the renormalization group theory, a hydraulic torque converter 3 D turbulent single flow passage model is constructed and boundary condition is determined for analyzing the influence of the fluid field characteristic and parameters on the macroscopic model. Numerical simulation of the single fluid path is processed by computational fluid dynamics and the calculated results approach to experimental data well, and especially in low transmission ratio the torque and head results are more close to experimental data than the calculated results of beam theory. This shows that the appropriate ternary analysis method and reasonable assumption of boundary condition may analyze the flow field more precisely and predict the performance of torque converter more accurately.

NUMERICAL ANALYSIS ON THREE-DIMENSIONAL FLOW FIELD OF TURBINE IN TORQUE CONVERTER

Three-dimensional flow field of turbine in torque converter is simulated by numerical calculation in order to improve the performance of torque converter. Calculation model of a torque converter is presented based on the mixing-plane technology. In the calculation of flow field, the 3D N-S equations are separated by finite-volume method and solved by semi-implicit method for pressure-linked equations（SIMPLE）. Based on flow field calculation, the flow field of turbine is simulated. The velocity and pressure in the flow field of turbine are analyzed. The external performance of the torque converter is also calculated. Results of flow simulation show that there are secondary flow, off flow and velocity gradient in turbine passage. The validity of numerical simulation is verified by comparing the results of numerical simulation with experiment data.

Application of Dual-blade Stator to Low-speed Ratio Performance Improvement of Torque Converters

With application of the lock-up clutch in the torque converter（TC）, fuel economy is not much determined by its high-speed ratio transmission efficiency. As a benefit, more researches are focused on its low-speed ratio performance so as to improve vehicle gradeability and launching acceleration performance. According to the results of computational fluid dynamics（CFD） analysis, hydrodynamic loss inside the stator cascade accounts for 42% of the total energy loss at stalling speed ratio. It is found that upstream flow with large impingement angle results in boundary layer separation at the leading edge, which aggregates hydrodynamic loss and decreases circular flow rate dramatically at low-speed ratio. In this paper, a dual-blade stator is proposed to suppress the boundary layer separation, which is parameterized by using the non-uniform rational B spline（NURBS） method. The mean camber line and blade profile curve are expressed by a three control points quadratic open NURBS and a cubic closed one respectively. The key design parameters included the slot width and suction side shape of the primary blade are analyzed. The most effective slot width is found to be between 4% and 8% chord length, and the boundary layer separation can be suppressed completely by decreasing distribution of momentum moment at the primary blade and adding it to the leading edge of the secondary blade. As a result, circular flow rate and impeller torque capacity is increased by 17.9% and 9.6% respectively at stalling speed ratio, meanwhile, low-speed ratio efficiency is also improved. Maximum efficiency at high-speed ratio decreases by 0.5%, which can be ignored as the work of lock-up clutch. This research focuses on using the dual-blade stator to optimize low-speed ratio performance of the TC, which is benefit to vehicle power performance.

Numerical simulation of the flow field of a flat torque converter

A flexible flat torque converter was proposed to fulfill the requirement of miniaturization and power density maximization for automobiles.Constructed by two arcs joined by lines,the torus was designed directly from design path.The influence of flatness on the performance of the torque converter was evaluated.The software CFX and standard k-ε model were adopted to simulate the internal flow fields of the torque converter under different flatness ratios.The results indicated that the performance of the torque converter got worse as the flatness declined,but the capacity of pump increased.The efficiency and the torque ratio dropped slightly as the flatness ratio decreased.So the torque converter could be squashed appropriately to get high power density without too much efficiency sacrifice.But when the flatness ratio was below 0.2,there was a significant drop in the efficiency.

Performance Optimization of Torque Converters Based on Modified 1D Flow Model

A methodology for performance optimization of torque converters is put forward based on the one-dimensional (1D) flow model. It is found that the inaccuracy of 1D flow model for predicting hydraulic performance at the low speed ratio is mainly caused by the separation phenomenon at the stator cascade which is induced by large flow impinging at the pressure side of the stator blades. A semi-empirical separation model is presented and incorporated to the original 1D flow model. It is illustrated that the improved model is able to predict the circumferential velocity components accurately, which can be applied to performance optimization. Then, the Pareto front is obtained by using the genetic algorithm (GA) in order to inspect the coupled relationship among stalling impeller torque capacity, stalling torque ratio and efficiency. The efficiency is maximized on the premise that a target stalling impeller torque capacity and torque ratio are achieved. Finally, the optimized result is verified by the computational fluid dynamics(CFD) simulation, which indicates that the maximal efficiency is increased by 0.96%.

Model Predictive Control-Based Direct Torque Control for Matrix Converter-Fed Induction Motor with Reduced Torque Ripple

To reduce the torque ripple in motors resulting from the use of conventional direct torque control(DTC),a model predictive control(MPC)-based DTC strategy for a direct matrix converter-fed induction motor is proposed in this paper.Two new look-up tables are proposed,these are derived on the basis of the control of the electromagnetic torque and stator flux using all the feasible voltage vectors and their associated switching states.Finite control set model predictive control(FCS-MPC)has then been adopted to select the optimal switching state that minimizes the cost function related to the electromagnetic torque.Finally,the experimental results are shown to verify the reduced torque ripple performance of the proposed MPC-based DTC method.

Semi-Automatic Modeling Technique of Torque Converter Flow Passage

The modeling technique of hydrodynamic torque converter flow passage was investigated. The semi-automatic modeling technique of torque converter flow passage was proposed. The flow passage model of each converter wheel is considered as a revolution entity sliced by two curved surfaces. In order to generate the revolution entity, a new approximation method, condition optimum arc approximation, was proposed. The method was used to approximate the meridional streamlines of the inner and outer wall. As a result, the three-dimensional revolution entity can be conveniently generated. In order to create slice surfaces, the central stream surface of flow passage was approximated with a quadric surface. The normal vector of the quadric surface and the thickness/thickness-function of bade were used to calculate the discrete point coordinates of blade surfaces. Via the rotation transformation to the coordinates, the discrete point coordinates of slice surfaces were obtained. A parameterized program code used for the hydrodynamic torque converter design and semi-automatic modeling was developed. Modeling errors were calculated and analyzed. The flow passage model was generated in several minutes with the help of the program code, Auto CAD and Solidworks software. Finally, the model was inputted into Gambit, and the pre-processing task used for the numerical simulation of torque converter flow field was successfully completed. The investigation results show that the semi-automatic modeling not only can ensure the accuracy of modeling, but also librates the research and design workers of torque converter from the time-consuming modeling work, which paves the way for the numerical simulation of the complex flow field of the hydrodynamic torque converter.

Modal analysis of the torque converter in different prestress

In order to study the mechanical properties and the dynamic performance of torque converter,to reduce the vibration and noise during the operation and to improve the stability,a 215 mm hydraulic torque converter is taken as the research object,and modal analyses are performed based on the finite element method.The weak parts of the impeller structure are obtained after calculating the models of the impeller and turbine without prestress.The variation of the modal frequency of the turbine and impeller are obtained under different prestress conditions by calculating different rotational speeds of the transmission shaft.The fundamental frequencies of the impeller and the turbine increase by 0.43%and 4.82%respectively when the rotational speed ranges from 100 rpm to 4500 rpm.The results of the present research indicate that the modal frequencies at different speeds are similar to the fundamental frequencies of the structure.Therefore,it is possible to estimate the vibration characteristics of the structure and optimize the structural design by numerical modal analysis in the static state instead of the dynamic state.

Fluid-solid interaction analysis of torque converters

In order to extend the service life of torque converters, it is essential to predict the pressure condition and improve its weak areas. According to computational fluid dynamics and structural statics, a model of torque converter is constructed using software ANSYS. Then, a fluid-solid interaction(FSI) analysis method is proposed to obtain its stress distribution, in which the fluid pressure is applied to the coupling surface to calculate the interaction between fluid and solid. The results show that the fluid pressure at the inlet of the impeller is maximum and decreases along the flow direction, the pressure at the inlet of the turbine blade is minimum and the outlet pressure is the largest, increasing along the flow direction gradually;the pressure distribution of the impeller is concentrated mainly at the corner, especially between the inner ring and the impeller blades;the pressure of the turbine is concentrated mainly on the connection between turbine and the outer edge of the blade.

Model predictive torque control of permanent magnet synchronous motor system driven by matrix converter

Employing matrix converter （MC） as driving mode, the strategy of model predictive torque control （MPTC） is proposed for three phase permanent magnet synchronous motor （PMSM） system. MC is applied instead of conventional AC DC AC converter to increase the power factor （PF） of the system input side. MPTC is used to select optimal voltage space vector to enable the system to have satisfactory torque and flux control effect. The resultant MPTC strategy not only makes the MC fed PMSM system operate reliably and have perfect control performance, but also makes the PF of the system input side be 1. Compared with direct torque control （DTC）, the proposed MPTC strategy guarantees that MC fed PMSM has better command following characteristics in the presence of variation of load torque and tracking reference speed. Simulation results verify the feasibility and effectiveness of the proposed strategy.

A New Front End Capacitive Converter Fed Switched Reluctance Motor for Torque Ripple Minimization

This paper presents new converter for torque ripple minimization of three phases Switched Reluctance Motor (SRM). The proposed converter has basic passive circuit which includes two diodes and one capacitor to the front end of an asymmetric converter with a specific end goal to get a high magnetization and demagnetization voltage. In view of this boost capacitor, the charge and demagnetization voltage are higher. Accordingly, it can reduce the negative torque generation from the tail current and enhance the output power. The proposed converter circuit is equipped for minimizing the SRM torque ripple furthermore enhancing the average torque when contrasted with traditional converter circuit. A three-phase SRM is modeled and the simulation output for no load and stacked condition depicts that the proposed converter has better performance when contrasted with traditional converter. It is appropriate for electric vehicle applications. The proposed framework is simulated by utilizing MATLAB/Simulink environment and their outcomes are examined extravagantly.

Influence of Charging Oil Condition on Torque Converter Cavitation Characteristics

Cavitation inside a torque converter induces noise,vibration and even failure,and these effects have been disregarded in previous torque converter design processes.However,modern torque converter applications require attention to this issue because of its high-speed and high-capacity requirements.Therefore,this study investigated the cavitation effect on a torque converter using both numerical and experimental methods with an emphasis on the influence of the charging oil feed location and charge pressure.Computational fluid dynamics(CFD)models were established to simulate the transient cavitation behaviour in the torque converter using different charging oil pressures and inlet arrangements and testing against a base case to validate the results.The CFD results suggested that cavitating bubbles mainly takes place in the stator of the torque converter.The transient cavitation CFD model yielded good agreement with the experimental data,with an error of 7.6%in the capacity constant and 7.4%in the torque ratio.Both the experimental and numerical studies showed that cavitation induced severe capacity degradation,and that the charge pressure and charging oil configuration significantly affects both the overall hydrodynamic performance and the fluid behaviour inside the torque converter because of cavitation.Increasing the charge pressure and charging the oil from the turbine-stator clearance were found to suppress cavitation development and reduce performance degradation,especially in terms of the capacity constant.This study revealed the fluid field mechanism behind the influence of charging oil conditions on torque converter cavitation behaviour,providing practical guidelines for suppressing cavitation in torque converter.

Optimization of the Impeller Geometry for an Automotive Torque Converter Using Response Surface Methodology and Desirability Function

Response surface methodology (RSM) based on desirability function approach (DFA) is applied to obtain an optimal design of the impeller geometry for an automotive torque converter. The relative importance of six design parameters including impeller blade number, blade thickness, bias angle, scroll angle, inlet angle and exit angle is investigated using orthogonal design approach. The impeller inlet angle, exit angle and bias angle are found to exert the greatest influence on the overall performance of a torque converter, with two flow area factors being considered, namely 17% and 20%. Then, RSM together with central composite design (CCD) method is used to in-depth evaluate the interaction effect of the three key parameters on converter performance. The results demonstrate that impeller exit angle has the strongest impact on peak efficiency, with larger angles yielding the most favorable results. The stall torque ratio maximization is attainable with the increase of impeller bias angle and inlet angle together with smaller exit angle. In the end, an optimized design for the impeller geometry is obtained with stall torque ratio and peak efficiency increased by 1.62% and 1.1%, respectively. The new optimization method can be used as a reference for performance enhancement in the design process of impeller geometry for an automotive torque converter.

Open-circuit Fault-tolerant Control Strategy Based on Five-level Power Converter for SRM System

Switched reluctance motor power converters are prone to open-circuit faults because it need to withstand large voltages and currents.Due to the small number of traditional asymmetrical half bridge topology switches,it is difficult to carry out fault tolerant control when power converters has an open-circuit fault,resulting in larger output torque ripple.This paper presents a five-level power converter based on the traditional asymmetric half-bridge power converter.The five-level topology has more switching states and can work in multi-level mode.Based on the topology,different excitation and demagnetization voltages can be choose at different speeds.A fault-tolerance strategy is developed to decrease the influence of the open-circuit fault.The five-level power converter has four switches per phase,and two of them will be used in one of the operating mode.So the remaining two of the switches can be used for safe backup,enabling fault-tolerant control when an open-circuit occur.Since each phase of the five-level power converter proposed in this paper is independent of each other,a reasonable control strategy can be used to avoid the unbalance of the midpoint potential.Finally,the topology and fault-tolerant strategy proposed in this paper are verified by simulation and experiment.

跟网型变换器的小扰动同步稳定机理分析与致稳控制

弱电网下,跟网型变换器易出现因阻尼不足导致的小扰动同步失稳问题。为此,该文借鉴复转矩分析理论,计及复杂控制耦合,建立跟网型变换器的复转矩模型。量化多环控制耦合、线路阻抗、控制参数等因素对系统阻尼转矩的影响,从阻尼的角度揭示跟网型变换器的小扰动同步失稳机理。根据理论分析,提出一种基于相位补偿的锁相环阻尼重塑控制策略,通过补偿多环控制耦合引入的负阻尼,增强变换器的小扰动同步稳定性。最后,开展相应的仿真与实验,验证理论分析的正确性与改进控制策略的有效性。