1 Introduction
2 Flat Torque Converter Design
2.1 Torus Design
Parameters | Type 1 | Type 2 | Type 3 | Type 4 |
---|---|---|---|---|
Nominal diameter D (mm) | 250 | 250 | 250 | 250 |
Width of torus W (mm) | 51 | 46.40 | 42.95 | 39.53 |
Flatness ratio \(e_{0}\) | 0.204 | 0.186 | 0.172 | 0.158 |
Redefined flatness ratio \(e\) | 1.0 | 0.9 | 0.8 | 0.7 |
2.2 Blade Design
Parameters | Impeller | Turbine | Stator |
---|---|---|---|
Inlet angle \(\beta_{1}\) (°) | 131 | 34 | 97.5 |
Outlet angle \(\beta_{2}\) (°) | 50 | 144 | 21 |
3 Flat Torque Converter Design
3.1 Computational Method
3.2 Results and Discussion
4 Optimal Design of a Flat Torque Converter
4.1 Sensitivity Analysis of Inlet and Outlet Angles
4.2 DOE Method
Case number | Factors | Responses | ||||||
---|---|---|---|---|---|---|---|---|
Turbine inlet angle \(\beta_{\text{T1}}\) (°) | Turbine outlet angle \(\beta_{\text{T2}}\) (°) | Impeller inlet angle \(\beta_{\text{I1}}\) (°) | Impeller outlet angle \(\beta_{\text{I2}}\) (°) | Stator inlet angle \(\beta_{\text{S1}}\) (°) | Stator outlet angle \(\beta_{\text{S2}}\) (°) | Stall torque ratio \(Tr_{0}\) | Peak efficiency \(\eta^{*}\) (%) | |
1 | 28 | 138 | 125 | 44 | 91.5 | 15 | 1.7996 | 80.96 |
2 | 28 | 141 | 128 | 47 | 94.5 | 18 | 1.8055 | 81.65 |
3 | 28 | 144 | 131 | 50 | 97.5 | 21 | 1.8359 | 82.98 |
4 | 28 | 147 | 134 | 53 | 100.5 | 24 | 1.8055 | 81.23 |
5 | 28 | 150 | 137 | 56 | 103.5 | 27 | 1.7852 | 80.36 |
6 | 31 | 138 | 128 | 50 | 100.5 | 27 | 1.7621 | 78.34 |
7 | 31 | 141 | 131 | 53 | 103.5 | 15 | 1.7961 | 79.17 |
8 | 31 | 144 | 134 | 56 | 91.5 | 18 | 1.8014 | 80.29 |
9 | 31 | 147 | 137 | 44 | 94.5 | 21 | 1.8147 | 80.37 |
10 | 31 | 150 | 125 | 47 | 97.5 | 24 | 1.8199 | 80.11 |
11 | 34 | 138 | 131 | 56 | 94.5 | 24 | 1.7699 | 77.19 |
12 | 34 | 141 | 134 | 44 | 97.5 | 27 | 1.7996 | 79.82 |
13 | 34 | 144 | 137 | 47 | 100.5 | 15 | 1.8269 | 82.36 |
14 | 34 | 147 | 125 | 50 | 103.5 | 18 | 1.8455 | 82.76 |
15 | 34 | 150 | 128 | 53 | 91.5 | 21 | 1.8347 | 83.21 |
16 | 37 | 138 | 134 | 47 | 103.5 | 21 | 1.7806 | 79.24 |
17 | 37 | 141 | 137 | 50 | 91.5 | 24 | 1.7982 | 81.25 |
18 | 37 | 144 | 125 | 53 | 94.5 | 27 | 1.7717 | 79.53 |
19 | 37 | 147 | 128 | 56 | 97.5 | 15 | 1.8426 | 83.24 |
20 | 37 | 150 | 131 | 44 | 100.5 | 18 | 1.8364 | 81.71 |
21 | 40 | 138 | 137 | 53 | 97.5 | 18 | 1.7998 | 80.21 |
22 | 40 | 141 | 125 | 56 | 100.5 | 21 | 1.7516 | 77.59 |
23 | 40 | 144 | 128 | 44 | 103.5 | 24 | 1.7817 | 79.24 |
24 | 40 | 147 | 131 | 47 | 91.5 | 27 | 1.7995 | 78.47 |
25 | 40 | 150 | 134 | 50 | 94.5 | 15 | 1.8106 | 81.56 |
4.3 Numerical Simulation
4.4 DOE Post-processing and Optimization
Indicator | Influence level | Turbine inlet angle \(\beta_{\text{T1}}\) | Turbine outlet angle \(\beta_{\text{T2}}\) | Impeller inlet angle \(\beta_{\text{I1}}\) | Impeller outlet angle \(\beta_{\text{I2}}\) | Stator inlet angle \(\beta_{\text{S1}}\) | Stator outlet angle \(\beta_{\text{S2}}\) |
---|---|---|---|---|---|---|---|
Stall torque ratio \(Tr_{0}\) |
K
1
| 1.80634 | 1.78240 | 1.79766 | 1.80640 | 1.80668 | 1.81516 |
K
2
| 1.79884 | 1.79020 | 1.80532 | 1.80648 | 1.79448 | 1.81772 | |
K
3
| 1.81532 | 1.80352 | 1.80756 | 1.81046 | 1.81956 | 1.80350 | |
K
4
| 1.80590 | 1.82156 | 1.79954 | 1.80156 | 1.79650 | 1.79504 | |
K
5
| 1.78864 | 1.81736 | 1.80496 | 1.79014 | 1.79782 | 1.78362 | |
\({\text{R}}\)
| 0.02668 | 0.03916 | 0.00990 | 0.02032 | 0.02508 | 0.03410 | |
\({\text{C}}\)
| 17% | 25% | 7% | 13% | 16% | 22% | |
Peak efficiency \(\eta^{*}\) (%) |
K
1
| 81.436 | 79.188 | 80.190 | 80.420 | 80.836 | 81.458 |
K
2
| 79.656 | 79.896 | 81.136 | 80.366 | 80.060 | 81.324 | |
K
3
| 81.068 | 80.880 | 79.904 | 81.378 | 81.272 | 80.678 | |
K
4
| 80.994 | 81.214 | 80.028 | 80.670 | 80.246 | 79.804 | |
K
5
| 79.014 | 81.390 | 80.910 | 79.734 | 80.154 | 79.304 | |
\({\text{R}}\)
| 2.022 | 2.202 | 1.232 | 1.644 | 1.212 | 2.154 | |
\({\text{C}}\)
| 19% | 21% | 12% | 16% | 12% | 20% |