It is important to realize that the torque converter does
not produce torque out of thin air. The torque increase is based
on three things: the angles of the turbine blades and the stator
blades, and the speed differential between the impeller and the
turbine. The angle of the blades in the turbine will determine
the exit angle of the fluid and its speed. The angle of the stator
blades will determine how much force the fluid will impart on
the impeller when it is redirected. The speed difference between
the impeller and the turbine will also affect the torque multiplication. Of these three, the
speed difference between the impeller
and the turbine is the most significant factor in torque multiplication. In a standard
transmission, when we gear down, we
sacrifice speed for increased torque. In an automatic transmission, the torque converter
does the same to increase torque; the
impeller must rotate faster than the turbine.
Torque-Converter Operational
Phases
Torque converters have two significant operational phases: the
torque multiplication phase and the coupling phase. As its name
suggests, the torque multiplication phase involves increasing
torque output, and there is a significant difference in the high
vortex flow and the speed of the impeller and turbine. The coupling phase occurs when the
impeller and turbine are close to
the same speed and the flow has changed to rotary. Let’s examine these phases in more
detail.
Torque Multiplication Phase
The torque multiplication phase occurs any time the torque
converter is increasing the engine’s torque output to the transmission’s input shaft.
Maximum torque multiplication occurs
when the engine is accelerated to the maximum speed, at which
point it can turn the impeller while the turbine remains stationary. That maximum speed is
also known as the torque converter’s stall speed. The engine cannot turn any faster,
because
of the resistance provided by the stationary turbine. Reaching
the stall speed rarely occurs in normal operation, because the
machine will usually start to move before maximum torque
multiplication is reached.
Normally, the torque converter will stall only during a
stall test procedure where the machine brakes are applied to
prevent it from moving or if the machine becomes severely
overloaded. Most torque converters are set up to have a torque
multiplication factor of around 2:1 to 3:1. Recall that torque
multiplication is primarily based on speed difference between
the turbine and the impeller. Therefore, torque converters
with higher torque multiplication typically have higher stall
speeds. Within certain limitations, stall speeds and the torque
multiplication factor can be manipulated in the design stage
by changing the size of the torque-converter elements, the
angle of the turbine blades, the angle of the stator blades,
and the clearance between the elements. A high-stall or
high-torque-multiplication torque converter can be excellent
for picking up heavy loads. A lower-stall torque converter is
usually more suitable for high-speed operation.
Vortex Flow
Impeller
Turbine
Stator
(Locked)
Engine Rotation
FIGURE 47-18 Vortex flow is greatest at full stall and decreases as the