Torque converter operation & maintenance

Operation & maintenance of Torque Converter

1. TORQUE CONVERTER OPERATION
Presented By Prem Baboo Sr. Manager(Prod)
Plant’s & Equipment's Designer
National fertilizers Ltd. India,
An Experts for
www.ureaknowhow.com
Fellow of Institution of Engineers, India

2. VOITH TORQUE CONVERTER
Thehydrodynamictorqueconverterisprovidedforsteplessspeed/torque
transmission.
TURBINE WHEEL
ADJUSTABKE GUIDE BLADES
PUMP IMPELLER
INPUT AND OUT PUT SHAFT
ADJUSTMENT MECHANISM
TheheartofVoith’shydrodynamictorqueconverterisitshydrauliccircuit;
consisting of a pump, turbine, and a guide wheel with adjusta ble guide
vanes (see picture above right). This is combined in a commonhousing
filled with hydraulic oil. The mechanical energy of the moto r is converted
into hydraulic energy through the pump wheel. In the turbine wheel the
same hydraulic energy is converted back into mechanical energy and
transmittedtothegasturbine/generatorshaft.The

3. CONSTRUCTION DETAIL

4. adjustable vanes of the guide
wheel
regulatethemassflowinthecircuit.
At
closedguidevanes(smallmassflow)
the
power transmission is at its minimum
.
With the guide vanes completely
open
(large mass flow), the
power
transmission is at its max imum
.
Commonly,aconstantspeeddriver
such
asaninductionmotororadiesel
engine
drivesthepumpwheel(inputshaftof
the
torqueconverter)

5. Becauseofthechangeinmassflow(due
to the adjustable guide vanes) the
turbinewheels’speedisvariableandcan
be adjusted to match the various
operatingpointsofthe turbine.Atlow
speed,theturbinedevelopsitshighest
torque. With increasing turbine speed,
outputtorquedecreases

6. The input shaft is connected with the pump
impeller. The output shaft is connected with the
turbinewheel.Bothconvertershaftaresupported
byantifrictionbearings.Theinputshaftsaresealed
using shaft seal rings. The guide vane adjustable
mechanism is actuated via the control piston. In
this position, two servo pistons follow(hydraulic
followercontrol).Theservopistonsaremovedby
pressure oil supplied by the gear pump and
adjustableofthebladesismadebythetwopiston
rodsviathefork,theregulationringandadjustable
leaver.Bythiscontrolcombination,theguidevanes
are moved to 0% or 100 % guide vane position
department
on
the
converter
operating
state
.

7. The pump impeller, the guide wheel and the
turbine wheel form the oil-filled circuit together
withtheconvertershell.
A gear pump is installed in the torque converter
which is driven directly and connected with the
inputshaft.
The housing of torque converter supports the
internal parts controlling the oil supply and oil
discharge.
In addition the converter housing is used as oil
tank.

8. OPERATION-TORQUE CONVERTER
The hydrodynamic torque converter is provided for
steeples speed/torque transmission (multiplication)
between motor & driven machine. The pump impeller
absorbsthemechanicalenergyofdrivingmachine(motor)
withthe3
rd
powerofinputspeed(n
3
).Theturbinewheel
convertsthekineticenergyexistinginthefluidmassback
to mechanical energy. The guide wheel absorb the
differential torque between pump impeller and turbine
wheelwhichresultsinatorquemultiplication.Theguide
vanesofthesecondguidewheelareadjustableandeffecta
changeoftheflowdirection.Theinsidediameterbetween
theguidevanes,relativetothevalueinthedesignpoint,is
provided as "relative guide vane position”(in %) to
describe theoperatingbehavior.

9. Dependent
ontheguidevanepositionbetween0%
and
100%,acorrespondingtorqueistransmitted
via
the turbine wheel as a function of the output
speed
. the pump impeller and the turbine wheel
rotate
inthesamedirection.Thereisnomechanical
connection
between the pump impeller, turbine
wheel
andguidewheel.Torquetransmissionisload
independent,
i.e.thetorqueproducedintheturbine
wheel
has its max. point during standstill of the
output
shaftsincereversaloffluidismaximumhere,
and
decreases with increasing speed. Thus the
torque
converter adapts sleeplessly and
automatically
totheresistanceoccurring

15. OIL CIRCUIT
ThehousingisprovidedasoiltankThesameoilisusedas
workingoil,controloil,lubeoilandcoolingoil.Thetorque
converter is supplied with working oil by gear pump
installedinside.
WORKING OIL CIRCUIT
Thegearpumpsuppliestheworkingoildirectlyintothe
working chamber of the torque converter. For heat
dissipation, a certain quantity of working oil flows from
the closed circuit of the working chamber through the
working oil orifice plate , the heat exchanger and the
bypass oil filter back to the torque converter. The
converter pressure in the flow to the working oil outlet
must be approx. 5 bar. The converter pressure is
determinedasafunctionofworkingoilorificeplatebore.

16. CONTROL OIL
A gear pump pinion supplies the adjustment
mechanismwithcontroloil.Theoilpressureofthis
circuit is provided by a pressure relief valve. The
control oil pressure is limited to 15 bar via the
pressurereliefvalve.
LUBE OIL CIRCUIT
Allantifrictionbearingsaresurroundedbythe
torque converter working oil. A separate
lubrication of the bearings is not necessary
duringoperationoftheconverter.

17. GUIDE VANE ADJUSTMENT
The guide vane adjustment enables a continuous change of the
powertransmission.Thismeansthataspeedadaptationispossible
for any drive of driven machine whereas the load dependency
remainsunchanged.
PNEUMATIC LEVER ACTUATOR
The pneumatic actuator with lever acts on the servo piston vi a the
control piston. The control piston moves in the piston rod wh ich
runs in the mechanically connected with the regulating ring . The
guidevanesareadjustedwithexistingcontroloilpressure.Apinion
onthegearpumpsuppliestheservounitwithcontroloilthroughthe
ducts in the control piston and the position of the piston rod to the
correspondingcylinder.Thetwoservocylindersareconnectedbyoil
ducts in the housing. The control piston adjust the position of the
vanesguidewheelviatheregulatingringuntiltheservopistonisno
longersuppliedwithoilduetothepositionofthepistonrod.

18. DESCRIPTIONFREQUENCYOF
MAINTENANCE
Crankcase InspectionTwo Year
MPI of Crankshaft / Connecting Rod Two Year
Main Bearing Replacement 40000 hrs.
Tandem Valves & it’s ‘O’ Rings Replacement
3000 hrs.
Torque Convertor Inspection Two year
Valve Block Inspection3000 hrs
Gear Box High Speed Shaft Seal Inboard Two Year
Torque Converter Shaft Seal Outboard
Two Year

19. GUIDE VANES

20. INTERNAL GEAR PUMPS ATTACHED WITH
INPUT SHAFT

21. OUTPUT SHAFT

27. THANKING YOU
For any types of queries please write me [email protected] [email protected] Mob-[phone]