Abstract: A method for lapping the gears of a gear set as well as a gear lapping system. The gear set generally includes a first gear in meshed engagement with a second gear, each of the first and second gears having a plurality of gear teeth each with drive and coast flank surfaces. The method includes the steps of lapping the gear set by rotating the first gear in a first direction while the first gear is in mesh with the second gear. The method further includes sensing the vibrations occurring in the gear mesh during rotation and controlling the step of lapping based on the sensed vibrations. The gear lapping system includes an automated lapping machine that is adapted to lap the gear set including a ring gear and a pinion gear. The automated lapping machine is adapted to lap the gear set by rotating at least one of the ring and pinion gears while in mesh, in the presence of a lapping compound, and while translating the gear mesh back and forth across the gear flank surfaces for a plurality of cycles.

Abstract: A vaned element of a fluid coupler such as a torque converter includes vanes having a depression extending from a leading surface area to a trailing edge of the vane. The depression avoids multiple surface layer changes which introduce turbulence to flow of fluid past the vane. The depression also forms reinforcing ribs in the form of raised walls which dimensionally stabilize the mounting tabs for the vane. In addition the vane construction is light weight since it permits the use of simple cross-sectionally shaped vanes while improving the speed capability of the torque converter and the strength of the vaned elements. The blade construction permits automated assembly techniques for the vaned elements.

Abstract: A method for welding torque converter blades to an impeller housing by laser beam welding includes forming the blades with a tab fitted within a recess formed in the impeller housing such that the blade tab stands clear of the adjacent surfaces of the housing by the width of an air gap. A laser beam is directed onto an adjacent surface of the housing a short distance from an edge of the housing adjacent a blade tab to be welded to the housing. A laser beam, whose axis is inclined with respect to the recess, strikes a surface of the housing adjacent the tab. The welding gun is energized with electrical power and the welding beam is moved parallel to the blade tab at a predetermined speed consistent with the power. The blade tab is welded to the housing without the use of filler material and the housing is rotated with respect to its longitudinal axis to bring successive blade tabs into position for welding.

Abstract: A method for welding two portions of a cover for a torque converter at an overlap joint using a welding beam includes directing the welding beam at the radially outer cover in the vicinity of the overlap at an acute angle with the plane of the over portions in the vicinity of the overlap. The angle is chosen so that the focal point of the welding beam is located on the radially outermost cover portion near the inner surface and distant from the outer surface. In this way, before fusion occurs, temperature gradients are induced through the thicknesses of the cover portions tending to reduce radial expansion of the outer cover and increase radial expansion of the inner cover. The effect of these thermal bending moments and the effect of the increase in mean temperature of the covers due to the welding beam combine to reduce or eliminate the thickness of the gap that exists before welding begins.