Electric motor rotors for hybrid modules

Abstract

An electric motor rotor for a hybrid module includes a rotor carrier, a piston carrier, and a tapered snap ring. The rotor carrier includes: a first inner peripheral surface having an inner spline for receiving a first plurality of clutch plates; a second inner peripheral surface located radially outside the first inner peripheral surface; a radial wall connecting the first inner peripheral surface to the second inner peripheral surface; and a groove having a tapered wall. The piston carrier includes a radially outer ring mounted between the groove and the radial wall. The tapered snap ring is a ring mounted in the groove and pushes the piston carrier into contact with the radial wall.

Description

Technical Field

[0001] The present disclosure relates generally to hybrid modules and, more particularly, to electric motor rotors for hybrid modules. Background Art

[0002] Hybrid modules are known. Examples are shown in commonly assigned U.S. Patent Applications Serial No. 16 / 527,329 entitled Hybrid Module, Serial No. 16 / 527,663 entitled Hybrid Module Configuration, and Serial No. 16 / 527,686 entitled Hybrid Module, the entire contents of which are hereby incorporated by reference as if fully set forth herein. Summary of the invention

[0003] Example aspects generally include an electric motor rotor for a hybrid module, the electric motor rotor including a rotor carrier, a piston carrier, and a tapered snap ring. The rotor carrier includes: a first inner peripheral surface having an inner spline for receiving a first plurality of clutch plates; a second inner peripheral surface located radially outward of the first inner peripheral surface; a radial wall connecting the first inner peripheral surface to the second inner peripheral surface; and a groove having a tapered wall. The piston carrier includes a radially outer ring mounted between the groove and the radial wall. The tapered snap ring is a ring mounted in the groove and pushes the piston carrier into contact with the radial wall.

[0004] In an example embodiment, the second inner circumferential surface has a key and the radially outer ring has a groove that drivingly engages the key. In an example embodiment, the electric motor rotor has a tapered nut. The piston carrier includes a threaded portion, the tapered nut is mounted on the threaded portion, and the tapered nut includes a tapered surface that pushes the tapered snap ring radially outward into the groove. In an example embodiment, the electric motor rotor includes a plurality of rotor segments that are mounted on the outer circumferential surface of the rotor carrier.

[0005] In some example embodiments, the electric motor rotor includes: a first plurality of clutch plates drivingly engaged with the internal splines; and a piston sealed to a piston carrier for axially pressing the first plurality of clutch plates to transmit torque. In an example embodiment, the electric motor rotor has an annular gasket. The piston includes an annular protrusion for pressing the first plurality of clutch plates, and the annular gasket is axially disposed between the annular protrusion and the first plurality of clutch plates. In an example embodiment, the piston is sealed to the piston carrier by a radially outer seal and a radially inner seal. In some example embodiments, the electric motor rotor includes: a piston sealed to the piston carrier; a balancing dam sealed to the piston; and a retaining ring. The piston carrier includes a groove, and the retaining ring is installed in the groove and axially retains the balancing dam. In an example embodiment, the electric motor rotor includes a spring for urging the piston axially away from the balancing dam.

[0006] In some example embodiments, an electric motor rotor includes a rotary transformer adapter plate and a rotary transformer rotor. The rotary transformer adapter plate has: a radially outer ring portion, the radially outer ring portion including a first axial groove; a radially inner ring portion, the radially inner ring portion having a second axial groove; and a tapered connector portion extending from the radially inner ring portion to the radially outer ring portion. The rotary transformer rotor has a first key mounted in the first axial groove. The second inner peripheral surface has a second key mounted in the second axial groove. In some example embodiments, the rotary transformer adapter plate includes: a radial wall, the radial wall contacts a first axial face of the rotary transformer rotor; and a radially extending protrusion, the radially extending protrusion contacts a second axial face of the rotary transformer rotor opposite to the first axial face. In example embodiments, the rotary transformer adapter plate has a close sliding fit with the rotary transformer rotor. In example embodiments, the radially extending protrusion is formed by riveting.

[0007] In some example embodiments, the electric motor rotor includes a torque converter fixed to the rotor carrier. In some example embodiments, the rotor carrier has a first annular segment and the torque converter has a second annular segment fixed to the first annular segment. In example embodiments, the rotor carrier has a third inner circumferential surface and the torque converter has an outer circumferential surface mounted in the third inner circumferential surface for radially positioning the torque converter in the rotor carrier.

[0008] Example aspects also include a hybrid module for connecting an internal combustion engine to a multi-stage transmission. The hybrid module includes an electric motor stator, an electric motor rotor with a torque converter, a module input shaft, and a first plurality of clutch plates and a second plurality of clutch plates. The torque converter includes: an impeller, a turbine, and a stator for transmitting torque through a transmission fluid; a torque converter clutch, the torque converter clutch for transmitting torque through a mechanical connection; and a damper, the damper is arranged in a torque path between the turbine or the torque converter clutch and the multi-stage transmission. The damper has an output hub, which is arranged to be drivingly engaged with the input shaft of the multi-stage transmission. The module input shaft has a clutch inner carrier. The first plurality of clutch plates are drivingly engaged with the rotor carrier, and the second plurality of clutch plates are drivingly engaged with the clutch inner carrier. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 An upper half cross-sectional view of a hybrid module according to an example aspect of the present disclosure is illustrated.

[0010] Figure 2 Pictured Figure 1 Detailed view of a portion of the hybrid block module. DETAILED DESCRIPTION

[0011] Various embodiments of the present disclosure are described herein. It should be appreciated that the same reference numerals appearing in different figures identify identical or functionally similar structural elements. It should also be understood that the various embodiments disclosed are examples only, and other embodiments may take various forms and alternative forms. These figures are not necessarily to scale; some features may be enlarged or minimized in order to show the details of a particular component. Therefore, the specific structural and functional details disclosed herein should not be interpreted as restrictive, but only as a representative basis for teaching those skilled in the art to adopt various embodiments in various ways. As will be understood by those of ordinary skill in the art, the various features illustrated and described with reference to any of the figures in the accompanying drawings may be combined with the features illustrated in one or more other figures to produce an embodiment that is not explicitly illustrated or described. The combination of the illustrated features provides a representative embodiment for a typical application. However, for a particular application or implementation, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0012] The terms used herein are only for the purpose of describing specific aspects and are not intended to limit the scope of the present disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as that commonly understood by one of ordinary skill in the technical field to which the present disclosure belongs. Although any method, device or material similar to or equivalent to those described herein may be used in the practice or testing of the present disclosure, the following example methods, devices and materials are now described.

[0013] Reference Figure 1 to Figure 2 The following description is given. Figure 1 An upper half cross-sectional view of a hybrid module 100 is illustrated, according to example aspects of the present disclosure. Figure 2 Pictured Figure 1 Detailed view of a portion of a hybrid module 100 of FIG. The hybrid module 100 for a motor vehicle (not shown) includes an electric motor 102 having a stator 104 and a rotor 106. The stator 104 is fixed to the housing and receives electrical energy in a coil 108 to rotate a rotor segment 109 mounted on an outer peripheral surface of the rotor 106. The rotor 106 works in conjunction with an internal combustion engine (not shown) to propel the motor vehicle. That is, the rotor 106 includes a torque converter 110 that is drivingly engaged with a multi-speed vehicle transmission and transmits torque to a vehicle driveline as is known in the art.

[0014] The electric motor rotor 106 includes a rotor carrier 112, a piston carrier 114, and a tapered snap ring 116. The rotor carrier includes an inner peripheral surface 118 having an inner spline 120 for receiving a plurality of clutch plates 122; an inner peripheral surface 124 located radially outward of the inner peripheral surface 118; a radial wall 126 connecting the surfaces 118 and 124; and a groove 128 having a tapered wall 130. The piston carrier 114 includes a radially outer ring 132 mounted between the groove and the radial wall. The tapered snap ring 116 is mounted in the groove and pushes the piston carrier into contact with the radial wall. The inner peripheral surface 124 includes a key 134 and the radially outer ring 132 includes a groove 136 drivingly engaged with the key.

[0015] The electric motor rotor also includes a tapered nut 138. The piston carrier 114 includes a threaded portion 140, the tapered nut 138 is mounted on the threaded portion, and the tapered nut includes a tapered surface 142 that pushes the tapered snap ring radially outward into the groove. That is, when the nut is tightened onto the threaded portion, the tapered surface extends under the tapered snap ring and causes the snap ring to expand radially. As the snap ring expands, the taper on the snap ring is forced against the tapered wall 130 of the groove 128, thereby pushing the snap ring away from the tapered wall and toward the piston carrier 114. Therefore, when the nut 138 is tightened, the piston carrier outer ring 132 is tightly pressed against the radial wall 126. As described below, eliminating the axial clearance between the rotor carrier 112 and the piston carrier 114 reduces the clutch release tolerance.

[0016] The electric motor rotor 106 includes a clutch plate 122 and a piston 144. The clutch plate 122 is drivingly engaged with the internal spline 120. The piston 144 is sealed to the piston carrier by a radially outer seal 146 mounted in the piston 144 and a radially inner seal 148 mounted in the piston carrier 114. The piston 144 is used to axially press the plurality of clutch plates to transmit torque. That is, hydraulic pressure is introduced through the passage 150 in the diaphragm 152 and the passage 154 in the hub 156 and enters the hydraulic chamber 158. The high pressure in the chamber 158 pushes the piston 144 toward the clutch plate 122 to engage the clutch and transmit torque from the clutch inner carrier 160 to the rotor carrier 112.

[0017] The electric motor rotor 106 includes a shim 162. The piston 144 includes an annular protrusion 164 for pressing the clutch plates 122, and the shim 162 is axially disposed between the annular protrusion and the plurality of clutch plates. The thickness of the shim 162 is selected to adjust the separation of the clutch. That is, in order to better control the distance between the piston and the clutch plates when the clutch is disengaged, the components for each rotor carrier assembly can be measured and a shim of a specific thickness can be selected to reduce the separation tolerance when the clutch is disengaged. The reduced tolerance helps to improve the clutch engagement and reduce the resistance when the clutch is disengaged.

[0018] The electric motor rotor 106 includes a piston 144 sealed to the piston carrier 114 as described above, a balance dam 166 sealed to the piston 144 by a seal 168, and a snap ring 170. The piston carrier 114 includes a groove 172, and the snap ring is installed in the groove. The snap ring axially holds the balance dam. The balance dam retains fluid in a balance chamber 174 between the piston 144 and the balance dam 166 to offset the dynamic effect of the rotating fluid in the hydraulic chamber 158. That is, when the fluid in the hydraulic chamber 158 rotates, the centrifugal effect forces the fluid to push the piston radially outward to engage the clutch even in the absence of any engagement pressure for the fluid in the chamber 158. The rotating fluid in the balance chamber is subjected to similar dynamic effects and offsets the effects in the chamber 158, so that the piston remains substantially balanced and the resistance in the clutch is limited. The spring 176 pushes the piston 144 away from the balance dam 166.

[0019] The electric motor rotor 106 includes a resolver adapter plate 178 and a resolver rotor 180. The resolver adapter plate includes a radially outer ring portion 182 having an axial slot 184, a radially inner ring portion 186 having an axial slot 188, and a tapered connector portion 190 extending from the inner ring portion to the outer ring portion. The resolver rotor includes a key 192 mounted in the axial slot 184, and the inner peripheral surface 124 includes a key 194 mounted in the axial slot 188. The resolver adapter plate also includes a radial wall 196 that contacts an axial face 198 of the resolver rotor and a radially extending protrusion 200 that contacts an axial face 202 of the resolver rotor opposite the axial face 198.

[0020] The resolver adapter plate has a close sliding fit with the resolver rotor. The radially extending protrusion is formed by riveting. That is, the resolver adapter plate is tightly held between the radial wall 196 and the protrusion 200 due to the resolver adapter plate deforming against the axial face 202. The material extending axially through the resolver rotor is pressed using a die (not shown) to form a material that tightly holds the resolver rotor axially and radially. The resolver stator 203 is fixed to the hub 156 by rivets 204, and the resolver rotor and resolver stator together communicate the rotational position of the rotor carrier to the controller. The bearing 206 mounted between the piston carrier 114 and the hub 156 positions the rotor 106 relative to the stator 104 and allows relative rotation with minimal friction between the rotor and the stator.

[0021] The electric motor rotor 106 includes a torque converter 110 fixed to a rotor carrier 112. The rotor carrier 112 includes an annular segment 208, and the torque converter 110 includes an annular segment 210 fixed to the annular segment 208. The rotor carrier 112 includes an inner peripheral surface 212, and the torque converter 110 includes an outer peripheral surface 214, which is mounted on the surface 212 for radially positioning the torque converter in the rotor carrier. The arrangement of the segments 208 and 210 and the surfaces 212 and 214 allows the assembled torque converter to be mounted on the rotor carrier. That is, the fully assembled and welded torque converter (e.g., by weld 216) can be fixed to the rotor carrier 112 by weld 218.

[0022] The hybrid module 100 is used to connect an internal combustion engine (not shown) to a multi-speed transmission (not shown). The module includes an electric motor stator 102, an electric motor rotor 106 with a torque converter 110, a module input shaft 220 with a clutch inner carrier 160, a clutch plate 122, and a clutch plate 222. The torque converter includes an impeller 224 fixed to a cover shell 225 at a weld 216, a turbine 226, and a stator 228 for transmitting torque through a transmission fluid (not shown). The torque converter also includes: a torque converter clutch 230, which is used to transmit torque through a mechanical connection; and a damper 232, which is arranged in the torque path between the turbine or torque converter clutch and the multi-speed transmission. The damper includes an output flange 234, which is arranged to be drivingly engaged with an input shaft (not shown) of the multi-speed transmission (for example, at a spline 236). The clutch plates 122 are drivingly engaged with the rotor carrier and the clutch plates 222 are drivingly engaged with the clutch inner carrier.

[0023] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms covered by the claims. The words used in the specification are descriptive rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the various features of the various embodiments can be combined to form other embodiments of the present disclosure that may not be clearly described or illustrated. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations in terms of one or more desired characteristics, it is recognized by those of ordinary skill in the art that one or more features or characteristics can be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, applicability, weight, manufacturability, ease of assembly, etc. Therefore, to the extent that any embodiment is described as less ideal than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments do not depart from the scope of the present disclosure and may be expected to be used for specific applications.

[0024] Reference numerals list

[0025] 100 hybrid module 102 electric motor 104 stator 106 rotor 108 stator coil 109 rotor segment 110 torque converter 112 rotor carrier 114 piston carrier 116 tapered snap ring 118 inner circumferential surface (first) 120 inner spline (rotor carrier) 122 multiple clutch plates (first) 124 inner circumferential surface (second) 126 radial wall (rotor carrier) 128 groove (rotor carrier) 130 tapered wall (groove) 132 radial outer ring (piston carrier) 134 key (second inner circumferential surface) 136 groove (radial outer ring) 138 tapered nut 140 threaded portion (piston carrier) 142 tapered surface (tapered nut) 144 piston 146 radial outer seal (piston) 148 radial inner seal (piston carrier) 150 passage (spacer) 152 spacer 154 passage (hub) 156 hub 158 hydraulic chamber 160 clutch inner carrier 162 gasket 164 annular protrusion (piston) 166 balance dam 168 seal (balance dam) 170 snap ring 172 groove (piston carrier) 174 balance chamber 176 spring 178 resolver adapter plate 180 resolver rotor 182 radial outer ring portion 184 axial groove (first) 186 radial inner ring portion 188 axial groove (second) 190 tapered connector portion 192 key (first) 194 key (second) 196 radial wall (resolver adapter plate) 198 axial face (first, resolver rotor) 200 radially extending protrusion (resolver adapter plate) 202 axial face (second, resolver rotor) 203 resolver stator 204 rivet (resolver stator to hub) 206 bearing 208 annular segment (first, rotor carrier) 210 annular segment (second, torque converter) 212 inner peripheral surface (third) 214 outer peripheral surface 216 weld (torque converter) 218 ​​weld (torque converter to rotor carrier) 220 module input shaft 222 multiple clutch plates (second) 224 impeller 225 cover shell 226 turbine 228 stator 230 torque converter clutch 232 damper 234 output flange 236 spline (output flange).

Claims

1. An electric motor rotor for a hybrid power module, the electric motor rotor comprising: A rotor carrier, the rotor carrier comprising: a first inner peripheral surface including internal splines for receiving a first plurality of clutch plates; a second inner peripheral surface, the second inner peripheral surface being located radially outward of the first inner peripheral surface; a radial wall connecting the first inner peripheral surface to the second inner peripheral surface; and a groove, the groove comprising a tapered wall; a piston carrier including a radially outer ring mounted between the groove and the radial wall; a piston sealed to the piston carrier; and A tapered snap ring is mounted in the groove and urges the piston carrier into contact with the radial wall.

2. The electric motor rotor according to claim 1, wherein: The second inner peripheral surface includes a key; and The radially outer ring includes a groove drivingly engaged with the key.

3. The electric motor rotor of claim 1 , further comprising a tapered nut, wherein: The piston carrier includes a threaded portion; The tapered nut is mounted on the threaded portion; and The tapered nut includes a tapered surface that pushes the tapered snap ring radially outward into the groove. 4 . The electric motor rotor of claim 1 , further comprising a plurality of rotor segments mounted on an outer circumferential surface of the rotor carrier.

5. The electric motor rotor of claim 1 , further comprising: the first plurality of clutch plates drivingly engaged with the internal splines; as well as A piston is sealed to the piston carrier for axially pressing the first plurality of clutch plates to transmit torque.

6. The electric motor rotor of claim 5, further comprising an annular spacer, wherein: The piston includes an annular protrusion for pressing the first plurality of clutch plates; and The annular spacer is disposed axially between the annular protrusion and the first plurality of clutch plates.

7. The electric motor rotor according to claim 5, wherein: The piston is sealed to the piston carrier by a radially outer seal and a radially inner seal.

8. The electric motor rotor of claim 1 , further comprising: a balancing dam sealed to the piston; as well as A snap ring, wherein the piston carrier includes a groove, and the snap ring is installed in the groove and axially retains the balance dam.

9. The electric motor rotor of claim 8, further comprising a spring for urging the piston axially away from the balance dam.

10. The electric motor rotor of claim 1, further comprising: A rotary transformer adapter board, the rotary transformer adapter board comprising: a radially outer ring portion, the radially outer ring portion comprising a first axial groove; a radially inner ring portion comprising a second axial groove; and a tapered connector portion extending from the radially inner ring portion to the radially outer ring portion; and A resolver rotor includes a first key mounted in the first axial groove, wherein the second inner peripheral surface includes a second key mounted in the second axial groove.

11. The electric motor rotor according to claim 10, wherein: The resolver adapter board includes: a radial wall contacting a first axial face of the resolver rotor; and A radially extending protrusion contacts a second axial surface of the resolver rotor opposite the first axial surface.

12. The electric motor rotor according to claim 11, wherein: The resolver adapter plate has a close sliding fit with the resolver rotor.

13. The electric motor rotor of claim 11, wherein: The radially extending protrusion is formed by riveting.

14. The electric motor rotor of claim 1 further comprising a torque converter secured to the rotor carrier.

15. The electric motor rotor of claim 14, wherein: The rotor carrier comprises a first annular section; and The torque converter includes a second annular segment fixed to the first annular segment.

16. The electric motor rotor of claim 15, wherein: The rotor carrier includes a third inner circumferential surface; and The torque converter includes an outer peripheral surface mounted in the third inner peripheral surface for radially positioning the torque converter in the rotor carrier.

17. The electric motor rotor of claim 14, wherein: The rotor carrier includes a third inner circumferential surface; and The torque converter includes an outer peripheral surface mounted in the third inner peripheral surface for radially positioning the torque converter in the rotor carrier.

18. A hybrid power module for connecting an internal combustion engine to a multi-speed transmission, the hybrid power module comprising: Electric motor stators; The electric motor rotor of claim 17, wherein the torque converter comprises: impeller, turbine and stator for transmitting torque through the transmission fluid; a torque converter clutch for transmitting torque via a mechanical connection; and a damper disposed in a torque path between the turbine or the torque converter clutch and the multi-speed transmission, the damper including an output hub disposed for driving engagement with an input shaft of the multi-speed transmission; a module input shaft, the module input shaft including a clutch inner carrier; a first plurality of clutch plates drivingly engaged with the rotor carrier; and A second plurality of clutch plates drivingly engages the clutch inner carrier.

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