Integrated hydraulic module for first-gear rear-drive DHT hybrid transmission

Abstract

The invention discloses an integrated hydraulic module for a first-gear rear-drive DHT hybrid transmission, and belongs to the technical field of hybrid automobile transmissions. Comprising an upper valve body, an oil pump supporting assembly, a base plate assembly fixed between the upper valve body and the oil pump supporting assembly, an ON-OFF electromagnetic valve installed in a preset valve hole of the upper valve body, a mechanical pump installed on the oil pump supporting assembly, an oil pump driven gear and a one-way valve assembly. The main pressure regulating valve mechanism, the pressure limiting valve assembly, the oil temperature sensor support and the connecting plug fixing plate are fixed to the upper valve body. The hybrid transmission solves the technical problems that an existing hybrid transmission is low in energy conversion efficiency, not compact in structure, large in occupied space, high in cost and the like. A power source, a control valve, a sensor, a safety device and wire harness management are integrated, high integration of hydraulic control, lubricating and cooling functions is achieved, the arrangement space is remarkably reduced, and the research and development cost is reduced.

Description

Technical Field

[0001] This invention relates to an integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission, belonging to the field of hybrid vehicle transmission technology. Background Technology

[0002] In terms of energy utilization, the DHT hybrid transmission can flexibly switch between various operating modes, such as pure electric drive, parallel drive, and engine direct drive, depending on the vehicle's driving conditions (e.g., urban congestion, highway driving). This allows the engine to operate within its most efficient range, significantly improving energy efficiency and effectively reducing fuel consumption and emissions. Regarding power performance, this type of transmission enables coordinated power output from the electric motor and engine, resulting in stronger performance during acceleration, hill climbing, and other scenarios requiring high power output, thus enhancing the driving experience.

[0003] However, existing hybrid transmission technology in China still has several issues that need to be optimized:

[0004] Firstly, the energy conversion efficiency of some traditional hybrid transmissions is relatively low, leading to energy waste and thus increasing fuel consumption;

[0005] Secondly, some transmission structures are not compact and reasonable enough, occupying a large space, which is not conducive to the overall layout and lightweight design of the vehicle, and the complex structure also increases production and maintenance costs.

[0006] Based on the current state of the technology, there is an urgent need to develop an integrated hydraulic module suitable for hybrid transmissions to meet the technical requirements of simple structure, small footprint, high efficiency, low cost, and safety and reliability. Summary of the Invention

[0007] To address the problems existing in the background art, the present invention provides an integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: an integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission, comprising:

[0009] The upper valve body is fixed to the transmission housing and has an internal oil passage and valve hole. The upper part has an interface for connecting external oil passages and sensors.

[0010] The oil pump support assembly is installed at the lower part of the upper valve body and includes a pump housing, bearings and seals. It has oil passages and valve holes inside to support the inner rotor and outer rotor.

[0011] The gasket assembly is fixed between the upper valve body and the oil pump support assembly. It has oil holes and bolt through holes corresponding to the upper valve body and the oil pump support assembly to achieve sealing, connection and positioning functions.

[0012] The ON-OFF solenoid valve is installed in the preset valve hole of the upper valve body. It receives the PWM signal sent by the TCU and outputs a linear hydraulic pressure proportional to the control current to control the engagement and disengagement of the clutch. At the same time, it is connected to the main pressure regulating valve mechanism through the main oil pressure feedback oil circuit to change the oil pressure of the entire hydraulic system.

[0013] The mechanical pump includes an inner rotor, an outer rotor, an oil pump support assembly, and an oil pump driven gear. The outer rotor is installed in the cavity of the oil pump support assembly. The inner rotor is driven to rotate by the drive shaft and drives the outer rotor to rotate eccentrically.

[0014] The driven gear of the oil pump is mounted on the oil pump support assembly and meshes with the oil pump drive gear. It is used to balance oil pulsation and realize oil suction and delivery.

[0015] The main pressure regulating valve mechanism is installed in a dedicated valve cavity inside the upper valve body. The first oil inlet acts the oil pressure of the main oil circuit on the first feedback surface of the mechanical valve core to stabilize the oil pressure in the main oil circuit within the set range.

[0016] The check valve assembly, mounted on the oil pump support assembly, is used to prevent the oil output from the mechanical pump from causing the electronic pump to reverse.

[0017] The pressure relief valve assembly is installed in the preset valve hole of the upper valve body. It is installed in the main oil circuit as a safety valve. The oil outlet end is connected to the oil pan through the oil suction and oil discharge oil circuits.

[0018] An oil temperature sensor bracket is fixed on the upper valve body and used to install the oil temperature sensor, which extends into the internal oil passage of the upper valve body.

[0019] The connector mounting plate is fixed to the upper valve body. It has a slot and a wire harness fixing hole for centrally fixing all the electrical connectors and sensor wire harnesses of the solenoid valves.

[0020] Furthermore, the upper valve body is made of cast aluminum alloy.

[0021] Furthermore, the pad assembly is made of aluminum alloy sheet by stamping.

[0022] Furthermore, the mechanical pump and the electronic pump share a single oil suction and drain circuit that extends from the oil pan through a filter. A one-way valve assembly is connected in series at a branch of the oil suction and drain circuit. The inlet of the one-way valve assembly is connected to the oil outlet of the electronic pump, and the outlet of the one-way valve assembly is connected to the main oil circuit.

[0023] Furthermore, the main pressure regulating valve mechanism includes a main pressure regulating valve, a spring, and a stop plug; the stop plug is fixed to the end of the valve cavity inside the upper valve body, one end of the spring abuts against the stop plug, and the other end of the spring presses against the valve core of the main pressure regulating valve.

[0024] Furthermore, the main pressure regulating valve has a two-stage pressure control logic, wherein: the first stage is low oil pressure, i.e. EV mode, in which the C1 clutch is not engaged; the second stage is high oil pressure mode, in which the oil pressure ensures that the C1 clutch is engaged, while keeping the system pressure stable at the target value and releasing excess flow.

[0025] Furthermore, the main pressure regulating valve mechanism is connected to the cooling and lubrication oil circuit, and distributes hydraulic oil to the rear lubrication oil circuit, the intermediate shaft lubrication oil circuit, and the motor cooling oil circuit through different throttling orifices.

[0026] Furthermore, the hydraulic circuit of the hydraulic module includes:

[0027] The main oil circuit is used to transmit system pressure and flow.

[0028] The oil suction and drain circuit is used to drain excess flow from the hydraulic system after the main oil circuit pressure is adjusted.

[0029] The electronic pump outlet circuit is used to transport the oil output by the electronic pump, introduce the pressurized oil provided by the electronic pump into the main oil circuit, and work with the mechanical pump to supplement the flow and stabilize the pressure of the hydraulic system;

[0030] The clutch pressure oil circuit and the main oil pressure feedback oil circuit work together to apply the adjusted main oil pressure to the clutch, thereby realizing the clutch engagement function.

[0031] Cooling and lubrication circuits are used to achieve lubrication, friction reduction, and cooling of components;

[0032] The lubricating oil pressure relief circuit is used to cool the oil pressure in the lubricating oil circuit.

[0033] Compared with the prior art, the beneficial effects of the present invention are:

[0034] This invention addresses the technical challenges of existing hybrid transmissions, such as low energy conversion efficiency, non-compact structure, large space occupation, and high cost, through an integrated hydraulic module design. By integrating the power source, control valves, sensors, safety devices, and wiring harness management into a single unit, it achieves a high degree of integration of hydraulic control, lubrication, and cooling functions, significantly reducing layout space and R&D costs. Through the coordinated operation of mechanical and electronic pumps and a two-stage pressure control logic of the main pressure regulating valve, it adapts to the oil pressure requirements of different operating conditions (such as EV mode and parallel drive mode). While ensuring stable engagement of the C1 clutch, it stabilizes the system pressure at the target value and releases excess flow, improving energy utilization efficiency. Combined with a multi-path distribution design for the cooling and lubrication oil circuit, it meets the differentiated needs of rear-end lubrication, intermediate shaft lubrication, and motor cooling. Ultimately, it optimizes the first-gear rear-wheel-drive DHT hybrid transmission in terms of efficient operating condition switching, power synergy output, and compact layout, improving energy utilization and driving experience, reducing fuel consumption and maintenance costs, and enhancing system reliability. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the upper valve body;

[0036] Figure 2 This is a structural schematic diagram of the oil pump support assembly;

[0037] Figure 3 This is a schematic diagram of the oil circuit of the upper valve body;

[0038] Figure 4 This is a schematic diagram of the oil circuit of the oil pump support assembly. Detailed Implementation

[0039] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0040] An integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission, including

[0041] The upper valve body 1 is the basic structural component of the entire hydraulic module. It is fixed to the transmission housing by bolts. It has complex oil passages and valve holes inside, and the upper part has an interface for connecting external oil passages and sensors.

[0042] The oil pump support assembly 3 is installed at the lower part of the upper valve body 1. It includes the pump housing, bearings and seals. It has complex oil passages and valve holes inside to support the inner rotor 6 and the outer rotor 7, which can ensure the stable operation and sealing performance of the oil pump.

[0043] The gasket assembly 2 is a key intermediate component that is fixed to the upper valve body 1 and the oil pump support assembly 3 by bolts. It has oil holes and bolt through holes corresponding to the upper valve body 1 and the oil pump support assembly 3 to achieve sealing, connection and positioning functions.

[0044] The core function of the gasket assembly 2 is to form a reliable sealing interface between the valve body 1 and the oil pump support 3, ensuring that high-pressure oil does not leak when flowing in the oil passages between different components. At the same time, it also serves to connect and position, ensuring the precise alignment of the upper and lower oil passages.

[0045] The ON-OFF solenoid valve 4 is a high-frequency response, high-precision proportional pressure control solenoid valve. It is threaded into the preset valve hole of the upper valve body 1, receives the PWM pulse width modulation signal from the TCU transmission control unit, and outputs linear hydraulic pressure proportional to the control current. It is used to control the engagement and disengagement of the clutch, so as to achieve smoothness and fast response in the shifting process. At the same time, it is connected to the main pressure regulating valve mechanism through the main oil pressure feedback oil circuit 17 to change the oil pressure of the entire hydraulic system.

[0046] The mechanical pump adopts a rotor pump structure, including an inner rotor 6, an outer rotor 7, an oil pump support assembly, and an oil pump driven gear. The outer rotor 7 is installed in the cavity of the oil pump support assembly 3. The inner rotor 6 is driven to rotate by the drive shaft and drives the outer rotor 7 to rotate eccentrically. The process of oil suction and oil pressure is realized through the change of volume.

[0047] The oil pump driven gear 5 is mounted on the oil pump support assembly 3 and meshes with the oil pump drive gear. It is used to balance oil pulsation, realize oil suction and delivery, improve oil supply stability, and establish a pressure foundation for the hydraulic system.

[0048] The main pressure regulating valve mechanism is installed in a dedicated valve cavity inside the upper valve body 1. The first oil inlet acts the oil pressure of the main oil circuit 15 on the first feedback surface of the mechanical valve core, generating the first feedback force of the main oil pressure, which forms a force balance with the spring force, and is used to stabilize the oil pressure in the main oil circuit 15 within the set range to meet the needs of the hydraulic system.

[0049] One-way valve assembly 12 is mounted on oil pump support assembly 3 to prevent the oil output from the mechanical pump from causing the electronic pump to reverse.

[0050] The pressure relief valve assembly 13 is installed in the preset valve hole of the upper valve body 1 by thread, and is installed in the main oil circuit 15 as a safety valve. The oil outlet end is connected to the oil pan through the oil suction and oil discharge oil circuit 16.

[0051] When the system pressure exceeds the limit value set by its spring due to some abnormal reason, the pressure relief valve assembly 13 opens to release pressure and guide some oil back to the oil pan, thereby protecting the hydraulic pump and precision components such as seals and sensors in the system from high pressure damage.

[0052] The oil temperature sensor bracket 11 is fixed to the upper valve body 1 by bolts and is used to install the oil temperature sensor. The oil temperature sensor is inserted into the internal oil passage of the upper valve body 1 and can accurately sense the working temperature of the hydraulic oil and feed the signal back to the TCU. The TCU can then correct the hydraulic control strategy, such as adjusting the pressure according to the oil temperature, to ensure the accuracy of control under different working conditions.

[0053] The connector fixing plate 14 is fixed to the upper valve body 1 by bolts. It is provided with a slot and a wire harness fixing hole for centrally fixing all electrical connectors and sensor wire harnesses of the solenoid valves, so as to make the wire harness layout neat, prevent it from loosening in the vibration environment, and improve the reliability and assembly convenience of the system.

[0054] Furthermore, the upper valve body 1 is made of aluminum alloy casting.

[0055] Furthermore, the pad assembly 2 is stamped from a high-precision aluminum alloy sheet.

[0056] Furthermore, the mechanical pump and the electronic pump share a single oil suction and drain circuit 16, which runs from the oil pan through a filter. This is a key design feature of the system and represents a highly integrated layout of the hydraulic modules. A one-way valve assembly 12 is connected in series at a branch of the oil suction and drain circuit 16. The inlet of the one-way valve assembly 12 connects to the electronic pump's oil outlet circuit 17, and the outlet of the one-way valve assembly 12 connects to the main oil circuit 15.

[0057] Furthermore, the main pressure regulating valve mechanism includes a main pressure regulating valve 8, a spring 9, and a stop plug 10; the stop plug 10 is fixed to the end of the valve cavity inside the upper valve body 1 by threads, one end of the spring 9 abuts against the stop plug 10, and the other end of the spring 9 presses against the valve core of the main pressure regulating valve 8.

[0058] Furthermore, the main pressure regulating valve has a two-stage pressure control logic, wherein: the first stage is low oil pressure, i.e. EV mode, in which the C1 clutch is not engaged; the second stage is high oil pressure mode, in which the oil pressure ensures that the C1 clutch is engaged, while keeping the system pressure stable at the target value and releasing excess flow.

[0059] Furthermore, the main pressure regulating valve mechanism is connected to the cooling and lubrication oil circuit 20, and distributes hydraulic oil to the rear lubrication oil circuit, the intermediate shaft lubrication oil circuit, and the motor cooling oil circuit (EM1, EM2) through different throttling orifices.

[0060] Furthermore, the hydraulic circuit of the hydraulic module includes:

[0061] Main oil circuit 15 is used to transmit system pressure and flow;

[0062] Oil suction and discharge circuit 16 is used to discharge excess flow from the hydraulic system after adjusting the pressure of the main oil circuit.

[0063] The electronic pump outlet oil passage 21 is used to transport the oil output by the electronic pump and introduce the pressurized oil provided by the electronic pump into the main oil passage 15, working together with the mechanical pump to supplement the flow and stabilize the pressure of the hydraulic system;

[0064] The clutch pressure oil circuit 22 and the main oil pressure feedback oil circuit 17 work together to apply the adjusted main oil pressure to the clutch, thereby realizing the clutch engagement function.

[0065] Cooling and lubrication oil circuit 20 is used to achieve lubrication, friction reduction, and cooling of key components;

[0066] The lubricating oil pressure relief circuit 23 is used to cool the oil pressure of the lubricating oil circuit 20, prevent the lubrication / cooling oil circuit pressure from being too high, and ensure stable lubrication flow and cooling effect.

[0067] The valve body assembly is the core of the hydraulic module, converting electrical control signals into hydraulic signals. By changing the oil circuit within the valve body, it controls the shifting mechanism to achieve gear switching. The oil passages and various throttle holes on the gasket assembly 2 connect the main oil circuit to the main pressure regulating valve mechanism and the high-flow switching valve.

[0068] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0069] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission, characterized in that: include: The upper valve body (1) is fixed on the transmission housing and has an oil passage and valve hole inside. The upper part has an interface for connecting external oil passages and sensors. The oil pump support assembly (3) is installed at the lower part of the upper valve body (1) and includes a pump housing, bearings and seals. It has oil passages and valve holes inside to support the inner rotor (6) and the outer rotor (7). The gasket assembly (2) is fixed between the upper valve body (1) and the oil pump support assembly (3). It has oil holes and bolt through holes corresponding to the upper valve body (1) and the oil pump support assembly (3) to achieve sealing, connection and positioning functions. The ON-OFF solenoid valve (4) is installed in the preset valve hole of the upper valve body (1), receives the PWM signal sent by the TCU, and outputs a linear hydraulic pressure proportional to the control current to control the engagement and disengagement of the clutch. At the same time, it is connected to the main pressure regulating valve mechanism through the main oil pressure feedback oil circuit (17) to change the oil pressure of the entire hydraulic system. The mechanical pump includes an inner rotor (6), an outer rotor (7), an oil pump support assembly, and an oil pump driven gear. The outer rotor (7) is installed in the cavity of the oil pump support assembly (3). The inner rotor (6) is driven to rotate by the drive shaft and drives the outer rotor (7) to rotate eccentrically. The oil pump driven gear (5) is mounted on the oil pump support assembly (3) and meshes with the oil pump drive gear to balance the oil pulsation and realize oil suction and delivery. The main pressure regulating valve mechanism is installed in a special valve cavity inside the upper valve body (1). The first oil inlet acts the oil pressure of the main oil circuit (15) on the first feedback surface of the mechanical valve core to stabilize the oil pressure in the main oil circuit (15) within the set range. A one-way valve assembly (12) is mounted on the oil pump support assembly (3) to prevent the oil output by the mechanical pump from causing the electronic pump to reverse. The pressure relief valve assembly (13) is installed in the preset valve hole of the upper valve body (1) and is installed in the main oil circuit (15) as a safety valve. The oil outlet end is connected to the oil pan through the oil suction and oil discharge circuit (16). Oil temperature sensor bracket (11) is fixed on the upper valve body (1) for installing oil temperature sensor. The oil temperature sensor extends into the internal oil passage of the upper valve body (1). The connector fixing plate (14) is fixed on the upper valve body (1), and has a slot and a wire harness fixing hole for centrally fixing the electrical connectors and sensor wire harnesses of all solenoid valves.

2. The integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 1, characterized in that: The upper valve body (1) is made of aluminum alloy casting.

3. The integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 1, characterized in that: The pad assembly (2) is made of aluminum alloy sheet by stamping.

4. An integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 2 or 3, characterized in that: The mechanical pump and the electronic pump share a single oil suction and drain circuit (16) leading from the oil pan through the filter. A one-way valve assembly (12) is connected in series at a branch of the oil suction and drain circuit (16). The inlet of the one-way valve assembly (12) is connected to the oil outlet circuit (21) of the electronic pump, and the outlet of the one-way valve assembly (12) is connected to the main oil circuit (15).

5. The integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 1, characterized in that: The main pressure regulating valve mechanism includes a main pressure regulating valve (8), a spring (9), and a stop plug (10); the stop plug (10) is fixed to the end of the valve cavity inside the upper valve body (1), one end of the spring (9) abuts against the stop plug (10), and the other end of the spring (9) presses against the valve core of the main pressure regulating valve (8).

6. The integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 5, characterized in that: The main pressure regulating valve has a two-stage pressure control logic. The first stage is low oil pressure, i.e., EV mode, in which the C1 clutch is not engaged. The second stage is high oil pressure mode, in which the oil pressure ensures that the C1 clutch is engaged, while keeping the system pressure stable at the target value and releasing excess flow.

7. The integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 6, characterized in that: The main pressure regulating valve mechanism is connected to the cooling and lubrication oil circuit (20), and distributes hydraulic oil to the rear lubrication oil circuit, the intermediate shaft lubrication oil circuit and the motor cooling oil circuit through different throttle holes.

8. The integrated hydraulic module for a one-speed rear-wheel drive DHT hybrid transmission according to claim 1, characterized in that: The hydraulic circuit of the hydraulic module includes: The main oil circuit (15) is used to transmit system pressure and flow. Oil suction and drain circuit (16) is used to drain excess flow from the hydraulic system after adjusting the pressure of the main oil circuit; The electronic pump outlet circuit (21) is used to transport the oil output by the electronic pump and introduce the pressure oil provided by the electronic pump into the main oil circuit (15), working together with the mechanical pump to supplement the flow and stabilize the pressure of the hydraulic system; The clutch pressure oil circuit (22) and the main oil pressure feedback oil circuit (17) work together to apply the adjusted main oil pressure to the clutch to achieve the clutch engagement function; Cooling and lubrication oil circuit (20) is used to achieve lubrication, friction reduction and cooling of components; The lubricating oil pressure relief circuit (23) is used to cool the oil pressure of the lubricating oil circuit (20).

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