Drive Plate Assembly for Hybrid Module

Abstract

The hybrid module includes a rotor carrier. The hybrid module further includes a rotor segment supported by the rotor carrier. The hybrid module further includes a torque converter, the torque converter having an impeller, the impeller having an impeller shell fixed to the rotor carrier. The impeller shell and the rotor carrier define a housing therebetween. The torque converter further includes a turbine, the turbine having a turbine shell in fluid communication with the impeller shell. The turbine is disposed within the housing. The hybrid module further includes a drive plate assembly disposed outside the housing. The drive plate assembly includes an inner drive plate fixed to the rotor carrier. The drive plate assembly further includes an outer drive plate fixed to the inner drive plate and configured to receive torque.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Non - Provisional Application No. 17 / 876,602, filed on July 29, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] Technical Field The present disclosure generally relates to hybrid modules, and more specifically, to a drive plate assembly for a hybrid module.

Background Art

[0003] Hybrid modules are generally known. Often, packaging and / or fitting all desired components, such as an e - motor, a crank damper, a torque converter, a torque converter clutch, a disconnect clutch, and a resolver, within a hybrid module architecture is difficult due to axial and radial constraints. Additionally, magnetizing the rotor segment of an e - motor after assembling the torque converter is difficult due to limitations in the gap between the drive plate and the rotor segment. The lack of sufficient clearance for the magnetizing tool to access the rotor segment can result in insufficient magnetization of the rotor segment, which can degrade the performance of the e - motor.

Summary of the Invention

Means for Solving the Problems

[0004] The embodiments disclosed in this specification provide a hybrid module including a rotor carrier, a rotor segment supported by the rotor carrier, a torque converter, and a drive plate assembly. The torque converter includes an impeller, and the impeller has an impeller shell fixed to the rotor carrier. The impeller shell and the rotor carrier define a housing therebetween. The torque converter further includes a turbine, and the turbine has a turbine shell in fluid communication with the impeller shell. The turbine is disposed within the housing. The drive plate assembly is disposed outside the housing. The drive plate assembly includes an inner drive plate fixed to the rotor carrier. The drive plate assembly further includes an outer drive plate fixed to the inner drive plate and configured to receive torque.

[0005] In an embodiment, the outer drive plate may extend radially outward of the outer surface of the rotor segment. In an embodiment, the inner drive plate may be disposed radially inward of the outer surface of the rotor segment. In an embodiment, the outer drive plate may be fixed to the inner drive plate radially inward of the outer surface of the rotor segment. In an embodiment, the outer drive plate may be fixed to the inner drive plate via a weld. The weld may be located radially inward of the outer surface of the rotor segment.

[0006] In an embodiment, the outer drive plate may be fixed to the inner drive plate via a connector. The connector may be located radially inward of the outer surface of the rotor segment. The hybrid module may include a flex plate. The outer drive plate may be disposed axially between the rotor segment and the flex plate. The outer drive plate may be fixed to the flex plate radially outside the connector. The flex plate may include a window aligned radially and circumferentially with the connector. The connector may extend into the window.

[0007] In an embodiment, the inner drive plate can be fixed to the rotor carrier radially inside the outer drive plate. In an embodiment, the hybrid module can include a stud configured to receive torque. The stud can be supported by the outer drive plate and disposed at its radially outer end. The outer drive plate can be fixed to the inner drive plate radially inside the stud.

[0008] Embodiments of the present disclosure further provide a method of assembling a drive plate assembly to a hybrid module having a rotor carrier, a rotor segment supported by the rotor carrier, and a torque converter. The method includes fixing an inner drive plate of the drive plate assembly to the rotor carrier. The method further includes attaching the rotor segment to the rotor carrier. The method further includes attaching an impeller shell of the torque converter to the rotor carrier. The method further includes fixing an outer drive plate of the drive plate assembly to the inner drive plate after magnetizing the rotor segment.

[0009] In an embodiment, fixing the outer drive plate to the inner drive plate can be performed via a weld. In an embodiment, the inner drive plate can be disposed radially inside the outer surface of the rotor segment. The outer drive plate can extend radially outside the outer surface of the rotor segment. In an embodiment, fixing the outer drive plate to the inner drive plate can be performed via a connector. The method can further include aligning a window in the flex plate with the connector. The method can further include fixing the flex plate to the outer drive plate via a stud. In an embodiment, the outer drive plate can be fixed to the inner drive plate radially inside the outer surface of the rotor segment. In an embodiment, the method can further include fixing the outer drive plate to the flex plate via a stud.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

DETAILED DESCRIPTION OF THE INVENTION

[0011] Embodiments of the present disclosure are described herein. It should be understood that like drawing numbers appearing in different drawings identify the same or functionally similar structural elements. Also, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take various alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as representative criteria for teaching one skilled in the art to use the embodiments in various ways. As will be understood by those skilled in the art, the various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to create embodiments that are not explicitly illustrated or described. Combinations of the illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for a particular application or implementation.

[0012] The terms used in this specification are for the purpose of describing particular embodiments only and are not intended to limit the scope of the disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods, devices, or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the exemplary methods, devices, and materials are described herein.

[0013] Typically, a hybrid vehicle that combines a battery-driven e-motor and an automatic transmission driven by an internal combustion engine has limited available space. The hybrid module includes a rotor segment that requires magnetization of the e-motor supported by a rotor carrier, and a drive plate fixed to the rotor carrier and configured to receive torque from a flex plate connected to the internal combustion engine. For example, in order to reduce the risk of contamination of the rotor segment via debris that can be attracted to the magnetized rotor segment, and to avoid, for example, the introduction of magnetic forces from the rotor segment that need to be overcome during the assembly of the rotor segment into the hybrid module, it is desirable to magnetize the rotor segment after the assembly of the torque converter to the rotor carrier in order to maintain ease of assembly. Additionally, it is desirable to fix the drive plate to the rotor carrier before the assembly of the torque converter, for example via rivets, in a manner that prevents fluid leakage from the rotor carrier. Thus, the drive plate is assembled into the hybrid module before magnetizing the rotor segment. The drive plate limits the gap available for the magnetization tool to reach the rotor segment.

[0014] Embodiments of the present disclosure provide a hybrid module including a drive plate assembly having an inner drive plate fixed to a rotor carrier and an outer drive plate fixed to the inner drive plate. The two-piece drive plate assembly enables assembly of the outer drive plate to the inner drive plate after magnetization of the rotor segment, which enlarges the gap for the magnetization tool to magnetize the rotor segment.

[0015] FIG. 1 shows a cross-sectional view of the upper half of a hybrid module 100 according to an embodiment of the present disclosure. The hybrid module 100 includes a rotor assembly 102 and a stator assembly 104 that form an e-motor assembly. The rotor assembly 102 includes a rotor carrier 106, a rotor segment 108, an end ring 110, a spring end plate 112, and a spring end plate 114. The rotor carrier 106 includes an axially extending portion 116 and a radially extending portion 118. The rotor segment 108 is disposed on the outer surface of the axially extending portion of the rotor carrier 106. For example, the rotor segment 108 can be a stacked segment. The spring end plates 112, 114 are assembled on both axial sides of the rotor segment 108. That is, the spring end plate 112 is axially disposed between the rotor segment 108 and the end ring 110, and the spring end plate 114 is axially disposed between the rotor segment 108 and the radially extending portion 118. The end ring 110 is configured to compress the spring end plates 112, 114 to clamp and / or fix the rotor segment 108 to the rotor carrier 106 to transmit frictional torque between the rotor segment 108 and the rotor carrier 106. When the desired compressive force is achieved, the end ring 110 is fixed to the rotor carrier 106, for example, by welding.

[0016] The stator assembly 104 is disposed radially outside the rotor assembly 102 and is fixed to the bell housing 120 for the transmission. The stator assembly 104 includes a stator carrier 122, a stator segment 124, and a water jacket 126. The stator segment 124 can be, for example, stacked stator segments and is mounted on the inner surface of the stator carrier 122, for example, by shrink fitting. In other words, the stator carrier 122 is heated to expand the inner surface, and the stator segment 124 is placed thereon. When the stator carrier 122 cools, the inner surface is shrink-fitted to the stator segment 124. The water jacket 126 is fixed to the stator carrier 122 and encloses a shield chamber 128 therebetween.

[0017] The hybrid module 100 further includes a torque converter 142 having a turbine 144 with a turbine shell 146 and at least one blade attached thereto, and an impeller 148 with an impeller shell 150 and at least one blade attached thereto. For example, the impeller shell 150 is fixed to the rotor carrier 106 at the weld 152. The impeller shell 150 and the rotor carrier 106 define a housing or casing for the torque converter 142.

[0018] The torque converter 142 is disposed axially between the impeller 148 and the turbine 144 and may include a stator 158 for redirecting the fluid flowing from the blades of the turbine 144 before the fluid reaches the impeller 148 to increase the efficiency of the torque converter 142. For example, when the impeller 148 blades rotate about the rotational axis AR, they push the fluid outward. The fluid pushes the turbine 144 of the torque converter 142 and rotates the turbine 144 about the rotational axis AR. The stator 158 functions to return the fluid from the turbine 144 to the impeller 148 with minimal or no power loss. The driving force is transmitted from the turbine 144 to the transmission input shaft (not numbered).

[0019] The torque converter 142 further includes a lock-up clutch 154 and a damper 156. The lock-up clutch 154 and the damper 156 are disposed within a housing defined by the impeller shell 150 and the rotor carrier 106. The lock-up clutch 154 includes a piston 160 and a clutch plate 162 for transmitting torque between the rotor carrier 106 and the damper 156. The damper 156 may include a spring 164, cover plates 166, 168 radially connected to each other outside the spring 164, and an output portion 170. The cover plate 166 may be connected to at least one of the clutch plates 162, and the cover plate 168 may be connected to the turbine shell 146. That is, the cover plates 166, 168 are arranged to act as an input to the damper 156. Torque is transmitted from the damper 156 to the transmission input shaft.

[0020] The torque converter 142 further includes an impeller hub 172 connected to the inner end of the impeller shell 150, for example, via welding. The impeller hub 172 extends axially away from the impeller shell 150. The torque converter 142 further includes a resolver assembly 174 having a resolver rotor 176 and a resolver stator 178. The resolver rotor 176 is fixed to the impeller hub 172. The resolver stator 178 is fixed to the bell housing 120 via a plate 180. For example, a connector 182, such as a bolt, fixes the plate 180 to the bell housing 120, and a connector 184, such as a rivet, fixes the resolver stator 178 to the plate 180. The connector 182 is disposed radially outside the resolver stator 178. The resolver rotor 176 is axially aligned with the resolver stator 178. In other words, a line perpendicular to the rotation axis AR extending through both the resolver stator 178 and the resolver rotor 176 can be drawn.

[0021] The hybrid module 100 further includes a drive plate assembly 130. The drive plate assembly 130 includes an inner drive plate 132 and an outer drive plate 134 fixed to the inner drive plate 132. The inner drive plate 132 is fixed to the rotor carrier 106 at its radially inner end. Specifically, the inner drive plate 132 is fixed to the rotor carrier 106 via a rivet. The inner drive plate 132 is disposed radially inward of the outer surface of the rotor segment 108. The inner drive plate 132 can be fixed to the outer drive plate 134 via a weld portion 140. In such an example, the weld portion 140 is disposed radially outside the rivet and radially inside the outer surface of the rotor segment 108.

[0022] The outer drive plate 134 extends radially outside the outer surface of the rotor segment 108. The outer drive plate 134 is fixed to a flex plate 138 of a crankshaft (not numbered) of a vehicle engine (not shown) via a stud 136. That is, the stud 136 transmits torque from the flex plate 138 to the drive plate assembly 130. The stud 136 can be fixed to the outer drive plate 134 at its radially outer end via, for example, a press-fit connection.

[0023] Figure 2 provides an alternative embodiment of the drive plate assembly 230. In contrast to the drive plate assembly 130 shown in FIG. 1, which includes an inner drive plate 132 welded to an outer drive plate 134, the drive plate assembly 230 includes an inner drive plate 232 fixed to an outer drive plate 234 via a connector 240, such as a bolt. In one such example, the connector 140 is disposed radially outside the rivet and radially inside the outer surface of the rotor segment 108. The flex plate 238 may include a window 241 that extends axially therethrough. The window 241 of the flex plate 238 may be radially and circumferentially aligned with the connector 240 such that the connector 240 extends into the window 241. Aligning the window 241 with the connector 240 enables the drive plate assembly 230 to be packaged within the envelope of the hybrid module 100. That is, disposing the connector 240 within the window 241 can reduce the space required to package the hybrid module 100.

[0024] The embodiments disclosed herein provide a drive plate assembly having an inner drive plate and an outer drive plate fixed to the inner drive plate to expand the space available within a typical hybrid module during magnetization of the rotor segment. By having an outer drive plate and an inner drive plate, the outer drive plate can be fixed to the inner drive plate after magnetization of the rotor segment, which expands the space within the hybrid module for the magnetization tool to magnetize the rotor segment. Additionally, the inner drive plate can be fixed to the rotor carrier via a rivet prior to assembly of the torque converter, which enables the drive plate assembly to be fixed to the rotor carrier in a manner that prevents fluid from leaking from the rotor carrier. In this way, the hybrid module can be assembled to prevent fluid from leaking from the rotor carrier while achieving the desired magnetization of the rotor segment.

[0025] Figure 3 is a diagram of an exemplary process 300 for assembling a hybrid module 100 that includes drive plate assemblies 130, 230 having inner drive plates 132, 232 and outer drive plates 134, 234. The process 300 disclosed herein includes exemplary steps that are executed in an exemplary order. However, it should be understood that the process 300 may include fewer steps and / or the steps may be executed in a different order.

[0026] The process 300 begins at block 305. At block 305, the inner drive plates 132, 232 are secured to the rotor carrier 106, for example, via rivets. The process 300 continues to block 310.

[0027] At block 310, the rotor segment 108 is assembled to the rotor carrier 106. For example, as discussed above, the end rings 110 may be secured to the rotor carrier 106, such as by welding, to compress the spring end plates 112, 114 that clamp and / or secure the rotor segment 108 to the rotor carrier 106. The process 300 continues to block 315.

[0028] At block 315, the impeller shell 150 of the torque converter 142 is secured to the rotor carrier 106 via a weld 152. Before securing the impeller shell 150 to the rotor carrier 106, other components of the torque converter 142, such as the turbine 144, lock-up clutch 154, damper 156, etc., may be assembled to the impeller shell 150 and / or the rotor carrier 106. The process 300 continues to block 320.

[0029] At block 320, the rotor segment 108 is magnetized according to, for example, known rotor magnetization techniques. For example, a magnetization tool, such as one that is known, is disposed radially outside the rotor segment 108. In this situation, the inner drive plates 132, 232 are radially spaced from the magnetization tool, which expands the available space for placing the magnetization tool in order to sufficiently magnetize the rotor segment 108, which can assist in achieving the desired performance of the e - motor including the rotor segment 108. The magnetization tool is removed after magnetizing the rotor segment 108. The process 300 continues to block 325.

[0030] At block 325, the outer drive plates 134, 234 are fixed to the inner drive plates 132, 232. For example, as shown in FIG. 1, the outer drive plate 134 can be fixed to the inner drive plate 132 via a weld 140. As another example, as shown in FIG. 2, the outer drive plate 234 can be fixed to the inner drive plate 232 via a connector 240, such as a bolt. The process 300 continues to block 330.

[0031] At block 330, the outer drive plates 134, 234 are fixed to the flexure plates 138, 238 via studs 136. In the embodiment shown in FIG. 2, block 330 can further include aligning the window 241 of the flexure plate 238 with the connector 240 before fixing the flexure plate 238 to the outer drive plate 234, as discussed above. The process 300 ends after block 330.

[0032] While the exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms encompassed by the claims. The terms used in this specification are terms for explanation rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the present disclosure. As described above, it is possible to combine the characteristic parts of the various embodiments to form further embodiments of the present disclosure that may not be explicitly described or illustrated. The various embodiments have been described as providing advantages with respect to one or more desired characteristics, or as being preferred over other embodiments or prior art implementations, but those skilled in the art will recognize that it is possible to compromise on one or more characteristics or features to achieve the desired overall system attributes that depend on the specific application and implementation. These attributes can include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Therefore, as long as any embodiment is not described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the present disclosure and may be desirable for a particular application.

Description of Reference Numerals

[0033] 100 Hybrid Module 102 Rotor Assembly 104 Stator Assembly 106 Rotor Carrier 108 Rotor Segment 110 End Ring 112 Spring End Plate 114 Spring End Plate 116 Axial Extension Portion 118 Radial Extension Portion 120 Bell Housing 122 Stator Carrier 124 Stator Segment 126 Water Jacket 128 Shield Chamber 130 Drive Plate Assembly 132 Inner Drive Plate 134 Outer Drive Plate 136 Stud 138 Flex Plate 140 Weld Joint 142 Torque Converter Assembly 144 Turbine 146 Turbine Shell 148 Impeller 150 Impeller Shell 152 Weld Joint 154 Lock-up Clutch 156 Damper 158 Stator 160 Piston 162 Clutch Plate 164 Spring 166 Cover Plate 168 Cover Plate 170 Output Section 172 Impeller Hub 174 Resolver Assembly 176 Resolver Rotor 178 Resolver Stator 180 Plate 182 Connector 184 Connector 230 Drive Plate Assembly 232 Inner Drive Plate 234 Outer Drive Plate 238 Flex Plate 240 Connector 241 Window AR Rotation Shaft

Claims

1. A hybrid module, comprising: a rotor carrier; a rotor segment supported by the rotor carrier; a torque converter, the torque converter comprising: an impeller having an impeller shell fixed to the rotor carrier, the impeller shell and the rotor carrier defining a housing therebetween; a turbine having a turbine shell in fluid communication with the impeller shell, the turbine being disposed within the housing; a drive plate assembly disposed outside the housing, the drive plate assembly comprising: an inner drive plate fixed to the rotor carrier; an outer drive plate fixed to the inner drive plate and configured to receive torque; the hybrid module.

2. The hybrid module according to claim 1, wherein the outer drive plate extends radially outward of an outer surface of the rotor segment.

3. The hybrid module according to claim 1, wherein the inner drive plate is disposed radially inward of an outer surface of the rotor segment.

4. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate radially inward of an outer surface of the rotor segment.

5. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate via a weld.

6. The hybrid module according to claim 5, wherein the weld is located radially inward of an outer surface of the rotor segment.

7. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate via a connector.

8. The hybrid module according to claim 7, wherein the connector is located radially inward of an outer surface of the rotor segment.

9. The hybrid module according to claim 7, further comprising a flex plate, wherein the outer drive plate is disposed axially between the rotor segment and the flex plate and is fixed to the flex plate radially outside the connector.

10. The hybrid module according to claim 9, wherein the flex plate includes a window aligned with the connector in the radial direction and the circumferential direction, and the connector extends into the window.

11. The hybrid module according to claim 1, wherein the inner drive plate is fixed to the rotor carrier inside the outer drive plate in the radial direction.

12. The hybrid module according to claim 1, further comprising a stud configured to receive the torque, the stud being supported by the outer drive plate and disposed at its radially outer end.

13. The hybrid module according to claim 12, wherein the outer drive plate is fixed to the inner drive plate inside the stud in the radial direction.

14. A method of assembling a drive plate assembly to a hybrid module having a rotor carrier, a rotor segment supported by the rotor carrier, and a torque converter, the method comprising: fixing an inner drive plate of the drive plate assembly to the rotor carrier; attaching the rotor segment to the rotor carrier; attaching an impeller shell of the torque converter to the rotor carrier; after magnetizing the rotor segment, fixing an outer drive plate of the drive plate assembly to the inner drive plate. A method including the above steps.

15. The method according to claim 14, wherein fixing the outer drive plate to the inner drive plate is performed via a welded joint.

16. The method according to claim 14, wherein the inner drive plate is disposed radially inside the outer surface of the rotor segment.

17. The method according to claim 16, wherein the outer drive plate extends radially outside the outer surface of the rotor segment.

18. The method according to claim 14, wherein fixing the outer drive plate to the inner drive plate is performed via a connector, and the method further includes: aligning a window in the flex plate with the connector; fixing the flex plate to the outer drive plate via a stud. The method according to claim 14, further including the above steps.

19. The method according to claim 14, wherein the outer drive plate is fixed to the inner drive plate inside the outer surface of the rotor segment in the radial direction.

20. The method according to claim 14, further comprising fixing the outer drive plate to the flex plate via a stud.

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