Hybrid module

Abstract

The invention relates to a hybrid module for arrangement between an internal combustion engine (2) and a transmission (3), by means of which hybrid module a torque of an electric machine (4) and a torque of the internal combustion engine (2) can be applied to a module output member (10) which can be coupled to the transmission (3), for which purpose a clutch device (12) for opening and closing a coupling of the internal combustion engine (2) to the module output member (10), which coupling transmits the torque, and an actuator (14) for actuating the clutch device (12) are provided, wherein: the actuator (14) has an actuator electric machine (15), an actuator transmission (16), and an actuator output member (18) which is coupled to the actuator transmission (16) and which is coupled to a control element (13) by means of which the clutch device (12) can be actuated; the actuator electric machine (15) and the actuator transmission (16) are arranged at a distance from one another along a parallel to an axis of rotation of the module output member (10) and are coupled to one another by means of a shaft connection (23); the actuator output member (18) is arranged axially between the actuator electric machine (15) and the actuator transmission (16).

Description

[0001] Hybrid module

[0002] The invention relates to a hybrid module for arrangement between an internal combustion engine and a transmission, via which a torque of an electric machine and a torque of the internal combustion engine can be transmitted to a module output element that can be coupled to the transmission, for which a clutch device for opening and closing a torque-transmitting coupling of the internal combustion engine with the module output element and an actuator for actuating the clutch device are provided, wherein the actuator comprises an actuator-electric machine and an actuator-transmission as well as an actuator output element coupled to the transmission, which is coupled to an actuating element via which the clutch device can be actuated.

[0003] Such a hybrid module is placed between the internal combustion engine and the transmission of a motor vehicle's drivetrain and offers the possibility of varying the torque supplied to the transmission. The hybrid module is coupled to, or includes, an electric motor that serves as a traction motor. The electric motor operates in a direct drive configuration with the transmission, meaning that the torque supplied by the electric motor is always transmitted to the transmission. The hybrid module is also coupled to an internal combustion engine, whose torque can be engaged as needed. For this purpose, the hybrid module has a coupling device, often also called a knock-out coupling, through which the torque-transmitting connection between the internal combustion engine and a module output element, which connects to the transmission, can be selectively opened and closed.An actuator is provided to operate the coupling device. This actuator can be controlled via a control unit and can be used to actuate the coupling device or to position the actuating element. The actuator comprises an electric motor, a gearbox downstream of the electric motor, and an actuator output element coupled to the gearbox, which in turn is coupled to the actuating element or its input. When the actuator is activated, the electric motor drives the gearbox, which provides a reduction in speed. This reduction in speed moves the actuator output element, which in turn moves the actuating element.

[0004] Integrating such a hybrid module, which can ultimately be manufactured and assembled as a prefabricated, separate unit, is often restricted by limited installation space. In many cases, the electric motor, i.e., the traction motor, must be attached to the hybrid module as a separate component and coupled to a corresponding module-side input element, which requires installation space. This space is sometimes no longer available for the appropriate arrangement or integration of the actuator, resulting in integration problems with regard to the actuator.

[0005] The invention is based on the problem of providing an improved hybrid module in comparison.

[0006] To solve the problem, according to the invention, in a hybrid module of the type mentioned above, the actuator electric machine and the actuator gearbox are arranged a distance apart from each other along a parallel axis to a rotational axis of the module output element and are coupled to each other via a shaft connection, wherein the actuator output element is arranged axially between the actuator electric machine and the actuator gearbox.

[0007] The actuator is therefore ultimately a two-part assembly, consisting of the separate actuator electric motor and the separate actuator gearbox. According to the invention, these are axially spaced apart from each other, meaning they are not physically housed in a common casing, but rather form two separate units mounted axially apart and coupled to each other via a shaft connection. The arrangement is such that the actuator output element, which may be, for example, a drive pinion or an actuating lever, is located axially between the actuator electric motor and the actuator gearbox.Dividing the actuator into two separate units allows for flexible axial installation, enabling the mounting of one unit, which is significantly shorter axially, on one side of the hybrid module even in smaller installation spaces, while the other unit is located on the opposite side. This means the actuator units can be installed as compactly and nested as possible. Furthermore, this design allows for excellent adaptation to the structural conditions on the combustion engine and transmission side.The hybrid module can also be designed as a complete, self-contained unit containing all necessary components. During assembly, it simply needs to be initially positioned on the combustion engine, so that the engine's output is coupled to an input element on the hybrid module. If an external electric motor is used, it is also connected to a corresponding input element on the hybrid module, after which the connection to the transmission is made to the module's output element. As a self-contained unit, the hybrid module can be a wet-running system, meaning it includes an oil sump for lubrication.

[0008] According to a first embodiment of the invention, the hybrid module comprises a housing containing a gear arrangement comprising a first gear that is to be coupled to the electric machine, a second gear that is coupled to or forms the module output element, and the coupling device, wherein the actuator electric machine and the actuator gearbox are arranged axially spaced apart on opposite sides of or within the housing. This embodiment provides a hybrid module to which an external electric machine is to be connected. For this purpose, the gear arrangement provided in the module housing comprises a first gear that is to be coupled to the output of the electric machine, wherein this coupling is effected, for example, via an output shaft of the electric machine that is connected to the first gear, or via a shaft journal provided on the hybrid module that is to be coupled to the electric machine, and the like.The first gear can either engage directly with a second gear or be indirectly coupled to it via further gears, with this second gear either forming the module output element itself, to which the gearbox input is coupled, or being coupled to such an output element. The coupling device is also housed within the casing. The actuator electric motor and the actuator gearbox are arranged axially spaced apart on opposite sides of or within the housing of the hybrid module. They are arranged circumferentially offset from the first gear, which rotates about an axis of rotation radially offset from the axis of rotation of the module output element, while the second gear rotates about the axis of rotation of the module output element.The actuator and its components are arranged radially offset from the axis of rotation of the module output element, and circumferentially offset from the axis of rotation of the first gear. For the most compact design possible, the actuator's shaft connection should be positioned as close as possible to the axis of rotation of the first gear. The arrangement can be such that the first gear engages almost in the space between the actuator electric motor and the actuator gearbox, meaning the actuator's shaft connection is only slightly separated from the teeth of the first gear.

[0009] In a specific embodiment of this variant, the actuator electric motor can be arranged adjacent to the actuator output element, with an electric motor drive shaft extending through the actuator output element to the actuator gearbox. The gearbox has a hollow output shaft in which the electric motor drive shaft runs and which is connected to the actuator output element. In this variant, the actuator electric motor is thus arranged directly adjacent to the actuator output element, e.g., a drive pinion, while the actuator gearbox is located on the opposite side of the housing. The electric motor drive shaft and the hollow shaft are correspondingly long, as both must extend over virtually the entire axial distance between the two units.

[0010] An alternative embodiment to this arrangement provides that the actuator gearbox is located adjacent to the actuator output element and is connected to it via a gearbox output shaft designed as a hollow shaft, with the electric motor drive shaft extending through the actuator output element and the hollow shaft to the gearbox. In this variant, the actuator gearbox is located directly adjacent to the actuator output element, e.g., the drive pinion, while the electric motor is located on the opposite side of the housing. As a result, only the electric motor drive shaft is longer, since it must extend over the entire distance between the units, while the gearbox's hollow shaft is very short because the actuator output element is positioned adjacent to the gearbox.

[0011] As described above, in the embodiments described above, the electric motor, i.e., the traction motor, is arranged externally to the hybrid module and connected to it separately. In contrast, one variant provides for the integration of the electric motor into the hybrid module or its housing. Accordingly, the hybrid module is provided with a housing in which the electric motor is arranged coaxially to the axis of rotation of the module's output element, along with the coupling device and the actuating element, with the actuator electric motor, the actuator gearbox, and the actuator output element being arranged outside the housing. The electric motor, or traction motor, is thus integrated into the housing and arranged coaxially to the axis of rotation of the module's output element. Only the actuator with its two units is arranged externally, with the units preferably being attached to the housing in a suitable manner.However, they are axially spaced in any case and accommodate the actuator output element between them; however, the axial distance between them is considerably variable.

[0012] In a specific embodiment of this invention, it is provided that the module output element is arranged between the actuator electric machine and the actuator gearbox, wherein the electric machine drive shaft extends through the actuator output element to the actuator gearbox, which has a gearbox output shaft designed as a hollow shaft in which the electric machine drive shaft runs and which is connected to the actuator output element.

[0013] All variants have in common that the actuator output is mechanically coupled to the actuating element in a suitable manner. This mechanical coupling can be achieved in different ways. According to one variant, the actuator output can be a drive pinion that meshes with a toothed disc of the actuating element. Alternatively, the actuator output can also be a pulley over which a traction element coupled to the actuating element runs. Finally, the actuator output can also be a lever pulley to which a pull rod connected to the actuating element is attached.

[0014] As described, the clutch assembly is actuated via a corresponding actuating element. This actuating element is preferably a ball ramp release mechanism. This includes, for example, a corresponding toothed disc that meshes with the actuator output element in the form of a drive pinion, such that rotation of the drive pinion leads to rotation of the toothed disc, which causes several balls of the ball ramp release mechanism to run onto ball ramps. This, in turn, leads to an axial displacement of the pressure element acting directly on the clutch assembly and thus to actuation of the clutch assembly. Other embodiments of such an actuating element, including different designs of the actuator output element, are of course conceivable.

[0015] Furthermore, it is advantageous to integrate a torsional damper into the hybrid module to dampen the torque supplied by the combustion engine. This torsional damper allows inherent torque fluctuations resulting from the operation of the combustion engine to be dampened, ensuring that these fluctuations are only transmitted in a damped form to the module's output element and from there to the transmission. This torsional damper can be located directly on the input side, where the combustion engine is coupled to a corresponding interface of the hybrid module, for example, via an output shaft.

[0016] In addition to the hybrid module, the invention further relates to a powertrain of a motor vehicle, comprising an internal combustion engine and a transmission, between which a hybrid module of the type described above is connected. The powertrain can either have an electric motor external to the hybrid module as a traction motor, or, as described, an electric motor already integrated into the hybrid module. The invention is explained below with reference to exemplary embodiments and the drawings. The drawings are schematic representations and show:

[0017] Figure 1 shows a schematic representation of a hybrid module according to the invention in the mounting position between an internal combustion engine and a transmission, with an external electric machine.

[0018] Figure 2 shows a detailed view of the essential components of the hybrid module and the actuator.

[0019] Figure 3 shows a schematic representation of the arrangement of the actuator relative to the gear arrangement.

[0020] Figure 4 shows a schematic representation corresponding to Figure 3, but with a different arrangement of the actuator.

[0021] Figure 5 shows a more detailed representation of the individual units of the actuator in its arrangement on the hybrid module,

[0022] Figure 6 shows a detailed representation of the individual units of the actuator in its arrangement on the hybrid module of a second variant,

[0023] Figure 7 shows a schematic representation of a hybrid module according to the invention in its arrangement between the combustion engine and the transmission with coaxially integrated electric machine and externally arranged actuator, and

[0024] Figures 8-11 show different variants of the mechanical coupling of the actuator and the actuating element.

[0025] Figures 1-3 show a first embodiment of a hybrid module 1 according to the invention, which is mounted between an internal combustion engine 2 and a transmission 3. An external electric motor 4 is also arranged on the hybrid module 1. The task of the hybrid module 1 is, on the one hand, to continuously drive the torque supplied by the electric motor 4 to the transmission and, on the other hand, to engage the internal combustion engine 2 as needed, so that its torque is also driven to the transmission 3. Figure 1 shows a sectional view along line 11 and Figure 2 shows a sectional view along line 11-12 in Figure 3.

[0026] For the continuous transmission of the torque of the electric machine 4, a gear assembly 6 is provided in a housing 5 of the hybrid module 1. This assembly comprises a first gear 7, which is coupled to an output of the electric machine 4 via an input element 8, for example, an input shaft. A second gear 9, which, for example, directly represents the module output element 10 and is coupled to an input 11 of the gearbox 3, meshes with the first gear 7. The torque of the electric machine 4 is transmitted directly via this gear assembly 6.

[0027] To selectively engage the internal combustion engine 2, a clutch assembly 12 is provided, which is also commonly referred to as a knock-out clutch. An actuating element 13, for example a ball ramp release, is associated with it. When this is actuated, the clutch assembly 12 is closed, and the torque of the internal combustion engine 2, which is preferably coupled to the clutch assembly 12 via a torsional damper 37, is also transmitted via the closed clutch assembly 12 to the module output element 10 and via this to the input 11 of the transmission.

[0028] An actuator 14, which is multi-part, is provided to actuate the actuating element 13. It consists of an actuator electric motor 15, which, in the example shown, is arranged as a separate unit on the right side of the housing 5. It also includes an actuator gearbox 16, which is arranged on the opposite side of the housing 5. The torque of the actuator electric motor 15 is transmitted to the reducing actuator gearbox 16 via an electric motor drive shaft 17. The actuator gearbox 16 itself is, for example, a planetary gear or a Harmonic Drive gearbox and has a gear ratio of i = 1.2 <-> 120. As Figure 2 shows, an actuator output element 18, here, for example, in the form of an output pinion 19, is provided on the side where the actuator electric motor 15 is also positioned. The actuator gearbox 16 has a gearbox output shaft 20, which is designed as a hollow shaft and extends to the actuator output element 18.The electric motor drive shaft 17 extends through the hollow gearbox output shaft 20 to the actuator gearbox 16. Since the actuator output element 18 is, for example, a drive pinion 19, the actuating element 13 is equipped with a toothed disc 21 that meshes with the drive pinion 19, so that a rotation of the drive pinion 19 leads to a rotation of the toothed disc 21, via which the actuating element 13, i.e., the ball ramp release, is actuated, so that a pressure element 22 is moved axially against the clutch device 12 and actuates it.

[0029] As shown in Figure 2, the actuator electric motor 15 and the actuator gearbox 16 are axially spaced apart; they are therefore two separate units housed in separate casings and not physically connected except via the shaft connection 23. The first gear 7 is evidently positioned between the actuator electric motor 15 and the actuator gearbox 16, meaning that the shaft connection 23 runs axially adjacent to the first gear 7. This is also shown in Figure 3, which depicts the first gear 7 and the second gear 9, each rotating about axes D1 and D2, respectively. The actuator 14 itself is clearly arranged radially offset from the axis of rotation D2 and circumferentially offset from the axis of rotation D1. In the embodiment shown in Figure 3, the actuator 14 is arranged clockwise relative to D1.

[0030] An alternative embodiment, regarding the arrangement of the actuator 14 relative to the axis of rotation D1, is shown in Figure 4. There, the actuator 14 is arranged counterclockwise relative to the first gear 6 in the circumferential direction, yet extremely close to it, resulting in a very compact design. Figure 5 shows a more detailed view of the hybrid module 1 from the preceding figures. The actuator electric motor 15 has a housing 24 in which a stator 25 and a rotor 26 are accommodated, the rotor 26 being connected to the electric motor drive shaft 17, which runs into the actuator gearbox 16. This gearbox has a housing 27 in which the actual gearbox assembly 28 is accommodated, e.g., the planetary gear set or similar. The gearbox output shaft 20, designed as a hollow shaft and very short, extends from the gearbox housing 27.

[0031] Figure 6 shows an arrangement in which the actuator 14 units are arranged in reverse. In this variant, the actuator gearbox 16 is located on the right side of the housing 5 of the hybrid module 1, i.e., adjacent to the actuator output element 18, while the actuator electric motor 15 is located on the opposite side of the housing 5. The electric motor drive shaft 17 extends from the actuator electric motor 15 through the housing 5 into the actuator gearbox 16 and is therefore, as in the initial example of the preceding figures, correspondingly long. However, since the actuator gearbox 16 is located very close to the actuator output element 18, the gearbox output shaft 20, which is also designed as a hollow shaft and is connected to the actuator output element 18 (e.g., the drive pinion), is very short.

[0032] The initial example shown in Figure 7 depicts a hybrid module 1 in a different embodiment. The electric motor 6 is already integrated into the housing 5 of the hybrid module 1 and is arranged coaxially with the axis of rotation of the module output element, here exemplified by an output shaft 29. The rotor 30, which is housed inside the stator 31 of the electric motor 6, is coupled to this module output element 29. A coupling device 12 with an associated actuating element 13 and a torsional damper 37 are again provided, meaning that the structure in this respect corresponds to that of the preceding embodiment. An actuator 14 is also provided, which again comprises two separate units: the actuator electric motor 15 and the actuator gearbox 16, which are arranged axially spaced apart from each other, with the axial offset also running parallel to the axis of rotation of the module output element.The actuator output element 18, which is, for example, a drive pinion, is also located between the actuator electric motor 15 and the actuator gearbox 16. The actuator 14 units are mounted on suitable supports, such as the housing 5, but are located externally, with the actuator output element 18 being appropriately coupled to the actuating element 13. Due to the division of the actuator 14 into separate units, adaptation to available installation space is also possible.

[0033] Figures 8-11 show four different ways in which the actuator output element 18 can be coupled to the actuating element 13. As already described in Figure 8, the actuator output element 18 is a drive pinion 19 that meshes with the toothed disc 21 via a toothed engagement.

[0034] In the embodiment according to Figure 9, the actuator output element 18 is a pulley 31 which is encircled by a traction element 32, i.e. a belt, which in turn encircles a pulley 33 of the actuating element 13.

[0035] In the variant according to Figure 10, the actuator output element 18 is designed as a pulley disk 33, on which a pulley 32 is arranged, which, however, has only one strand, and which is suitably connected to a disk 34 of the actuating element 13. A rotation of the pulley disk 33 leads to a tightening of the pulley 32, which in turn leads to a rotation of the disk 34.

[0036] In the variant according to Figure 11, the actuator output element 18 is a lever disc 35 connected to a pull rod 36, which in turn is connected to the disc 34 of the actuating element 13. (List of reference symbols)

[0037] Hybrid module

[0038] internal combustion engine

[0039] transmission

[0040] electric machine

[0041] Housing

[0042] Gear arrangement

[0043] gear

[0044] Inlet element

[0045] gear

[0046] Starting element

[0047] Entrance

[0048] Coupling device

[0049] Actuator

[0050] actuator

[0051] Actuator electric machine

[0052] Actuator gearbox

[0053] Electric motor drive shaft

[0054] Actuator output element

[0055] Output pinion

[0056] Transmission output shaft

[0057] toothed disc

[0058] Pressure element

[0059] Shaft connection

[0060] Housing

[0061] stator

[0062] rotor

[0063] gearbox housing

[0064] Gear arrangement

[0065] Output shaft 30 Rotor

[0066] 31 Pulley

[0067] 32 traction elements

[0068] 33 Pulley

[0069] 34 discs

[0070] 35 Lever disc

[0071] 36 pull rod

[0072] 37 Torsional dampers

[0073] II line

[0074] II-ll Line

[0075] D1 axis of rotation

[0076] D2 axis of rotation

Claims

Patent claims 1. Hybrid module for arrangement between an internal combustion engine (2) and a transmission (3), via which a torque of an electric machine (4) and a torque of the internal combustion engine (2) can be transmitted to a module output element (10) that can be coupled to the transmission (3), wherein a coupling device (12) for opening and closing a torque-transmitting coupling of the internal combustion engine (2) with the module output element (10) and an actuator (14) for actuating the coupling device (12) are provided, wherein the actuator (14) comprises an actuator electric machine (15) and an actuator transmission (16) as well as an actuator output element (18) coupled to the transmission (3) and coupled to an actuating element (13) via which the coupling device (12) can be actuated, characterized in thatthat the actuator electric machine (15) and the actuator gearbox (16) are arranged spaced apart from each other along an axis of rotation parallel to an axis of rotation of the module output element (10) and are coupled to each other via a shaft connection (23), wherein the actuator output element (18) is arranged axially between the actuator electric machine (15) and the actuator gearbox (16).

2. Hybrid module according to claim 1, characterized in that a housing (5) is provided, comprising a gear arrangement (6) comprising a first gear (7) to be coupled to the electric machine (4), a second gear (9) coupled to or forming the module output element (10), and the coupling device (12), wherein the actuator electric machine (15) and the actuator gearbox (16) are arranged axially spaced apart on opposite sides of or in the housing (5).

3. Hybrid module according to claim 2, characterized in that the actuator electric machine (15) is arranged adjacent to the actuator output element (18), wherein an electric machine drive shaft (17) extends through the actuator output element (18) to the actuator gearbox (16), which has a hollow shaft listed gearbox output shaft (20) in which the electric machine drive shaft (17) runs and which is connected to the actuator output element (18).

4. Hybrid module according to claim 2, characterized in that the actuator gearbox (16) is arranged adjacent to the actuator output element (18) and is connected to it via a gearbox output shaft (20) designed as a hollow shaft, wherein the electric machine drive shaft (17) extends through the actuator output element (18) and the hollow shaft to the actuator gearbox (3).

5. Hybrid module according to claim 1, characterized in that a housing (5) is provided in which the electric machine (4) is arranged coaxially to the axis of rotation of the module output element, as well as the coupling device (12) and the actuating element (13), wherein the actuator electric machine (15), the actuator gearbox (16) and the actuator output element (18) are arranged outside the housing (5).

6. Hybrid module according to claim 5, characterized in that the actuator output element (18) is arranged between the actuator electric machine (15) and the actuator gearbox (16), wherein the electric machine drive shaft (17) extends through the actuator output element (18) to the actuator gearbox (16), which has a gearbox output shaft (20) designed as a hollow shaft in which the electric machine drive shaft (17) runs and which is connected to the actuator output element (818).

7. Hybrid module according to one of the preceding claims, characterized in that the actuator output element (18) is a drive pinion (19) that meshes with a toothed disc (21) of the actuating element (13), or a pulley (31, 33) over which a traction element (32) coupled to the actuating element (13) runs, or a lever disc (35) to which a pull rod (36) connected to the actuating element (13) is connected.

8. Hybrid module according to one of the preceding claims, characterized in that the actuating element (13) is a ball ramp release.

9. Hybrid module according to one of the preceding claims, characterized in that a torsional damper (37) is provided which dampens the torque supplied by the internal combustion engine (2).

10. Powertrain of a motor vehicle comprising an internal combustion engine (2) and a transmission (3), between which a hybrid module (1) according to one of the preceding claims is connected.

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