Compact P2 Hybrid Module With Axial Motor and Disconnect Clutch
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hybrid vehicles face limitations in extending the mileage range due to the constraints of battery technology in all-electric vehicles, requiring frequent recharging or additional vehicles for longer trips, while consumers prefer hybrid powertrains that offer a balance between electric and combustion engine usage.
Innovation Solution
A P2 module for hybrid powertrains incorporating a torque converter, electric motor, connect/disconnect clutch, and one-way clutch, allowing for efficient power transmission between the engine and transmission, enabling alternative operational modes that optimize torque transfer and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional P2 configuration with radial electric motor mounting is used, then the electric motor can be integrated into the powertrain, but the available space for the electric motor is limited and the packaging is constrained
Solution Approach 1:
The patent transitions from radial mounting (2D plane) to axial mounting (3D space along the torque converter axis), effectively utilizing the axial dimension to accommodate the electric motor. This dimensional change allows the electric motor to be positioned along the axis of the torque converter rather than radially around it, significantly increasing the available volume for the electric motor while maintaining a compact overall powertrain configuration.
2Adaptability or versatility
If the electric motor is located between the combustion engine and transmission, then hybrid powertrain functionality is achieved, but the combustion engine cannot be easily disconnected from the transmission when not in use
Solution Approach 1:
The patent segments the power transmission path into distinct controllable sections by introducing a disconnect clutch positioned between the combustion engine and the torque converter. This clutch allows the combustion engine to be independently disconnected from the transmission while the electric motor remains connected to the transmission through the torque converter, enabling versatile operational modes including electric-only driving, hybrid driving, and engine braking without mechanical connection.
3Adaptability or versatility
If a disconnect clutch is added to allow engine disconnection, then operational versatility is improved, but the device complexity increases
Solution Approach 1:
The patent merges the disconnect clutch functionality with the existing torque converter housing and mounting structure. The clutch is integrated into the powertrain assembly rather than being a completely separate component, and the clutch actuation system is coordinated with the existing hybrid powertrain control architecture. This integration approach reduces the overall device complexity compared to adding a completely independent disconnect mechanism.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The P2 module enhances the mileage range of hybrid vehicles by allowing seamless switching between electric motor and combustion engine power, reducing the need for frequent recharging and providing a versatile powertrain configuration that minimizes modifications to existing systems, thus addressing the range limitations of all-electric vehicles.
Implementation Method 1
a torque converter, having a rotatable shell and an output member configured for coupling to the input member of the transmission
Implementation Method 2
an electric motor, having a stator and a rotor, with the rotor being fixedly connected to the torque converter
Implementation Method 3
a connect/disconnect clutch, having a first clutch member configured to be coupled to the output of the engine, a second clutch member, with the second clutch member fixedly connected to the torque converter
Implementation Method 4
a one-way clutch, coupled between the connect/disconnect clutch and the torque converter and having a locked up configuration and an overrunning configuration
Data Source
AI summary
A device for power transmission within a hybrid motor vehicle and a method of operating the device. The device is a P2 module and includes a torque converter, an electric motor, a connect/disconnect clutch and a one-way clutch. The torque converter is configured to be coupled to an input member of the transmission. The electric motor includes a rotor that is fixedly connected to the input of the torque converter. The connect/disconnect clutch has an input member configured to be coupled to the output of the engine and has first and second clutch members moveable between a disengaged and engaged positons. The second clutch member is also fixedly connected to the torque converter. The one-way clutch is coupled between the connect/disconnect clutch and the torque converter and has a locked up configuration and an overrunning configuration.