Compact P2 Hybrid Module Layout for Tight Axial Packaging
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Solution Overview
Problem
Current hybrid powertrain architectures, particularly P2 configurations, face challenges in axial packaging, especially in vehicles with front wheel drive configurations, necessitating a compact module for efficient integration.
Innovation Solution
A compact P2 module incorporating a torque converter, electric motor, electro-mechanical controllable clutch, and electric connect/disconnect friction clutch, with the electro-mechanical controllable clutch positioned radially inward, reducing axial and radial package space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional P2 module configuration is used with radial clutch mounting and axial rotor constraint, then the clutch can be mounted inside the electric motor, but the axial packaging space is increased
Solution Approach 1:
The clutch is repositioned from a radial mounting configuration to an axial mounting configuration. The clutch disc is positioned axially adjacent to the torque converter housing instead of radially inside the motor, fundamentally changing the spatial arrangement from radial to axial dimension, thereby reducing the axial packaging space required for the P2 module
2Reliability
If the electric motor rotor is axially constrained by the clutch cylinder, then the rotor is securely positioned, but the axial packaging of the P2 module is increased
Solution Approach 1:
The rotor axial constraint function is extracted from the clutch cylinder and relocated to dedicated rotor support structures. The clutch cylinder is removed from its conventional position and repositioned axially, while the rotor is supported by bearing assemblies that provide axial constraint without increasing overall axial packaging space
Solution Approach 2:
The constraint mechanism transitions from radial clutch cylinder contact to axial bearing support, changing the dimensional approach to rotor positioning from radial constraint to axial support through dedicated bearing assemblies
3Length of moving object
If a compact P2 module is designed to reduce axial packaging, then integration into front wheel drive vehicles is improved, but the radial space requirements increase
Solution Approach 1:
The clutch and other components are redistributed from radial mounting positions to axial mounting positions. This dimensional shift moves components along the axial direction rather than radially outward, effectively trading radial space for axial space optimization, allowing the module to fit within the limited radial envelope of front wheel drive vehicle architectures
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 compact P2 module efficiently integrates into vehicles with front wheel drive configurations, minimizing packaging requirements and enhancing integration flexibility.
Implementation Method 1
a torque converter, an electric motor, an electro-mechanical controllable clutch (a dynamic controllable clutch) and an electric connect/disconnect friction clutch
Implementation Method 2
an electro-mechanical controllable clutch assembly, the electro-mechanical controllable clutch assembly having an input member and an output member, the input member and output member being rotationally lockable with one another during engagement of the electro-mechanical controllable clutch assembly
Implementation Method 3
the electric connect/disconnect friction clutch assembly having first and second sets of friction plates, the first and second sets of friction plates being rotationally lockable with one another during engagement of the electric connect/disconnect friction clutch assembly
Data Source
AI summary
A compact P2 hybrid module for connecting an internal combustion engine to a transmission of a vehicle. The P2 module includes an input shaft, an electric motor having a stator and a rotor, a torque converter having a front cover and a rear cover. The torque converter further including an impeller and a turbine coupled to one another so as to form a hydrodynamic circuit, and the turbine being further coupled to an output member of the torque converter. The front cover of the torque converter being rotationally fixed with the rotor of the electric motor. An electric connect/disconnect friction clutch assembly having first and second sets of friction plates. The first and second sets of friction plates being rotationally lockable with one another during engagement of the electric connect/disconnect friction clutch assembly. An electro-mechanical controllable clutch assembly having an input member and an output member.