Double eClutch Module for Hybrid Torque Transfer in Tight Space
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Solution Overview
Problem
The automotive industry faces challenges in developing transmission systems that can seamlessly integrate inputs from multiple power sources, such as hybrid systems combining combustion engines and electric motors, while also requiring improved torque transfer within restricted transmission spaces.
Innovation Solution
A modular clutch assembly with two independent power sources and an output device, featuring inner and upper clutch races with coil windings and armatures that selectively engage and disengage to transfer torque to an output hub, allowing for efficient power transfer between different power sources and output devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional single-clutch design is used, then the transmission space is smaller, but the torque transfer capability is insufficient for high power applications
Solution Approach 1:
The clutch assembly is divided into two independent clutch systems (first clutch with inner coil, second clutch with outer coil) that operate simultaneously within the same transmission space. Each clutch handles a portion of the torque transfer, allowing the system to achieve higher total torque capability without proportionally increasing the transmission space volume.
Solution Approach 2:
The first clutch components (inner clutch race, inner coil, inner armature) are nested within the second clutch components (outer clutch race, outer coil, outer armature). This concentric arrangement allows both clutch systems to occupy overlapping spatial volumes, effectively doubling torque capacity while minimizing the increase in overall transmission space.
2Adaptability or versatility
If hybrid systems with multiple power sources are implemented, then fuel economy and power flexibility improve, but the transmission system complexity increases
Solution Approach 1:
The transmission system incorporates two independently controllable clutch mechanisms that can be dynamically engaged or disengaged based on operating conditions. The control system can selectively activate the first clutch, second clutch, or both simultaneously, allowing flexible adaptation to different power source configurations (ICE-only, EV-only, or hybrid operation) without requiring physically different transmission designs.
Solution Approach 2:
The dual-clutch architecture provides a universal solution that can accommodate multiple power source configurations. The same transmission housing and output shaft can work with various combinations of internal combustion engines and electric motors by simply adjusting clutch engagement patterns, eliminating the need for separate transmission designs for different hybrid configurations.
3Force
If dual coil clutch assembly is used, then torque transfer capability is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into modular assembly steps: first the inner clutch components (inner clutch race, inner coil assembly, inner armature) are manufactured and pre-assembled, then the outer clutch components (outer clutch race, outer coil assembly, outer armature) are manufactured separately, and finally both modules are assembled together in the transmission housing. This modular segmentation allows each clutch subsystem to be manufactured using standard single-clutch processes, reducing overall manufacturing complexity despite the enhanced torque capability.
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
Enables seamless power transfer and enhanced torque management between multiple power sources, optimizing energy flow and reducing the size of the transmission system while accommodating various power source configurations.
Implementation Method 1
The inner coil includes an inner coil winding contained in a housing and a cover that together form a fixed part of the inner coil
Implementation Method 2
The armature further includes a magnetic portion that is moveably positioned within the passage at a gap distance from the inner diameter surface of the housing
Data Source
AI summary
A modular clutch assembly with two independent power sources and a connection with an output device. The two independent power sources and the output device can take many different forms. The modular clutch assembly has a housing that connects the two power sources with the output device and controls power transfer using an inner clutch and an upper clutch. There is further provided an output hub connected to the output device, where the output hub extends into the modular clutch assembly for selective rotation. The output device in one exemplary embodiment of the invention is a transmission of a vehicle.