Dry Double Clutch Drive Module for Easier Powertrain Assembly
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Solution Overview
Problem
Existing drive modules for motor vehicles are complex, costly, and inefficient due to the use of wet clutches, which complicate assembly and reduce robustness.
Innovation Solution
A drive module design featuring a dry double clutch system with a common central plate and reach-through openings for easy assembly, where at least one partial clutch has a passage opening for fastening elements to connect or separate parts from the electric machine, resulting in a compact, robust, and cost-effective configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wet clutches are used in the drive module, then the clutches can be actuated hydraulically, but the assembly becomes more complex and costly
Solution Approach 1:
The patent extracts the hydraulic actuation system from the clutch assembly, eliminating the need for hydraulic fluid supply lines and concentric slave cylinders within the rotor carrier. The clutch plates are designed to be actuated by external hydraulic pressure applied to the clutch disc, removing the complexity of internal hydraulic components while maintaining hydraulic actuation capability
Solution Approach 2:
The clutch assembly is segmented into separate components (clutch disc, clutch plates, spring elements) that can be assembled independently and then integrated into the drive module. This modular segmentation simplifies the assembly process and reduces the complexity of integrating hydraulic actuation mechanisms
2Ease of operation
If wet clutches are used in the drive module, then hydraulic actuation is enabled, but the cost increases
Solution Approach 1:
The patent removes the expensive internal hydraulic actuation mechanisms (concentric slave cylinders, hydraulic seals, fluid supply lines) from the clutch assembly. Instead, a simpler external hydraulic actuation system is used, which reduces manufacturing costs while maintaining the ability to actuate the clutch hydraulically
Solution Approach 2:
The clutch plates are designed as simpler, more cost-effective components that can be manufactured using conventional processes. The design accepts that these friction components will wear and need replacement, optimizing them for cost-effectiveness rather than indefinite service life
3Ease of operation
If wet clutches are used in the drive module, then hydraulic actuation is achieved, but assembly becomes more difficult
Solution Approach 1:
The patent extracts the complex internal hydraulic actuation mechanisms from the clutch assembly, eliminating the need to assemble concentric slave cylinders and hydraulic fluid supply lines within the rotor carrier. This significantly simplifies the assembly process while maintaining hydraulic actuation capability
Solution Approach 2:
The clutch assembly is divided into separable components that can be pre-assembled and tested independently before integration into the drive module. This segmentation allows for easier assembly and disassembly, reducing the difficulty of manufacturing and maintenance operations
4Volume of moving object
If the dual clutch is integrated into the rotor carrier, then installation space is optimized, but the design becomes less robust
Solution Approach 1:
The patent segments the clutch assembly from the rotor carrier, allowing the clutch components to be mounted on a separate carrier plate that is attached to the rotor carrier. This separation maintains compact installation space while improving design robustness by allowing independent optimization of each component
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a drive module (5) for the powertrain of a motor vehicle, having an electric machine (4) which has a rotor support (12) with a rotor (11) that can be rotated about an axis (A). A separating clutch (2) is held on the rotor support (12) in the rotor (11) of the electric machine (4). A double clutch (1) arranged downstream of the electric machine (4) and upstream of the transmission (6) has a first sub-clutch (21) and a second sub-clutch (22). At least one of the first sub-clutch (21) and the second sub-clutch (22) has a reach-through opening (62) through which a securing element (36) can be acted upon such that the double clutch (1) or at least parts of the double clutch (1) can be connected to the electric machine (4) or separated therefrom. The invention additionally relates to a method for assembling the drive module (5).