One-Piece Forged Hub Integrating Wet and Separating Clutches
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Solution Overview
Problem
Existing hybrid drive systems for motor vehicles face challenges in achieving extended functionality while maintaining compactness, low cost, and ease of assembly.
Innovation Solution
A hybrid drive system with a one-piece forged hub that integrates a wet clutch and a separating clutch, featuring radially mounted actuating pistons with aligned actuation directions, and includes a bearing for radial mounting and sealing, along with integrated oil ducts and seal receptacles for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple clutches and actuating chambers are integrated into the hub, then functionality is extended, but device complexity increases
Solution Approach 1:
The patent integrates multiple actuating chambers (first actuating chamber for wet clutch, second actuating chamber for separating clutch) and multiple seals into a single hub component. The hub serves as a common structural element that houses both clutches and their actuation systems, merging what would traditionally be separate components into one integrated unit, thereby extending functionality while managing complexity through consolidation
Solution Approach 2:
The hub is designed as a multi-functional component that simultaneously serves as the mounting structure for the wet clutch, the separating clutch, and their respective actuating chambers. It provides radial mounting surfaces for multiple pistons, contains multiple seals, and integrates oil ducts for hydraulic actuation. This universal design allows one component to perform multiple functions that would otherwise require separate parts
2Reliability
If multiple seals are integrated into the hub, then sealing functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates multiple seals (first seal for first actuating chamber, second and third seals for second actuating chamber) directly into the hub structure. The hub includes integrated seal receptacles and sealing surfaces that accommodate multiple seals simultaneously, combining multiple sealing functions into a single manufactured component rather than requiring separate sealing assemblies for each clutch
3Ease of manufacture
If the hub is designed as a one-piece forged part with integrated features, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: first, the hub is forged as a one-piece part with basic geometry; then, additional features (actuating chambers, oil ducts, seal receptacles, piston mounting surfaces) are added through subsequent machining and boring operations. This segmentation allows the core structure to be manufactured efficiently as a single piece while adding complexity only where necessary through controlled manufacturing steps
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 system achieves a compact, cost-effective, and easy-to-assemble design with enhanced functionality, ensuring efficient power transmission and cooling through the use of lamella clutches and integrated oil management.
Implementation Method 1
a bearing by means of which the hub is radially mounted relative to the output shaft
Implementation Method 2
the bearing also functions as a seal for sealing a cooling and lubricating oil area, to which the cooling oil duct belongs, against an actuating oil area, to which the first actuating oil duct belongs
Implementation Method 3
The hub has a cooling oil duct designed to supply cooling oil to a first lamella set of the wet clutch
Implementation Method 4
Both the wet clutch and the separating clutch are designed as lamella clutches
Data Source
AI summary
A hybrid drive system for a motor vehicle includes an input shaft, which introduces torques from an internal combustion engine into the hybrid drive system and which is mounted rotatably around an axis of rotation. An output shaft is arranged coaxially to the input shaft. The system also includes an electric machine having a stator and a rotor, and a hub non-rotatably connected to the rotor. The system further includes a wet clutch which has a first actuating piston. The hub is formed as a one-piece forged part and has a first running surface for the first actuating piston. The wet clutch is provided to non-rotatably connect the hub to the output shaft.