Hybrid Module Hub Assembly With Form-Fit Pre-Positioning
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Solution Overview
Problem
The existing methods for mounting hybrid modules, such as those in vehicle drive trains, require manual or complex automated positioning of rivets, which is time-consuming and costly, and lacks secure orientation of connection partners during the assembly process.
Innovation Solution
A hub assembly with a form-fitting connection mechanism that pre-positions connection partners via a form-fitting contour and mating contour, allowing for automated orientation and secure fixation, eliminating the need for manual positioning pins and enabling simplified and efficient mounting of connection elements like rivets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning pins or complex automated positioning systems are used to align connection partners, then positioning precision is improved, but device complexity and mounting time increase
Solution Approach 1:
The connection partners are pre-positioned relative to one another before the actual mounting process. The first connection partner is positioned on the second connection partner in advance, ensuring that receiving openings are already aligned. This preliminary positioning eliminates the need for complex positioning pins or automated positioning systems during mounting, thereby reducing device complexity while maintaining positioning precision.
Solution Approach 2:
The connection partners are designed with self-aligning features such as form-fitting contours and mating contours that automatically guide the alignment of receiving openings. The geometric design of the connection partners themselves provides the positioning function, eliminating the need for separate positioning mechanisms. This self-service approach reduces device complexity while ensuring accurate alignment.
2Adaptability or versatility
If manual positioning by workers is used, then flexibility is improved, but productivity and mounting speed decrease
Solution Approach 1:
Connection partners are pre-positioned and form-fitted together before the riveting or mounting process begins. This preliminary arrangement ensures that all receiving openings are automatically aligned, allowing automated systems to perform mounting operations rapidly without manual intervention for positioning. This maintains the flexibility of manual assembly while achieving the speed of automated production.
3Ease of operation
If positioning pins are removed before rivet installation, then ease of assembly is improved, but mounting security and precision are reduced
Solution Approach 1:
The connection partners incorporate self-aligning geometric features such as form-fitting contours and mating contours that maintain positioning throughout the entire mounting process. These features continuously constrain the relative positions of connection partners, ensuring mounting security and precision without requiring removable positioning pins. The design itself provides the positioning function that would otherwise require separate components.
4Adaptability or versatility
If multiple separate components are connected by rivets, then adaptability is improved, but mounting time and effort increase
Solution Approach 1:
Multiple connection partners are pre-positioned and form-fitted together in an assembly sequence that allows all receiving openings to be aligned simultaneously or in efficient sequences. This preliminary arrangement enables automated systems to install multiple rivets quickly without repeated positioning operations, thereby reducing mounting time while maintaining the ability to connect multiple separate components for adaptability.
Data Source
AI summary
A hub assembly for a hybrid module having a first and a second connection partner arranged coaxially with one another, the first connection partner has a first bearing portion and the second connection partner has a second bearing portion, and a plurality of connecting elements. The first and the second bearing portion have receiving openings for receiving the connecting elements. The first and the second connection partner are prepositioned with respect to one another via a form-fitting connection such that the receiving openings in the first and the second bearing portion are each oriented in pairs in a positionally correct manner with respect to one another in the circumferential direction about the main axis H.