Hybrid Powertrain Clutch Sleeve Layout for Compact Torque Coupling
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Solution Overview
Problem
Conventional clutch designs in hybrid vehicles face challenges such as energy losses in hydraulic systems and increased axial size in motor-driven clutches, which hinder efficient power transmission and packaging in dual motor hybrid transmissions.
Innovation Solution
A mechanically simple clutch arrangement using a one-way clutch with a synchronizer ring and coupling sleeve unit, allowing for three operational positions: neutral, one-way drive, and two-way drive, enabling efficient power connection and disconnection, and reducing axial length and energy losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hydraulic driven clutch is used, then the clutch can be actuated effectively, but energy losses occur due to the hydraulic pump
Solution Approach 1:
The patent replaces the hydraulic actuation system with a purely mechanical coupling sleeve unit that can be directly actuated. The coupling sleeve unit engages with splines on the inner and outer races, providing mechanical actuation without requiring a hydraulic pump, thereby eliminating the energy losses associated with hydraulic fluid circulation and pump operation while maintaining effective clutch actuation capability
2Ease of operation
If a motor driven clutch is used, then the clutch can be actuated precisely, but the axial size increases due to clutch plate, fork and bearings
Solution Approach 1:
The patent extracts and eliminates the unnecessary components (clutch plate, fork, and bearings) from the motor driven clutch design. The coupling sleeve unit directly engages with splines on the races, removing the intermediate components that contribute to axial length. This extraction maintains precise actuation capability through the spline-coupling mechanism while significantly reducing the overall axial size of the clutch assembly
Solution Approach 2:
The patent merges the actuation function and the coupling function into a single integrated coupling sleeve unit. Instead of having separate components for actuation (fork) and coupling (clutch plate), the sleeve unit performs both functions simultaneously by engaging with splines on both the inner and outer races, thereby reducing the number of parts and minimizing axial dimension
3Force
If a conventional clutch design is used, then the clutch can transmit torque, but the axial length is increased
Solution Approach 1:
The patent transitions from an axial engagement approach to a radial engagement approach. The coupling sleeve unit engages with splines that extend radially from the races, allowing torque transmission to occur through radial forces rather than requiring significant axial overlap. This dimensional change enables effective torque transmission while minimizing the axial length of the clutch assembly
Data Source
Figure 1
Figure 2~4
Figure 5(a)~5(c)
AI summary
A clutch arrangement for a hybrid vehicle powertrain, comprises: an input shaft (30) to be connected to a crankshaft (26) of an internal combustion engine (12); an output shaft (32) for connection to a transmission (20); a one-way clutch (50) for comprising an inner race (52) connected to rotate with the input shaft (30) and an outer race (54); a coupling hub (58) rotationally coupled with the output shaft (32); and a synchronizer ring (60) arranged between the coupling hub (58) and the one-way clutch (50), the synchronizer ring cooperating with the outer race of the one-way clutch. A coupling sleeve unit (62) is selectively and axially moveable across the coupling hub (58), synchronizer ring (60) and outer race (54) between three positions: a neutral position, a first position where the coupling sleeve unit couples in rotation said coupling hub, the synchronizer ring and the outer race; and a second position where the coupling sleeve unit couples in rotation the coupling hub, the synchronizer ring, the outer race and the inner race. Also presented is a powertrain comprising such clutch arrangement.