Hybrid Friction Clutch Spring Layout for Stable Torque Modulation
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Solution Overview
Problem
Current friction clutch devices in hybrid modules for motor vehicles face challenges in starting a coupled combustion unit efficiently and controlling clutch torque, particularly when engaged in overrun mode, due to uneven axial force application and potential wear issues.
Innovation Solution
A friction clutch device with a spring device arranged to apply axial forces radially symmetrically, using a ring-shaped or segmented spring design that is fixed to the force transmission device, allowing for controlled modulation of contact pressure and torque transmission, ensuring reliable engagement and disengagement without tipping or wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional disc spring is used to generate clamping force, then the clutch can transmit torque, but the axial force is applied unevenly causing misalignment and wear
Solution Approach 1:
The disc spring is segmented into multiple independent spring elements (typically 3-6 segments) arranged radially around the clutch assembly. Each segment independently applies axial force to the friction pack, distributing the load evenly and preventing misalignment. This segmentation resolves the contradiction by maintaining reliable torque transmission while eliminating the harmful uneven force distribution that causes wear and misalignment in conventional single-disc spring designs.
2Ease of operation
If the clutch is engaged in overrun mode to start the combustion engine, then the combustion unit can be started, but the clutch torque must be precisely controlled within a specific range
Solution Approach 1:
The spring elements are designed with specific elastic properties and pre-load characteristics that automatically adjust the clamping force based on the operational state. During overrun mode, the dynamic response of the spring segments provides inherent torque control within the required range, enabling reliable combustion engine starting without requiring complex external control systems. This dynamic design resolves the contradiction by achieving ease of operation while minimizing device complexity.
3Ease of manufacture
If the spring device is positioned asymmetrically, then the structure may be simpler, but the axial force vectors are at different radial positions causing tilting and uneven wear
Solution Approach 1:
While individual spring segments are positioned asymmetrically around the clutch assembly to simplify manufacturing and assembly, their collective arrangement creates a balanced force distribution. The segments are strategically positioned at specific angular intervals (e.g., every 60 degrees for 6 segments) so that their combined axial force vectors converge at the same radial position, preventing tilting and uneven wear. This controlled asymmetry resolves the contradiction by maintaining ease of manufacture while eliminating harmful effects through geometric balancing.
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 efficient and low-wear starting of a coupled combustion unit by modulating contact pressure and controlling clutch torque, reducing the risk of component misalignment and wear, while maintaining torque transmission efficiency.
Implementation Method 1
a spring device (50), arranged axially between the force transmission device (10) and the friction pack (30), with which a spring force can be applied to the friction pack (30) in the axial direction, depending on the axial spring travel of the spring device (50)
Implementation Method 2
A friction clutch device for a motor vehicle for the frictional transmission of torque between a coupled internal combustion engine and a coupled transmission
Data Source
Figure 2~3
AI summary
The invention relates to a friction clutch unit, a hybrid module and a drive arrangement for a motor vehicle. The friction clutch unit comprises a force-transmitting unit (10) and a diaphragm spring (20), wherein the force-transmitting unit (10) is configured to transfer a substantially axially oriented compressive force (21), which is or can be exerted by the diaphragm spring (20), and further comprises a friction pack (30) which has a plurality of fins (31, 32) and by which torque can be transferred frictionally by means of an axially acting force (40) when the fins are pressed together, wherein a spring unit (50) is arranged axially between the friction pack (30) and the force-transmitting unit (10), with which spring unit (50) a spring force (61) can be applied to the friction pack (30) subject to the axial spring path (51) of the spring unit (50) in the axial direction, wherein the spring unit (50) is arranged and configured such that when the spring unit (50) is loaded with the compressive force (21), the vectors of the force pair (60) generated by the spring unit (50) in the axial direction have substantially the same radial position. With the friction clutch unit proposed here, a unit is provided that, with modulation of the pressing force acting on the friction pack, enables a coupled combustion engine to be started by means of a connected electrical machine.