Hybrid Drive Unit Segmentation for Assembly and Sealing
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Solution Overview
Problem
Existing hybrid systems for vehicles face complexity in assembly, high production accuracy demands, and operational impairments due to exposure of electric machines to service fluid, which affects the air gap and requires precise fitting accuracy, making them expensive and difficult to test individual components before full assembly.
Innovation Solution
A combined power transmission and drive unit with a dry-running electric machine and preassembled units that can be tested separately, allowing for axial and angular offset compensation, and integration of sealing functions, reducing the need for high assembly precision and simplifying the assembly process by using preassembled units that can be easily connected to the transmission input shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric machine is exposed to the service fluid of the power transmission device and switchable clutch device, then space-saving formation is achieved, but the air gap required for induction is impaired and operating mode is affected
Solution Approach 1:
The patent divides the hybrid drive system into separate functional units: the power transmission device with service fluid is segmented from the electric machine. The electric machine is positioned as a separate unit that can be coupled to the power transmission device through a flange connection, allowing independent operation and avoiding fluid exposure while maintaining compact overall arrangement.
2Volume of moving object
If the electric machine is disposed around the extension of the switchable clutch device with the rotor connected non-rotatably to the clutch device housing, then space is saved, but the assembly becomes complex and individual component testing is impossible
Solution Approach 1:
The electric machine is separated from the power transmission device into an independent module. This segmentation allows the electric machine to be manufactured, tested, and assembled separately from the power transmission components, significantly reducing assembly complexity while maintaining the compact spatial arrangement through external coupling via flange connections.
Solution Approach 2:
The electric machine is pre-assembled and tested as a complete unit before being coupled to the power transmission device. This preliminary action enables independent verification of electric machine functionality and allows any defects to be identified and corrected before final assembly, simplifying the overall manufacturing process.
3Volume of moving object
If the electric machine is disposed around the extension of the switchable clutch device, then space is saved, but high demands are put on production accuracy of individual components
Solution Approach 1:
By segmenting the electric machine from the power transmission device and coupling them externally through standardized flange connections, the patent eliminates the need for high-precision integration between these components. Each unit can be manufactured with standard tolerances and assembled with conventional alignment procedures, significantly reducing production accuracy demands while maintaining compact overall dimensions.
4Volume of moving object
If the electric machine is exposed to service fluid, then compact arrangement is achieved, but sealing requirements increase and fluid contamination risk arises
Solution Approach 1:
The electric machine is segmented from the fluid-filled power transmission device and coupled externally. This segmentation eliminates the need for complex sealing arrangements between the electric machine and service fluid, as the electric machine operates in a separate, fluid-free environment while maintaining compact overall system arrangement through external mounting.
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
This solution simplifies the assembly and testing of hybrid systems, reduces production costs, and enhances the reliability of the power transmission and drive unit by allowing for separate testing of individual components, minimizing the dependence on precise fitting accuracy and reducing the risk of operational impairments from fluid exposure.
Implementation Method 1
an electric machine (7) including at least one rotor (12) that is connected non-rotatably with the input of the power transmission device (6)
Data Source
AI summary
A combined power transmission and drive unit for use in hybrid systems between a first engine and a transmission device, broadly including at least an input connectable with the engine, a power transmission device by which the output is connected with a transmission input shaft, a device for selectively at least interrupting/establishing the power flow to the input of the power transmission device and an electric machine including at least one rotor that is connected non-rotatably with the input of the power transmission device. Furthermore, the invention relates to a hybrid system, including a first engine and a combined power transmission and drive unit connected downstream of the engine.