Hybrid Module Clogged Filter Detection via Motor Temperature
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Solution Overview
Problem
Existing hybrid vehicle systems face challenges in retrofitting existing vehicles due to significant modifications required for drive trains and often result in power loss, affecting fuel economy, with inadequate lubrication and cooling systems that depend on engine conditions and operational modes.
Innovation Solution
A self-sufficient hybrid module with a dual mechanical/electric pump system for fluid circulation, incorporating a lube splitter valve for prioritizing oil delivery and clogged filter detection, allowing independent operation from the transmission and engine, and featuring a compact design with an offset piston for precise clutch control and a dam-slinger arrangement to prevent fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common filter is used for multiple hydraulic portions, then the system complexity is reduced, but the reliability decreases when the filter becomes clogged as all portions are affected
Solution Approach 1:
The patent divides the hydraulic system into separate circuits with independent filters for each major portion (transmission circuit, clutch circuit, torque converter circuit). This segmentation ensures that a clogged filter in one circuit does not affect other circuits, maintaining system reliability while keeping each filter unit manageable in size and complexity.
2Reliability
If the mechanical pump size is increased to meet hybrid system lubrication and cooling needs, then the reliability improves, but the weight and power loss increase
Solution Approach 1:
The patent combines a mechanical pump (driven by the torque converter) with an electric pump (powered by the hybrid system's electric motor/generator). This merging allows the system to meet increased lubrication and cooling demands without significantly increasing mechanical pump size, as the electric pump provides supplemental capacity when needed.
Solution Approach 2:
The mechanical pump is designed to serve multiple functions: it provides lubrication for the torque converter, transmission, and clutch, while also serving as a starter motor for the engine. This multi-functionality reduces the need for dedicated components, thereby reducing overall weight while maintaining reliability.
3Reliability
If the mechanical pump is made larger to handle hybrid system demands, then the lubrication reliability improves, but the power loss increases affecting fuel economy
Solution Approach 1:
The patent merges a mechanical pump with an electric pump in a dual-pump configuration. The mechanical pump handles baseline lubrication demands, while the electric pump supplements capacity during high-demand hybrid operation modes. This allows the mechanical pump to remain smaller than it would need to be if it had to handle all demands alone, reducing parasitic power losses.
Solution Approach 2:
The system dynamically switches between mechanical pump-only operation, electric pump supplementation, and combined operation based on hybrid system mode and lubrication/cooling demands. This dynamic operation allows the mechanical pump to be sized for average demands rather than peak demands, reducing its size and associated power losses while maintaining reliability when needed.
4Reliability
If a lube splitter valve is used to prioritize oil delivery, then the reliability of critical components improves, but the device complexity increases
Solution Approach 1:
The patent introduces a lube splitter valve as an intermediary component that automatically prioritizes oil flow to critical components (torque converter, transmission, clutch) based on pressure differential. This single valve provides intelligent flow distribution without requiring complex electronic controls or multiple valves, maintaining relatively simple system architecture while improving critical component reliability.
5Adaptability or versatility
If the hybrid module operates independently from the transmission and engine, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The patent segments the hydraulic system into a self-contained hybrid module with its own pump, filter, and control valve that can operate independently of the traditional engine-transmission lubrication system. This modular segmentation allows the hybrid module to be adapted to different operational modes (electric-only, hybrid, engine-only) without requiring complex integration with existing systems, as it functions as a relatively independent unit.
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 solution reduces the need for modifications to other vehicle systems, enhances lubrication and cooling efficiency, minimizes power loss, and allows for efficient operation in various modes, including electric-only and propulsion-assist modes, while detecting clogged filters to maintain optimal performance.
Implementation Method 1
a temperature sensor which senses if the motor is overheating
Implementation Method 2
The fluid circulation system which can act as a lubricant, hydraulic fluid, and/or coolant, includes a mechanical pump for circulating a fluid, along with an electric pump that supplements workload for the mechanical pump when needed
Implementation Method 3
The lube splitter valve, also referred to as a lube regulator valve, controls the flow split and the delivery prioritizing
Implementation Method 4
featuring a compact design with an offset piston for precise clutch control
Implementation Method 5
and a dam-slinger arrangement to prevent fluid leakage
Implementation Method 6
When the engine is operating, the mechanical pump delivers oil to the hydraulic system
Implementation Method 7
the electric pump supplements workload for the mechanical pump when needed
Implementation Method 8
the filter (upstream from the lube splitter valve) becomes clogged
Data Source
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AI summary
A hydraulic system for a hybrid module which is located between an engine and a transmission includes a parallel arrangement of a mechanical pump and an electric pump. Each pump is constructed and arranged to deliver oil to other portions of the hydraulic system depending on the operational mode. Three operational modes are described including an electric mode, a transition mode, and a cruise mode. Included is a lube splitter valve which prioritizes the delivery of oil between downstream components and the motor (eMachine). The motor temperature is monitored and an elevated motor temperature provides an indication of a clogged oil filter.