Hybrid Module Annular Rotor Torque Transmission
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Solution Overview
Problem
Existing hybrid modules for vehicles lack an efficient and integrated solution for torque transmission and clutch engagement between combustion engines and multi-speed transmissions, leading to inefficiencies and potential mechanical stress.
Innovation Solution
A hybrid module comprising an annular stator, first and second annular rotors, and bearings, with a hub for driving engagement with the transmission input shaft, and a clutch pack for frictional connection to the crankshaft, utilizing annular magnets and tubular protrusions for enhanced mechanical engagement and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a hybrid module integrates both electric motor and combustion engine components, then torque transmission efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the electric motor stator and combustion engine crankshaft into a single integrated housing structure. The stator is fixed to the housing which is arranged for fixing to the combustion engine, creating a unified assembly that reduces the number of separate components while maintaining both electric and mechanical torque transmission pathways
Solution Approach 2:
The hub structure serves multiple functions simultaneously: it acts as a bearing support for the rotors, provides driving engagement with the transmission input shaft, and serves as a mounting structure for the clutch pack. This multi-functionality reduces the overall component count while improving torque transmission efficiency
2Power
If annular rotors with magnets are used for electric motor function, then power transmission capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses annular magnets positioned specifically in the rotors where magnetic fields are needed for electromagnetic interaction with the stator. This localized application of magnetic components provides the necessary power transmission capability only where required, rather than throughout the entire assembly
Solution Approach 2:
The hub and first annular rotor are formed from a same piece of material, creating an integrated composite structure. This reduces manufacturing steps by eliminating separate assembly operations while maintaining the functional properties of both the hub and rotor components
3Stability of the object's composition
If multiple bearings are installed between rotors and stator, then mechanical stability is improved, but device complexity increases
Solution Approach 1:
The bearings are pre-positioned within the hub structure during manufacturing, rather than being installed separately during assembly. This preliminary placement ensures proper alignment and reduces the complexity of the assembly process while maintaining the mechanical stability provided by multiple bearings
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 hybrid module provides improved torque transmission efficiency and mechanical stability by integrating annular rotors, bearings, and a clutch pack, reducing mechanical stress and enhancing the connection between the combustion engine and multi-speed transmission.
Implementation Method 1
The first annular rotor or the second annular rotor includes an annular magnet
Implementation Method 2
The first bearing is installed between the first annular rotor or the second annular rotor, and the annular stator
Implementation Method 3
The piston plate is for compressing the at least one first clutch plate and the at least one second clutch plate to frictionally connect the clutch carrier and the drive plate
Data Source
AI summary
A hybrid module includes a housing, an annular stator, first and second annular rotors, and a first bearing. The housing is arranged for fixing to a combustion engine and a multi-speed transmission of a vehicle. The annular stator is fixed to the housing. The first annular rotor is disposed on a first axial side of the stator. The second annular rotor is disposed on a second axial side of the stator, opposite the first axial side. The first bearing is installed between the first annular rotor or the second annular rotor, and the annular stator. In an example embodiment, the first annular rotor or the second annular rotor includes an annular magnet. In an example embodiment, the first annular rotor is fixed to the second annular rotor.