Hybrid Module Axial Actuator Arrangement
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Solution Overview
Problem
Hybrid modules with integrated dual-clutch devices face installation space challenges and increased bearing-induced losses due to the need for more components and bearings, which generate drag losses through bearing friction.
Innovation Solution
The hybrid module design arranges actuating systems next to each other in the axial direction, with at least one partial clutch within the rotor's space, using ring-shaped piston cylinder units and actuating bearings with smaller diameters to reduce drag losses and optimize space utilization, and incorporates a rotor carrier and intermediate shaft for torque transmission, allowing for a compact and energy-efficient configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If actuating systems are arranged radially within the electrical machine to achieve compact axial length, then the axial space is optimized, but the radial extent increases requiring larger and more numerous bearings which generate increased drag losses
Solution Approach 1:
The actuating systems are arranged axially adjacent to one another instead of radially, changing the spatial dimension from radial to axial arrangement. This allows the actuating systems to be positioned next to each other in the axial direction, reducing the need for large radial bearings and thereby minimizing bearing-induced drag losses while maintaining compact overall dimensions.
Solution Approach 2:
The actuating systems are arranged within the space surrounded by the rotor of the electrical machine, nesting the actuating systems within the existing radial envelope of the electrical machine. This allows efficient space utilization without requiring additional radial clearance, thereby reducing bearing size and drag losses.
2Stability of the object's composition
If multiple bearings are used to support the additional components in the hybrid module with integrated dual clutch, then the structural stability is improved, but the bearing friction increases leading to higher drag losses
Solution Approach 1:
The actuating systems are extracted from the radial arrangement and positioned axially adjacent to one another, removing them from the radial space. This extraction reduces the number and size of bearings required in the radial direction, thereby reducing bearing friction and drag losses while maintaining structural stability through the axial arrangement.
3Productivity
If the hybrid module is positioned between the internal combustion engine and gearbox to achieve functional integration, then the torque transmission path is optimized, but the installation space is reduced leading to compactness challenges
Solution Approach 1:
The actuating systems are nested within the space surrounded by the rotor of the electrical machine, utilizing the existing radial envelope efficiently. This nesting allows the actuating systems to be positioned without increasing the overall radial or axial dimensions of the hybrid module, maintaining compactness for optimal installation space utilization.
Data Source
AI summary
A hybrid module for a motor vehicle for coupling an internal combustion engine includes a disconnect clutch, an electrical machine, a dual-clutch device, a disconnect clutch actuating system, a first actuating system, and a second actuating system. The disconnect clutch is for transmitting a first torque from the internal combustion engine to the hybrid module and disconnecting the hybrid module from the internal combustion engine. The dual-clutch device includes a first partial clutch and a second partial clutch. The disconnect clutch actuating system is for actuating the disconnect clutch. The first actuating system is for actuating the first partial clutch. The second actuating system is for actuating the second partial clutch. The disconnect clutch actuating system, the first actuating system, and the second actuating system are arranged next to one another in an axial direction.