Hybrid Module Baffle Blade Drag Loss Reduction

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Solution Overview

Problem

Hybrid motor vehicle drive trains experience drag loss due to vortices created by the torque converter in a wet environment, leading to inefficiencies.

Innovation Solution

A hybrid module with a baffle system that includes a flexible hook mechanism to securely attach the baffle between the electric motor stator and the housing, redirecting fluid flow and minimizing drag by clamping the baffle in place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a torque converter runs in a wet environment inside the bell housing, then torque transmission is enabled, but a vortex of oil is created causing drag loss

Engineering Contradiction:

Improvetorque transmissionVSAvoiddrag loss

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The baffle blade extracts the harmful vortex flow from the system by introducing a flow control element that separates the oil flow path, directing it away from the torque converter to reduce drag loss while maintaining torque transmission functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The baffle blade acts as an intermediary element between the torque converter and the oil reservoir, mediating the fluid flow to prevent direct vortex formation while allowing necessary lubrication and cooling to continue

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If a baffle is added to redirect fluid flow and reduce drag loss, then energy efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvedrag loss reductionVSAvoidbaffle structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The baffle is segmented into a blade portion and a connector portion, allowing the flow control function to be separated from the mounting function. This segmentation enables a simpler overall design where each part has a specific, optimized role in reducing drag loss

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of trying to eliminate the vortex at its source in the torque converter, the invention inverts the approach by using the baffle to redirect and control the oil flow path, achieving drag loss reduction through flow management rather than source elimination

Inventive Principle:

Principle #13The other way round (Inversion)

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 baffle system effectively reduces drag loss by stabilizing the fluid flow, enhancing the efficiency of torque transmission and reducing energy loss in the hybrid drive train.

Implementation Method 1

The torque converter can create a vortex of oil inside the bell housing, which has been linked to a drag loss on the order of 1 Nm

Methodology Applied

Scientific EffectVortex: Vortex Ring

Data Source

PatentUS10399427B2Hybrid motor vehicle drive train including hybrid module baffle blade

Publication Date: 2019.09.03 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A hybrid module is configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a drive unit including an electric motor and a housing, a torque converter connected to the electric motor and a baffle fixed to the housing and the stator. The baffle extends axially from the housing radially outside of the electric motor and the torque converter.