Hybrid Module Bearing Support for Load Management
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Solution Overview
Problem
Existing hybrid modules for internal combustion engines face challenges in effectively managing axial and radial loads, torque transmission, and disassembly complexity due to the lack of efficient bearing configurations and retention mechanisms.
Innovation Solution
A hybrid module design incorporating multiple bearings (deep groove ball, needle roller thrust, and cylindrical thrust bearings) and snap rings for load separation and retention, along with a damper for torque transmission, and a seal to prevent debris entry, which are strategically arranged within a housing with a bulkhead wall and K0 shaft for efficient operation and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple bearings are used to manage axial and radial loads, then load management and reliability are improved, but device complexity increases
Solution Approach 1:
The bearing support structure is segmented into multiple functional bearings: a first bearing for radial loads, a second bearing for first axial loads, and a third bearing for second axial loads. This segmentation allows each bearing to specialize in specific load directions, improving overall load management and reliability while maintaining a systematic approach to complexity.
Solution Approach 2:
The patent addresses load management by adding dimensional differentiation through multiple bearings oriented in different directions. The first bearing handles radial loads in one plane, while the second and third bearings handle axial loads along the shaft axis, effectively managing three-dimensional load vectors through dimensional separation.
2Ease of operation
If snap rings are used for retention, then ease of assembly and disassembly is improved, but device complexity increases
Solution Approach 1:
The retention system is segmented into multiple snap rings positioned at different locations along the K0 shaft. Each snap ring secures specific components (bearings, sleeves) independently, allowing for modular assembly and disassembly. This segmentation improves ease of operation by enabling component-level maintenance while keeping the retention mechanism relatively simple through standardized snap ring usage.
Solution Approach 2:
Snap rings serve as intermediary retention elements between the K0 shaft and various components (bearings, sleeves). These snap rings provide a simple mechanical retention mechanism that facilitates easy assembly and disassembly without requiring complex fastening systems, thereby improving ease of operation with minimal added complexity.
3Reliability
If a damper is added for torque transmission, then reliability is improved, but device complexity increases
Solution Approach 1:
The damper is merged with the K0 shaft to form an integrated torque transmission assembly. This combination allows the damper to perform torque transmission and vibration damping functions within the existing shaft structure, improving reliability of torque transmission while minimizing additional complexity by consolidating functions into a single integrated component.
4Reliability
If a seal is installed to prevent debris entry, then reliability is improved, but device complexity increases
Solution Approach 1:
The sealing function is extracted as a separate, dedicated component (seal) installed in the bulkhead wall. This extracted sealing element prevents debris entry at the interface between the hybrid module and the engine crankshaft, improving reliability through specialized debris protection while maintaining simplicity by using a single, focused sealing component rather than a complex multi-element sealing system.
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 provides improved load management, reduced friction, enhanced torque transmission, and simplified disassembly by using a combination of bearings and snap rings, resulting in increased durability and reliability of the hybrid module.
Implementation Method 1
the first bearing is a deep groove ball bearing
Implementation Method 2
the second bearing is a needle roller thrust bearing
Implementation Method 3
the third bearing is a cylindrical thrust bearing
Implementation Method 4
a seal installed in the bulkhead wall and contacting the K0 shaft
Implementation Method 5
a damper arranged for transmitting a torque from the crankshaft to the K0 shaft
Data Source
AI summary
A hybrid module includes a housing with a bulkhead wall, a K0 shaft, a rotor assembly, a rotor carrier and a first bearing. The K0 shaft is arranged for driving connection with a crankshaft. The rotor assembly has an electric motor rotor and a thrust surface for a K0 clutch. The K0 clutch is arranged to drivingly connect the rotor assembly to the K0 shaft. The rotor carrier is fixed to the rotor assembly and the first bearing is arranged to rotationally separate the bulkhead wall and the rotor carrier. In an example embodiment, the first bearing is a deep groove ball bearing. In an example embodiment, the hybrid module includes a seal installed in the bulkhead wall and contacting the K0 shaft. In an example embodiment, the hybrid module includes a bushing installed on the K0 shaft and arranged for contacting an inner bore of the crankshaft.