Hybrid Module Bulkhead Layout for Compact Torque Transmission
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Solution Overview
Problem
Existing hybrid modules for vehicle drive trains are complex, costly, and space-intensive, requiring improvements for simpler, more cost-effective, and space-saving designs.
Innovation Solution
A hybrid module with a housing containing a first electric motor, a clutch actuated by a clutch actuation unit, and a bulkhead that is axially positioned between the clutch and transmission, allowing for a highly integrated and fluid-cooled design with separate or shared fluid chambers, and featuring multiple clutch disc assemblies and brake systems for efficient torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hybrid module is designed with high integration and multiple components (electric motor, clutch, transmission), then functionality and power transmission efficiency are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The bulkhead is integrated into the housing structure, forming a unified component that serves multiple functions: structural support, fluid chamber separation, and mounting surface for transmission components. This merging of functions reduces the number of separate parts and simplifies manufacturing while maintaining the hybrid module's complex functionality
Solution Approach 2:
The bulkhead serves multiple purposes within the hybrid module: it acts as a structural support element, a separator for fluid chambers, and a mounting base for transmission components. This multi-functionality allows the hybrid module to achieve high adaptability and versatility without proportionally increasing device complexity
2Volume of moving object
If a hybrid module uses a common wet space for multiple clutches, then space is saved and integration is improved, but heat management and fluid circulation complexity increase
Solution Approach 1:
The common wet space is divided into separate fluid chambers by the bulkhead, creating distinct cooling zones for different clutches and the electric motor. This segmentation allows independent fluid circulation paths for each component, simplifying heat management while maintaining compact integration and reducing overall fluid circulation complexity
3Volume of moving object
If the hybrid module is designed as a single integrated unit, then space efficiency and power transmission are improved, but ease of manufacture and assembly decrease
Solution Approach 1:
The hybrid module is divided into separable components (housing with bulkhead, transmission unit, clutch assemblies) that can be manufactured and tested independently, then assembled into a compact integrated unit. This segmentation improves ease of manufacture and assembly while maintaining the space efficiency of the final integrated design
Solution Approach 2:
Components such as the bulkhead and clutch assemblies are pre-assembled and tested as separate units before final integration into the hybrid module. This preliminary action simplifies the overall manufacturing process by allowing parallel production and quality control of sub-components, reducing the complexity of final assembly
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 enables a cost-effective, easy-to-manufacture, and space-efficient hybrid module that simplifies the integration and testing of a transmission unit within a vehicle drive train, providing enhanced controllability and heat resistance while maintaining a compact and integrated power flow.
Implementation Method 1
The bulkhead can enable a fluid passage. The hybrid module and the transmission can also each have a separate fluid chamber, which can be separated from one another by the bulkhead.
Implementation Method 2
The speed sensor can be based on the eddy current principle, the resolver principle, or the Hall principle.
Implementation Method 3
The speed sensor can be based on the eddy current principle, the resolver principle, or the Hall principle.
Data Source
AI summary
A hybrid module for the transmission of torque in a drive train of a vehicle having a transmission. The hybrid module received in a housing has a first electric motor, a first clutch, which can be actuated by a first clutch actuation unit, and has a first multiple clutch disc assembly, first clutch input and first clutch output, and a bulkhead fastened to the housing. The bulkhead is arranged axially between the first clutch and the transmission and can be releasably connected to the housing. A transmission unit in a drive train of a vehicle having such a hybrid module and at least one first brake of a transmission, wherein the first brake is a first support element fixed to the housing and has a first rotary element which can be braked by the first brake. The first support element is connected in a rotationally fixed manner to or configured in one piece from the bulkhead.