Hybrid Module Dual Clutch Actuation for Motor Vehicle Drive Efficiency
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Solution Overview
Problem
Existing hybrid drive systems for motor vehicles suffer from reduced efficiency due to the series connection of electric motors, which requires one motor to be in rotation even when not actively driving, leading to unnecessary energy consumption and increased inertial mass factors.
Innovation Solution
A hybrid module design where two clutch devices are actuated simultaneously by a single actuating element, allowing one electric motor to be idle and not rotating when not in use, with a double coupling device and spring mechanisms to manage clutch operation, ensuring efficient torque transmission and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two electric motors are connected in series in a hybrid drive system, then the system can operate in multiple modes (electric motor drive, generator operation, combustion engine drive), but the efficiency is reduced because one motor must remain in rotation even when not actively driving, consuming unnecessary energy and increasing inertial mass factors
Solution Approach 1:
The hybrid drive system is segmented into two independent parallel branches: one branch contains the combustion engine with its associated clutch, and the other branch contains the two electric motors with their respective clutches. This segmentation allows each branch to be independently controlled and switched on/off, enabling the electric motors to be completely disconnected when not needed, eliminating parasitic energy consumption while maintaining all operating modes through selective engagement of different branches
Solution Approach 2:
The system employs dynamic clutch control mechanisms that can rapidly engage or disengage the electric motors from the drivetrain based on real-time operating conditions. The clutches enable the electric motors to be dynamically switched between rotational and stationary states, allowing the system to adapt to different operating modes (electric drive, generator, combustion-only) without forcing the motors to remain in rotation, thereby eliminating unnecessary energy consumption and reducing inertial mass effects
2Adaptability or versatility
If two electric motors are connected in series, then the system can provide electric drive and generator operation, but the inertial mass factors increase due to the additional rotating mass that must be accelerated and decelerated
Solution Approach 1:
The drive system is divided into independent segments with the electric motors placed in a parallel configuration rather than series. This allows the motors to be physically separated into distinct controllable units, each with its own clutch connection to the drivetrain. When the electric motors are not needed for driving or generating, they can be completely disengaged and held stationary, preventing their mass from contributing to the rotating inertial mass of the system, thus reducing the overall inertial load while maintaining full drive function versatility
Solution Approach 2:
The electric motors are extracted from the continuous rotational path of the drivetrain and placed in a parallel configuration with independent clutch connections. This extraction allows the motors to be removed from the rotating mass calculation when not in use, as they can be disengaged and held stationary. The clutch mechanisms enable the motors to be taken out of the power transmission path when not needed, effectively reducing the inertial mass that must be accelerated and decelerated during operation while preserving all necessary drive functions
3Adaptability or versatility
If a double coupling device with two sub-clutches is used, then torque can be transmitted from both the combustion engine and electric motor, but the device complexity increases with multiple clutch units and actuating systems
Solution Approach 1:
The clutch system is segmented into three independent single-clutch units rather than one complex double-clutch device. Each clutch is independently controlled by its own actuating system and manages a specific connection: one clutch connects the combustion engine to the drivetrain, while two separate clutches independently control the two electric motors. This segmentation simplifies each individual clutch unit, making them easier to manufacture, maintain, and control, while the coordinated operation of all three clutches provides the same versatile torque transmission capabilities as a complex double-clutch system
Solution Approach 2:
The functionality of what would traditionally require a complex double-clutch device is achieved by merging multiple simple single-clutch units into a coordinated system. Instead of one complex clutch unit with multiple sub-clutches and shared actuating systems, the solution merges several independent simple clutch units, each with its own dedicated actuator. This approach distributes the complexity across multiple simple, identical modules rather than concentrating it in one complex unit, improving manufacturability, reliability, and ease of maintenance while achieving the same functional versatility
Data Source
AI summary
A hybrid module for a motor vehicle for coupling an internal combustion engine, comprises a first drive shaft, a first electrical machine and a first coupling device, as well as a second drive shaft and, associated therewith, a second electrical machine, and a second coupling device; and further comprises an output element, the first or second drive shaft being connectable to the output element by way of a first or second coupling device, wherein the two coupling devices can be simultaneously actuated by a movement of an actuation element which is mechanically coupled to the two coupling devices. The hybrid module disclosed provides a drive device for a motor vehicle that offers energy-efficient operation in a plurality of different operating modes while requiring a small installation space.