Hybrid Module Clutch Leaf Spring Torque Transmission
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Solution Overview
Problem
Hybrid modules in motor vehicle powertrains face challenges in compactly integrating separating clutches and double clutches while maintaining independent operation and efficient torque transmission, often requiring complex toothing mechanisms that increase friction and reduce assembly space efficiency.
Innovation Solution
The hybrid module employs an outer lamella carrier connected rigidly to the counter-plate, using leaf springs for conjoint rotation and torque transmission, eliminating external and internal toothing between the intermediate and pressure plates, allowing for axial movement with reduced friction and simplified design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If toothing mechanisms are used to connect the pressure plate and intermediate plate to the outer lamella carrier, then torque transmission is achieved, but friction increases and assembly space is reduced
Solution Approach 1:
The patent removes the toothing mechanism from the connection between the pressure plate/intermediate plate and the outer lamella carrier. Instead of using interlocking teeth, the design extracts the toothing element entirely and replaces it with a friction-based clamping connection through the clutch pack, thereby eliminating the harmful friction and wear associated with toothing engagement while maintaining torque transmission capability.
Solution Approach 2:
The patent introduces the clutch pack (comprising clutch disks and friction plates) as an intermediary element between the pressure plate and the outer lamella carrier. This mediator enables torque transmission through controlled friction engagement, replacing the direct toothing connection and reducing harmful friction effects by distributing the load across multiple friction surfaces.
2Power
If toothing mechanisms are used to connect the pressure plate and intermediate plate to the outer lamella carrier, then torque transmission is achieved, but assembly space efficiency is reduced
Solution Approach 1:
The patent extracts the toothing mechanism from the design, removing the radial space requirements for tooth engagement and clearance. This extraction allows for a more compact arrangement of the clutch components, improving assembly space efficiency while maintaining the torque transmission function through the friction-based clutch pack connection.
3Reliability
If complex toothing mechanisms are used, then reliable torque transmission is achieved, but device complexity increases
Solution Approach 1:
The patent removes the complex toothing mechanisms from the clutch assembly, significantly simplifying the device structure. The reliability of torque transmission is maintained through the proven friction-based clutch pack design, which eliminates the need for precise toothing alignment and reduces the number of components requiring assembly and maintenance.
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
This configuration simplifies the design of the intermediate and pressure plates, reduces frictional engagement, and enables efficient torque transmission while allowing for compact assembly, enhancing the operational reliability and space efficiency of the hybrid module.
Implementation Method 1
The pressure plate and/or the intermediate plate are connected to the outer lamella carrier or the counter-plate for conjoint rotation therewith via at least one leaf spring
Implementation Method 2
The separating clutch has a pack which can be brought into frictional engagement, including a pressure plate, a counter-plate, at least one intermediate plate and clutch disks that extend between the plates
Data Source
AI summary
A hybrid module for a powertrain of a motor vehicle includes an electric machine, a clutch device, and a frictionally-engaging separating clutch. The separating clutch is arranged between a dual-mass flywheel and an intermediate shaft. The separating clutch includes a counter-plate, an outer lamella carrier rigidly connected to the counter-plate, a pressure plate, axially movable relative to the outer lamella carrier, an intermediate plate, axially movable relative to the outer lamella carrier, a first clutch disk, axially movable and extending between the pressure plate and the intermediate plate, and a second clutch disk, axially movable and extending between the counter-plate and the intermediate plate. The pressure plate or the intermediate plate is connected to the outer lamella carrier for conjoint rotation therewith via a leaf spring, or the pressure plate or the intermediate plate is connected to the counter-plate for conjoint rotation therewith via a leaf spring.