Hybrid Module Clutch Nesting for Selective Engine Connection
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Solution Overview
Problem
Current hybrid modules for vehicles lack an efficient mechanism for selectively connecting a torque converter to a combustion engine, particularly in hybrid configurations that integrate both electric motors and torque converters with hydrodynamic couplings, which limits their performance and flexibility.
Innovation Solution
The hybrid module incorporates a lockup clutch and a K0 clutch, where the torque converter is fixed to the rotor, and the K0 clutch is designed to selectively connect the torque converter to the combustion engine, with a hydrodynamic circuit for bypassing, and both clutches are axially positioned within the rotor's diameter, allowing for efficient engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a torque converter with hydrodynamic coupling is used in a hybrid module, then smooth power transmission and flexibility are improved, but the ability to selectively connect the torque converter to the combustion engine is limited
Solution Approach 1:
The patent combines the lockup clutch and K0 clutch mechanisms within a single hybrid module assembly, integrating multiple clutch types that can selectively connect the torque converter to either the electric motor or combustion engine. This merging approach enables versatile power source selection without requiring separate, independent clutch systems for each connection scenario.
Solution Approach 2:
The hybrid module incorporates a universal clutch system that can perform multiple functions: connecting the torque converter to the electric motor, connecting to the combustion engine, and selectively engaging or disengaging either power source. This multi-functional design allows a single mechanism to handle various power transmission scenarios, improving adaptability while managing complexity.
2Productivity
If the lockup clutch and K0 clutch are positioned within the rotor diameter, then engagement efficiency is improved, but the radial space requirement increases
Solution Approach 1:
The patent positions the lockup clutch and K0 clutch in a nested or concentric arrangement within the rotor's radial space. The clutches are arranged to utilize the available radial depth efficiently, with one clutch potentially positioned inside or adjacent to the other, allowing both mechanisms to engage effectively while minimizing the overall radial envelope of the hybrid module.
Solution Approach 2:
Instead of arranging the clutches side-by-side in a way that maximizes radial width, the patent utilizes the axial dimension by positioning the clutches at different axial locations within the rotor. This dimensional reorganization allows both clutches to be accommodated within the rotor diameter while maintaining efficient engagement characteristics, effectively trading radial space for axial space.
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 enhances the hybrid module's ability to seamlessly transition between electric motor and combustion engine power, improving vehicle performance, efficiency, and flexibility by enabling precise control over energy transfer.
Implementation Method 1
The torque converter is fixed to the rotor. The torque converter includes a hydrodynamic circuit
Data Source
AI summary
A hybrid module for a vehicle includes a torque converter and an electric motor. The torque converter includes an impeller shell and a cover. The cover is fixed to the impeller shell to form at least a portion of an outer shell for the torque converter. The electric motor includes a rotor supported on a rotor carrier. The cover and the rotor carrier are integrally formed from a same piece of material. In an example embodiment, the hybrid module includes a resolver rotor fixed to the rotor carrier. In some example embodiments, the hybrid module includes a cover disk, fixed to the rotor carrier and extending radially inward to form a portion of the outer shell.