Hybrid Module Clutch Assembly Space Optimization
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Solution Overview
Problem
Existing hybrid modules for vehicle drive trains are not compact enough, necessitating a design that integrates all components within a limited space while maintaining functionality and safety.
Innovation Solution
A hybrid module design featuring an outer disk carrier connected to a dual-mass flywheel with axially extending toothing, alignment elements for secure plate alignment, and a radially extending flange for connection, allowing for a compact and stable configuration of the separating clutch and dual clutch system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the hybrid module is designed to accommodate all components (separating clutch, dual clutch, electric motor) within limited space, then space utilization is improved, but device complexity increases
Solution Approach 1:
The patent combines the separating clutch (K0) and dual clutch (K1, K2) into a single integrated hybrid module assembly. The separating clutch is positioned adjacent to the dual clutch with shared structural elements, merging multiple clutch functions into one compact unit that accommodates all components within limited space while maintaining individual functionality of each clutch system
Solution Approach 2:
The patent implements a nested arrangement where the separating clutch components are positioned within the radial and axial space of the dual clutch assembly. The multi-disc clutch packs are arranged concentrically with shared housing and actuation mechanisms, allowing one clutch system to be nested within or adjacent to another, maximizing space utilization without excessive complexity
2Area of stationary object
If the clutches are designed to be radially small to fit limited space, then space utilization is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent divides each clutch into multiple thin friction discs and actuation stages. The multi-disc clutch packs separate the friction surfaces into individual discs that can be manufactured with standard precision, then assembled in sequence. This segmentation allows radially small individual components while maintaining overall clutch functionality through the cumulative effect of multiple discs
Solution Approach 2:
The patent applies different quality requirements to different regions of the clutch components. Critical mating surfaces and friction surfaces receive enhanced precision treatment, while non-critical structural areas use standard manufacturing tolerances. This localized quality approach ensures functional precision where needed while reducing overall manufacturing complexity and cost
3Reliability
If the separating clutch and dual clutch are designed to function individually with separate actuation, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent designs the integrated clutch assembly with universal actuation mechanisms that can independently control both the separating clutch and dual clutch. The shared housing and control systems provide multi-functionality, allowing each clutch to operate independently for safety-critical functions while sharing common structural and actuation resources, thus improving reliability without proportionally increasing complexity
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 design achieves a more compact hybrid module that maintains torque transmission efficiency and safety, with the alignment element ensuring stable assembly and operation without wear, and the flange configuration optimizing space usage near the dual-mass flywheel.
Implementation Method 1
at least one alignment element is provided which is attached to the pressure plate, the intermediate plate and the counter-plate formed external toothing, which engage in an axially extending internal toothing of the outer disk carrier
Implementation Method 2
a package that can be brought into frictional engagement, comprising a pressure plate, a counterplate and at least one intermediate plate and clutch disks engaging between them
Implementation Method 3
the friction elements (43, 44) of the dual-mass flywheel which can be pressed against one another by the force of a spring element (51)
Data Source
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AI summary
The invention relates to a hybrid module for a powertrain of a motor vehicle, comprising an electric machine (6), a clutch device (9), and a separating clutch (35). The separating clutch (35) is coupled to a dual mass flywheel (36) and an intermediate shaft (33) and has a packet which can be frictionally locked and comprises a pressure plate (42), a counter plate (40), and at least one intermediate plate (41) and clutch discs (43, 44) that engage between said plates, wherein the pressure plate (42), the intermediate plate (41), and the clutch discs (43, 44) can be moved axially. The invention is characterized in that - either an outer disc support (38) is provided which is rigidly connected to the dual mass flywheel (36), said pressure plate (42), intermediate plate (41), and counter plate (40) being connected to the outer disc support (38) in a rotationally fixed but releasable manner, or - a connection member is provided which is rigidly connected to the dual mass flywheel (36) and is connected to an outer disc support (38) in a rotationally fixed but releasable manner. The outer disc support (38) is rigidly connected to the counter plate (40), and the pressure plate (40) and the intermediate plate (41) are connected to the outer disc support (38) in a rotationally fixed but releasable manner.