Hybrid Module Dual Pump System for Reduced Weight and Power Loss
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Solution Overview
Problem
Existing hybrid vehicle systems require significant modifications to vehicle drive trains and often result in power loss, making them inefficient for retrofitting and affecting fuel economy.
Innovation Solution
A self-sufficient hybrid module with a dual mechanical/electric pump system that includes a mechanical pump and an electric pump, allowing for independent lubrication and cooling, reducing the need for modifications to other systems and enabling efficient operation in various modes such as electric, transition, and cruise modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single mechanical pump is used to provide lubrication and cooling, then the system is simpler, but the pump size and weight must be larger to handle all workload
Solution Approach 1:
The patent divides the single pump function into two separate pumps: a mechanical pump and an electric pump. This segmentation allows each pump to be smaller and lighter, as they share the workload. The mechanical pump handles primary lubrication needs while the electric pump provides supplemental flow, particularly during transition modes, reducing the size requirements for each individual pump.
Solution Approach 2:
The dual pump system provides multi-functionality by enabling the system to operate in different modes (engine-only, electric-only, transition) and handle varying lubrication and cooling demands. The electric pump can independently operate during engine auto-stop to maintain lubrication and cooling when the mechanical pump is not running.
2Reliability
If hydraulic pumps operate at full capacity continuously, then lubrication and cooling needs are met, but power loss increases
Solution Approach 1:
The system dynamically adjusts pump operation based on real-time engine conditions and operational mode. The control system monitors engine speed, load, and temperature to determine when the electric pump should supplement or replace the mechanical pump, optimizing power consumption while maintaining adequate lubrication and cooling.
Solution Approach 2:
The electric pump provides partial action by supplementing the mechanical pump only when needed, rather than operating continuously at full capacity. This partial action during specific transition periods reduces overall power loss while still meeting lubrication and cooling requirements.
3Ease of manufacture
If the hybrid system integrates with existing vehicle systems, then modifications are reduced, but the hybrid system must share resources with other systems
Solution Approach 1:
The dual pump system is designed to be universally applicable across different operational modes and vehicle configurations. It can independently provide lubrication and cooling during engine auto-stop, during electric-only operation, and during transition periods, making the hybrid module self-sufficient while integrating with existing vehicle systems.
Solution Approach 2:
The hybrid module's dual pump system serves itself by independently managing its own lubrication and cooling needs without relying on the vehicle's existing hydraulic systems. The electric pump can operate autonomously during engine off-periods to maintain fluid circulation and temperature control.
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 hybrid module reduces the size and weight of mechanical pumps, allows for electric-only operation, and minimizes power loss by balancing the workload between mechanical and electric pumps, enhancing fuel efficiency and ease of retrofitting.
Implementation Method 1
a mechanical pump for circulating a fluid
Implementation Method 2
an electric pump that supplements the workload for the mechanical pump when needed
Implementation Method 3
The fluid has been circulating through the hybrid module and has picked up heat from the eMachine and other components
Implementation Method 4
The cooler is in fluid communication with the sump and is configured to cool the fluid
Data Source
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AI summary
A hydraulic system for a hybrid module which is located between an engine and a transmission includes a parallel arrangement of a mechanical pump and an electric pump. Each pump is constructed and arranged to deliver oil to other portions of the hydraulic system depending on the operational mode. Three operational modes are described including an electric mode, a transition mode, and a cruise mode. Various monitoring and control features are incorporated into the hydraulic system.