Hybrid Module Radial Flow Plate Assembly
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Solution Overview
Problem
Current hybrid modules face challenges in efficiently integrating torque converters and electric motors within a unified configuration that effectively manages cooling and fluid dynamics for optimal performance and efficiency.
Innovation Solution
A hybrid module configuration that includes a housing with an electric motor, hydraulic coupling, and dual clutches, along with a flow plate assembly and drive hub, which utilizes radial flow channels for pressurized fluid and cooling flows to engage and cool the clutches, rotor, and stator, and incorporates sealing mechanisms like lip seals and garter springs for efficient fluid management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hybrid module integrates a torque converter and electric motor in a unified configuration, then space utilization and integration efficiency are improved, but fluid dynamics management and cooling efficiency deteriorate due to the complex arrangement of components
Solution Approach 1:
The torque converter is positioned radially inside the electric motor, creating a nested configuration where the hydraulic coupling sits within the motor assembly. This nesting arrangement optimizes space utilization while maintaining separate fluid management zones for the torque converter and motor cooling systems
Solution Approach 2:
The fluid management system is segmented into separate channels: a first radial flow channel for pressurized fluid to engage the first clutch, and a second radial flow channel for cooling flows to cool the first clutch, rotor, and stator. This segmentation allows independent optimization of engagement and cooling fluid dynamics
2Adaptability or versatility
If dual clutches are used for drivingly connecting the rotor to the engine and transmission, then operational flexibility and torque management are improved, but device complexity increases due to additional clutch mechanisms and fluid channels
Solution Approach 1:
The flow plate assembly serves multiple functions: it directs pressurized fluid to engage the first clutch for motor-to-engine connection, directs cooling fluid to cool the first clutch and motor components, and provides structural support for the clutch mechanisms. This multi-functionality reduces the need for separate dedicated components
Solution Approach 2:
The first clutch and second clutch are arranged in parallel and integrated into the same housing structure with shared fluid management pathways. Both clutches utilize the same flow plate assembly and radial flow channels, merging their fluid delivery systems to reduce overall complexity
3Productivity
If radial flow channels are used for providing pressurized fluid and cooling flows, then fluid delivery efficiency is improved, but manufacturing precision requirements increase due to the need for precise radial grooves and orifices
Solution Approach 1:
The flow plate assembly incorporates localized features with different precision requirements: radial grooves for fluid direction, radially inner orifices for pressurized fluid delivery, and radially outer orifices for cooling flow distribution. Each feature is optimized for its specific function, allowing selective manufacturing precision application
4Volume of moving object
If the hydraulic coupling is positioned radially inside the electric motor, then space utilization is improved, but cooling access and maintenance difficulty increase
Solution Approach 1:
The flow plate assembly acts as an intermediary structure that provides external access points for cooling fluid delivery to the internally positioned hydraulic coupling. The radial flow channels extend from the outer flow plate through the hydraulic coupling, allowing cooling fluid to reach internal components without requiring direct external access to the coupling itself
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 efficiency and performance of hybrid modules by ensuring effective fluid engagement and cooling of critical components, improving the overall operational reliability and efficiency of the hybrid module.
Implementation Method 1
a first radial flow channel for providing a pressurized fluid to engage the first clutch
Implementation Method 2
a second radial flow channel for providing a cooling flow to the first clutch, the rotor, and the stator
Implementation Method 3
a lip seal with a garter spring for sealing the flow plate assembly to the drive hub
Data Source
AI summary
A hybrid module includes a housing, an electric motor, a hydraulic coupling, a first clutch, a second clutch, and a flow plate assembly. The housing is arranged for fixing to a planetary transmission and an engine. The electric motor is disposed in the housing. The electric motor has a stator fixed to the housing and a rotor rotatable relative to the housing. The hydraulic coupling is disposed in the housing and is at least partially radially inside of the electric motor. The first clutch is for drivingly connecting the rotor to the engine. The second clutch is arranged in parallel with the hydraulic coupling for drivingly connecting the rotor to an input shaft of the planetary transmission. The flow plate assembly is fixed to the housing. The flow plate assembly has a first flow plate with a first radial groove forming a first portion of a first radial flow channel, and a second flow plate, fixed to the first flow plate, forming a second portion of the first radial flow channel.