Hybrid Module Dry Lamella Coupling Noise Reduction
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Solution Overview
Problem
Current hybrid modules in motor vehicle drive trains experience inadequate power transmission and noise issues due to the softness of lamella couplings, leading to vibrations and inefficient torque transfer during starting processes, particularly when using a combustion engine and electrical machine in conjunction.
Innovation Solution
The hybrid module design features a dry lamella coupling with an inner basket connected to the drive shaft and an outer basket connected to the gear shaft, both axially overlapping with torque recording components, which enhances stiffness and reduces noise emissions by using a roller bearing and radially slotted outer basket to improve torque transfer and reduce friction vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a dry lamella coupling is used to transmit torque in the hybrid module, then the torque transmission capability is improved, but noise emissions and vibrations increase due to the softness of the coupling
Solution Approach 1:
The coupling is segmented into multiple lamellae (thin plates) arranged in alternating inner and outer baskets. This segmentation allows the torque to be distributed across multiple friction surfaces, improving transmission capability while reducing the softness-induced vibrations through better torque distribution.
Solution Approach 2:
The patent employs a composite structure combining multiple materials with different properties: the lamellae are made of friction-resistant materials, the baskets provide structural rigidity, and spring elements add controlled elasticity. This composite approach enables the coupling to transmit torque effectively while dampening vibrations and reducing noise through the combined properties of different materials.
2Reliability
If the lamella coupling is made softer to accommodate starting processes, then the torque transfer during starting is improved, but noise and vibration increase
Solution Approach 1:
The coupling incorporates spring elements that provide dynamic compliance during starting processes. These springs allow the coupling to adapt its stiffness characteristics - being softer during transient starting conditions to ensure reliable torque transfer, and stiffer during steady-state operation to reduce noise and vibration. This dynamic behavior resolves the contradiction between starting reliability and noise reduction.
Solution Approach 2:
The patent changes the physical parameters of the coupling system by using multiple thin lamellae with specific friction coefficients and thicknesses. This parameter optimization allows the coupling to achieve the right balance between compliance for starting and rigidity for noise reduction, rather than relying on a single soft material that would always generate noise.
3Adaptability or versatility
If additional clutches are added to the hybrid module to improve torque control, then the torque management capability is improved, but the device complexity increases
Solution Approach 1:
The dry lamella coupling is designed to perform multiple functions: it transmits torque, controls torque transfer through friction regulation, and provides vibration damping. By making this single component multi-functional, the patent eliminates the need for additional separate clutches and control mechanisms, thereby maintaining torque management capability while reducing overall device complexity.
Solution Approach 2:
The patent merges the functions of torque transmission, torque control, and vibration damping into a single integrated lamella coupling system. Instead of having separate clutches for different torque management tasks, all these functions are combined in one component, simplifying the overall hybrid module architecture while maintaining versatile torque management capability.
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 significantly reduces noise emissions and wear, stabilizes torque transfer, and enhances the rigidity of the inner basket against tilting and deformation vibrations, allowing for efficient power transmission without the need for additional clutches, thus improving the overall performance and efficiency of the hybrid drive train.
Implementation Method 1
A target torque from the drive shaft connection to the torque recording and the gear shaft connection can only be transferred if the slat package is axially pressed with a target and turning force
Implementation Method 2
enhances the rigidity of the inner basket against tilting and deformation vibrations, allowing for efficient power transmission without the need for additional clutches
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a hybrid module (1) having a rotational axis (2) for a drive train (3) of a motor vehicle (4), comprising at least the following components: a driveshaft connection point (5) for receiving a torque; a transmission shaft connection point (6) for outputting a torque; a torque-receiving means (7) for receiving a torque from an electrical machine (8); a dry multiplate clutch (9) having two plate holders (10, 11), which can be rotated relative to one another about the rotational axis (2), specifically an outer holder (10) and an inner holder (11) comprising a stack (19) of plates, it being possible for a target torque to be transmitted from the driveshaft connection point (5) to the torque-receiving means (7) and to the transmission shaft connection point (4) only if the stack (19) of plates is axially pressed with a target contact pressure. The hybrid module (1) is particularly characterised in that in each case the inner holder (10) is torsionally rigidly connected to the driveshaft connection point (5) and the outer holder (10) is torsionally rigidly connected to the transmission shaft connection point (6) and the torque-receiving means (7). By means of the hybrid module according to the invention and the specific arrangement of the outer holder and the inner holder of the multiplate clutch, it is possible to achieve low noise emissions when the internal combustion engine is being started from cold by means of the electrical machine of the hybrid module.