Hybrid Module Actuation Unit With Axial Needle Bearing Packaging
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Solution Overview
Problem
Existing hybrid modules for motor vehicle drive trains are typically large, particularly in the axial direction, making them inflexible and requiring complex adjustments for different applications, leading to high development costs and expenses.
Innovation Solution
A hybrid module design featuring an axial needle bearing actuation system, where the first bearing ring is formed by a web and the second by a pressure element, with screw elements securing the support bearing rings, allowing for a compact installation space and easy adaptability to various powertrains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hybrid modules are used, then reliable power transmission is achieved, but the installation space requirement is large
Solution Approach 1:
The needle bearing is nested within the actuation unit, with the bearing rings formed directly by existing components (web and pressure element). This nested arrangement allows the bearing functionality to be integrated within the existing actuation space without requiring additional external space, thus reducing installation space while maintaining power transmission reliability
Solution Approach 2:
The actuating bearing is merged with the actuation unit components - the first bearing ring is formed directly by the web and the second bearing ring by the pressure element. This merging eliminates the need for separate bearing housings and reduces the overall installation space requirement while ensuring reliable power transmission through the integrated bearing structure
2Reliability
If conventional hybrid modules are used, then functional performance is maintained, but adaptability to different applications is poor
Solution Approach 1:
The actuation unit is designed with multi-functionality: the web and pressure element serve dual purposes as both structural components and bearing rings. This universal design allows the same actuation unit to be adapted to different applications and drive train configurations without requiring complex modifications, thereby improving application adaptability while maintaining functional performance
3Adaptability or versatility
If hybrid modules are modified for different applications, then application-specific requirements are met, but development complexity increases
Solution Approach 1:
The actuation unit is segmented into distinct functional elements (web, pressure element, needle bearing) that can be independently designed and combined. This segmentation allows for modular adaptation to different applications by simply reconfiguring or replacing specific segments rather than redesigning the entire actuation unit, thereby reducing development complexity while maintaining application-specific adaptability
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 compact design of the hybrid module using an axial needle bearing significantly reduces installation space, making it adaptable to different applications and reducing development work and expenses, while maintaining robust axial support for the support bearing.
Implementation Method 1
the actuating bearing 9 is designed as an axial needle bearing
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a hybrid module (1) for a drive train of a motor vehicle, having a housing (2), a disconnect clutch (3), a hydraulic actuation unit (4) cooperating with the disconnect clutch (3) and received on the housing (2), and an electric machine (5). A rotor (6) of the electric machine (5) is coupled or can be coupled rotatably to a coupling component (7) of the disconnect clutch (3), and the actuation unit (4) comprises a piston element (8) which is received displaceably relative to the housing (2) and which is fixed against displacement in an axial direction of the disconnect clutch (3) by means of an actuation bearing (9), but is connected rotatably relative to a press element (10) used to move the disconnect clutch (3) in and out, the actuation bearing (9) being formed as an axial needle bearing (9). The invention also relates to a hybrid drive train having a hybrid module (1).