Hybrid Module Pre-Assembly Groups for Compact Drive Train Integration
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Solution Overview
Problem
Axially parallel hybrid systems face challenges in efficiently utilizing installation space and simplifying assembly, particularly in the axial direction, while being adaptable to various engine/transmission combinations.
Innovation Solution
A hybrid module with a motor-side and transmission-side pre-assembly group connected via a separating clutch, utilizing axial joints and a multi-disk clutch for torque transmission, along with a modular design that includes a torsional vibration absorber, disk cages, and a support bearing for efficient space use and assembly, allowing connection of an electric machine and air-conditioning compressor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the hybrid module uses a compact modular design with pre-assembly groups, then installation space utilization is improved, but assembly complexity increases
Solution Approach 1:
The hybrid module is divided into motor-side and transmission-side pre-assembly groups that can be manufactured and tested separately before final assembly. This segmentation allows for optimized space utilization in each subsystem while maintaining overall modularity.
Solution Approach 2:
The pre-assembly groups are prepared in advance with pre-installed components (clutches, bearings, seals) before being integrated into the final hybrid module. This preliminary preparation reduces on-site assembly complexity and ensures proper positioning.
2Adaptability or versatility
If the hybrid module is designed for universal application across various engine/transmission combinations, then adaptability is improved, but design complexity increases
Solution Approach 1:
The hybrid module employs standardized flange connections and modular pre-assembly groups that can interface with different engine and transmission types. The separating clutch design allows the same module to work across multiple vehicle platforms without custom modifications.
Solution Approach 2:
While maintaining overall modular universality, the design allows for localized adaptations in the pre-assembly groups to accommodate specific engine or transmission requirements, balancing standardization with customization needs.
3Power
If the separating clutch is positioned between pre-assembly groups for torque transmission, then torque transmission efficiency is improved, but axial space requirement increases
Solution Approach 1:
The separating clutch is nested within the pre-assembly group structure, with clutch disks integrated into the motor-side and transmission-side groups. This nesting arrangement minimizes the axial space required while maintaining effective torque transmission 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
The solution enables efficient use of installation space, simplifies assembly, and allows for flexible integration of the hybrid module in drive trains, enabling operation of the air-conditioning system even when the internal combustion engine is not running.
Implementation Method 1
a separating clutch is arranged between the motor-side pre-assembly group and the transmission-side pre-assembly group, via which the pre-assembly groups can be connected in a torque-transmitting manner
Implementation Method 2
The motor-side pre-assembly group is formed by at least one torsional vibration absorber and one first disk cage
Data Source
AI summary
A hybrid module includes a first, motor-side pre-assembly group and a second, transmission-side pre-assembly group. A separating clutch is arranged between the motor-side pre-assembly group and the transmission-side pre-assembly group, via which the pre-assembly groups can be connected in a torque-transmitting manner.