Hybrid Module Radial Clutch Arrangement
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Solution Overview
Problem
Existing hybrid modules for motor vehicles require significant axial installation space, making them unsuitable for smaller vehicles or those with transverse combustion engines, as they cannot accommodate the necessary construction space effectively.
Innovation Solution
The hybrid module design rearranges the separation coupling and double coupling radially within the rotor, with the separation coupling closer to the axis of rotation, allowing for a compact structure that eliminates the need for additional axial space, and integrates actuating devices and sub-couplings directly into the rotor walls, reducing component count and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the dual clutch and disconnect clutch are arranged axially one behind the other, then the coupling functionality is ensured, but the axial installation space is excessive
Solution Approach 1:
The patent transitions from a conventional axial arrangement of clutches to a radial arrangement within the rotor. The disconnect clutch is positioned radially inward while the dual clutch is positioned radially outward, both within the rotor's radial space. This dimensional change from axial to radial arrangement dramatically reduces the axial installation space while maintaining all coupling functionalities.
Solution Approach 2:
The patent nests the disconnect clutch and dual clutch within the rotor structure. The disconnect clutch is arranged radially inward within the rotor, and the dual clutch is arranged radially outward also within the rotor. This nesting approach allows multiple clutch mechanisms to coexist within the same radial envelope of the rotor, eliminating the need for additional axial space.
2Reliability
If additional components are used for coupling clutches to rotor walls, then the coupling stability is improved, but the component count and assembly complexity increase
Solution Approach 1:
The patent merges the function of separate coupling components with the rotor walls themselves. The rotor walls are designed to directly serve as coupling surfaces for both the disconnect clutch and dual clutch. This integration eliminates the need for additional intermediate coupling components, reducing part count while maintaining stable coupling through the direct structural connection provided by the rotor walls.
Data Source
Figure 1
Figure 2
AI summary
Hybrid module (1, 24) for a motor vehicle, comprising an electric machine (4) which has a stator (2) and a rotor (3), a double clutch (7) which has a first and second component clutch (5, 6) and is configured to couple the hybrid module (1, 24) to a transmission of the motor vehicle such that it can be disconnected, and a separating clutch (8) which is configured to couple an internal combustion engine of the motor vehicle to the hybrid module (1, 24) such that it can be disconnected, wherein the double clutch (7) and the separating clutch (8) are arranged radially and axially within the rotor (3), wherein the first and the second component clutch (5, 6) are arranged behind one another in the axial direction, and the separating clutch (8) is arranged closer in the radial direction to the rotational axis (9) of the rotor (3) than the double clutch (7).