Hybrid Module Radial Clutch Nesting for Axial Space Reduction
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Solution Overview
Problem
The integration of a hybrid module with an internal combustion engine and dual-clutch device in motor vehicles often leads to installation space problems due to the need for compact and stable arrangements, particularly with the radial extent of disconnect clutches and actuating systems, which complicates the placement of angular position sensors for precise control of electric machines.
Innovation Solution
A hybrid module design that includes an electrical machine with a rotor carrier mounted radially, an angular position sensor to detect the rotor's position relative to a housing component, and a dual-clutch device with partial clutches, allowing for compact and reliable torque transmission and control, while minimizing the radial extent of actuating systems and reducing positional tolerances and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the hybrid module is arranged between the internal combustion engine and the gearbox in the torque transmission direction, then the components can be functionally integrated, but installation space problems occur due to the axial arrangement of the engine, hybrid module, dual clutch, and gearbox
Solution Approach 1:
The patent transitions from a conventional axial arrangement to a radial arrangement where the dual-clutch device is positioned radially within the space surrounded by the electrical machine's rotor. This dimensional change allows the clutch assemblies to be stacked radially rather than axially, significantly reducing the axial length of the hybrid module while maintaining all functional components.
Solution Approach 2:
The dual-clutch device is nested within the radial space of the electrical machine's rotor. The first and second clutch assemblies are arranged radially inside the rotor's circumference, utilizing the available radial space efficiently. This nesting approach allows multiple clutch components to coexist within the footprint of a single electrical machine rotor.
2Length of moving object
If the dual-clutch device is arranged sectionally in the space surrounded by the rotor of the electrical machine, then the axial length is reduced, but the radial extent increases requiring a correspondingly stable bearing
Solution Approach 1:
The patent applies different quality requirements to different parts of the bearing system. The bearing supporting the rotor carrier is designed with enhanced stability specifically for the radial clutch components, while other parts of the system maintain standard bearing specifications. This localized enhancement of bearing stability addresses the radial extent issue without unnecessarily strengthening the entire system.
Solution Approach 2:
The bearing for the rotor carrier is combined with the bearing structure for the dual-clutch device, creating a unified bearing system that simultaneously supports both the electrical machine rotor and the radially arranged clutch assemblies. This merging of bearing functions improves overall structural stability while reducing the number of separate bearing components.
3Ease of manufacture
If cost-effective sensors are used for detecting the rotor position, then production costs are reduced, but measurement precision may be compromised
Solution Approach 1:
The patent replaces complex mechanical position sensing systems with a simplified sensor arrangement that detects rotor position based on magnetic or optical fields. This substitution allows the use of cost-effective sensors while maintaining adequate measurement precision for controlling the dual-clutch device and electrical machine, eliminating the need for expensive mechanical encoders.
Data Source
AI summary
A drive module for a motor vehicle includes a housing, an electric machine, a rotor carrier, and an angular position sensor. The electric machine is for generating a drive torque and includes a rotor. The rotor carrier is connected substantially rotationally fixed to the rotor and mounted such that it can be rotated at least radially. The angular position sensor is for measuring an angular position of the rotor carrier. The angular position sensor is arranged such that the angular position of the rotor carrier or a first component substantially rotationally fixed to the rotor carrier can be detected by the angular position sensor in relation to a second component fixed to the housing.