Hybrid Module Rotor Integration for Compact Drive Trains
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Solution Overview
Problem
Existing vehicle hybridization technologies face challenges in creating a compact and efficient hybrid module that can couple an internal combustion engine with a gearbox while minimizing component changes, leading to increased costs and complexity.
Innovation Solution
A hybrid module design featuring a housing with a rotary input, rotary output, an electric machine, a separation clutch, and a torsional vibration damper, where the separation clutch and torsional vibration damper are integrated within the rotor of the electric machine, allowing for a compact structure and efficient torque transmission with minimal friction losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the separation clutch and torsional vibration damper are arranged within the rotor of the electric machine, then the structural length of the hybrid module is reduced, but the complexity of integrating multiple components increases
Solution Approach 1:
The separation clutch and torsional vibration damper are merged into the rotor of the electric machine, sharing the same spatial envelope. The clutch plates are arranged concentrically within the rotor, with friction plates alternating with damping elements, creating a compact integrated assembly that reduces overall structural length while distributing functional complexity across a unified structure
Solution Approach 2:
The separation clutch and torsional vibration damper are nested within the rotor structure. The clutch plates are positioned radially within the rotor's rotational path, and the damping elements are integrated into the same radial space, creating a nested arrangement where multiple functional components occupy overlapping spatial zones to minimize external dimensions
2Loss of energy
If the friction plates are fully separated in the open state of the clutch, then frictional losses are reduced, but the complexity of the separation mechanism increases
Solution Approach 1:
The friction plates are completely extracted or separated from contact with their friction partners when the clutch is in the open state. The actuating mechanism pulls the clutch plates axially away from the friction surfaces, creating full separation that eliminates frictional losses during non-torque transmission periods, with the plates remaining in this separated state until torque transmission is required
3Power
If a dry multi-plate friction clutch with multiple friction plate pairs is used, then torque transmission capability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The clutch is segmented into multiple friction plate pairs arranged in series within the rotor. Each friction plate pair consists of a friction plate and a friction partner, creating multiple independent torque transmission interfaces. This segmentation allows the clutch to handle higher torque loads by distributing the transmission across multiple plate pairs, with each pair contributing to the overall torque capacity
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
Enables the hybridization of conventional drive trains with minimal alteration to the existing gearbox, allowing for integration with various gearbox types and reducing frictional losses by fully separating friction plates during non-torque transmission, thus optimizing efficiency and maintaining a compact design.
Implementation Method 1
a torsional vibration damper (23) arranged within the rotor (16)
Implementation Method 2
a separation clutch (20), in particular a dry multi-plate friction clutch with a plurality of friction plate pairs
Data Source
AI summary
A hybrid module includes a housing, an input intended for rotationally coupling to an internal combustion engine, an output intended for rotationally coupling to an input of a gearbox, an electric machine arranged in the housing and having a stator and a rotor arranged within the stator radially, a separation clutch and a torsional vibration damper. The separation clutch and the torsional vibration damper are arranged within the rotor in both the radial and axial directions.