Hybrid Module Stator Assembly Jig Plate Alignment
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Solution Overview
Problem
Existing hybrid modules lack efficient mechanisms for secure positioning and assembly of stator and rotor assemblies during shipping and assembly, leading to potential damage and increased complexity in integration with transmission and engine systems.
Innovation Solution
The hybrid module incorporates a stator assembly with radially extending tabs and dowel holes, and a rotor assembly with a torque converter, utilizing a jig plate and fasteners/dowels for precise alignment and fixation, allowing for secure positioning during shipping and easy integration with transmission and engine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shipping methods are used for hybrid modules, then shipping simplicity is maintained, but component positioning security deteriorates leading to potential damage
Solution Approach 1:
The stator plate is segmented with multiple radially extending tabs that can be selectively engaged with the jig plate. This segmentation allows the stator assembly to be divided into discrete positioning points, providing secure component positioning during shipping while keeping the overall system modular and manageable.
Solution Approach 2:
The stator plate is pre-configured with radially extending tabs and holes positioned at specific locations before shipping. This preliminary action ensures that when the hybrid module is placed on the jig plate, the tabs automatically align with corresponding features on the jig plate, providing immediate secure positioning without requiring complex adjustment mechanisms during shipping.
2Manufacturing precision
If multiple separate tabs are used for different functions, then positioning precision is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple radially extending tabs that would traditionally be separate components are merged into a single integrated stator plate structure. The stator plate contains multiple tabs (first tab with threaded hole, second tab with dowel hole, third tab with dowel hole) that are all part of the same plate, simplifying manufacturing while maintaining precise positioning capabilities for the stator assembly.
Solution Approach 2:
The radially extending tabs on the stator plate serve multiple functions: they provide positioning references, mounting points for fasteners, and alignment features for different assembly stages. This multi-functionality reduces the need for separate components while maintaining manufacturing precision.
3Ease of manufacture
If integrated tabs are used to reduce complexity, then manufacturing ease is improved, but positioning precision may deteriorate
Solution Approach 1:
The radially extending tabs are positioned asymmetrically around the stator plate at specific radial distances and angular positions. This asymmetric arrangement provides unique positioning references that prevent misalignment while maintaining manufacturing simplicity. Each tab's position is optimized for its specific function, ensuring precise component alignment during assembly.
Data Source
AI summary
A hybrid module includes a rotational axis and an electric motor. The electric motor has a stator assembly and a rotor assembly. The stator assembly includes a stator plate with a first radially extending tab with a first threaded hole for receiving a first fastener for fixing the stator assembly to a jig plate, a second radially extending tab with a first dowel hole for receiving a first dowel to locate the stator assembly in the jig plate, and a third radially extending tab with a second dowel hole for receiving a second dowel to locate the stator assembly in a transmission housing. The rotor assembly is disposed radially inside of the stator assembly and includes a torque converter with a pilot for locating the torque converter relative to the jig plate or relative to an engine crankshaft.