Hybrid Module Installation Tooling for Torque Converter Alignment

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Solution Overview

Problem

The installation of hybrid modules with torque converters into transmission assemblies is challenging due to the torque converter's inaccessible positioning, making conventional tooling ineffective for aligning gear mesh engagements, especially in high-volume production settings.

Innovation Solution

A tooling system comprising a positioning device, a support structure, a gripper, a clutch actuator, a rotational actuator, and a controller, which positions and aligns the hybrid module relative to the transmission housing, engages the clutch, and rotates the input shaft to facilitate seating and gear mesh engagements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the torque converter is positioned inside the transmission housing to be inaccessible, then the transmission assembly structure is compact and stable, but conventional tooling cannot access the torque converter to align gear mesh engagements

Engineering Contradiction:

Improvetransmission assembly structureVSAvoidaccessibility of torque converter

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The tooling system nests multiple functional components within a single integrated apparatus that can be inserted into the transmission housing. The positioning device, gripper, rotational actuator, and clutch actuator are nested together to form a compact tool assembly that reaches the torque converter through the housing opening, enabling access to previously unreachable components while maintaining structural stability.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The tooling system introduces an intermediary positioning device with a gripper that mediates between the external operator and the internal torque converter. This intermediary tool assembly transmits rotational motion and positioning control to the torque converter without requiring direct access to it, solving the accessibility problem while preserving the sealed housing structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If conventional tooling is used to align gear mesh engagements, then the tooling system is simple, but the alignment process is difficult, time-consuming, or impossible for inaccessible torque converters

Engineering Contradiction:

Improvetooling system structureVSAvoidassembly time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The tooling system merges multiple functions into a single integrated device: the positioning device locates the hybrid module, the gripper holds the torque converter, the rotational actuator aligns gear meshes, and the clutch actuator engages the clutch simultaneously. This combination eliminates the need for multiple separate tools and sequential operations, dramatically reducing assembly time while managing complexity through functional integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tooling system performs preliminary positioning and alignment actions before final assembly. The positioning device pre-locates the hybrid module, the gripper pre-grasps the torque converter, and the rotational actuator pre-aligns the gear meshes before the clutch engagement is finalized. This preliminary action sequence ensures proper alignment is achieved before committing to the final assembly state, preventing rework and time loss.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the clutch is actuated to engage during installation, then the torque converter can be properly positioned, but additional actuation mechanisms are required

Engineering Contradiction:

Improveclutch engagementVSAvoidactuator system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The clutch actuator is designed as a multi-functional component that not only actuates the clutch engagement but also serves as part of the positioning and alignment mechanism. The actuator system performs multiple functions including clutch engagement, torque converter positioning, and alignment verification, reducing the need for separate dedicated components and managing overall system complexity through functional consolidation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11685455B2Tooling system and method for installing hybrid module with clutch and torque convertor into transmission assembly

Publication Date: 2023.06.27 FORD GLOBAL TECH LLC

AI summary

A tooling system for assembling a hybrid vehicle transmission includes a positioning device, support structure, gripper, clutch actuator, rotational actuator, and controller. The positioning device positions a hybrid module relative to a transmission housing. The gripper grips an input shaft of the hybrid module. The clutch actuator actuates the clutch of the hybrid module. The rotational actuator rotates the gripper about an assembly axis. The controller controls operation of the clutch actuator, positioning device, gripper, and rotational actuator such that an operation is performed that includes the clutch actuator actuating the clutch, the gripper gripping the input shaft of the hybrid module, the rotational actuator rotating the gripper to rotate the input shaft of the hybrid module relative to an input shaft of the transmission module, and the positioning device translating the hybrid module toward the transmission module to seat a housing of the hybrid module on the transmission housing.