Hybrid Module Torque Converter Axial Retention
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Solution Overview
Problem
Current hybrid module configurations face challenges in efficiently integrating torque converters and electric motors, particularly in ensuring effective cooling and sealing while maintaining torque transmission and rotational alignment.
Innovation Solution
The configuration includes a torque converter with a hydraulic coupling arrangement, an impeller shell, and an electric rotor, where the impeller shell is fixed to the front cover with a circumferential ring for axial retention, and a resilient element is used between the front cover and the bearing to allow axial displacement without torque converter displacement, along with a sealing arrangement using ring-shaped axial protrusions and integrated ring seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the electric rotor is integrated with the torque converter, then space utilization is improved, but thermal management becomes more difficult
Solution Approach 1:
The hybrid module is divided into functionally independent housings: a torque converter housing containing the hydraulic coupling and a separate electric motor housing containing the electric rotor and stator. This segmentation allows each component to be thermally managed independently, with dedicated cooling channels for the electric motor windings and a separate cooling system for the torque converter, eliminating thermal interference while maintaining compact integration.
2Device complexity
If the electric rotor is axially retained by the impeller shell, then assembly complexity is reduced, but rotational alignment precision becomes more difficult to ensure
Solution Approach 1:
The electric rotor is axially retained by the impeller shell through self-aligning features: the impeller shell includes an axial retention feature that engages with a corresponding feature on the electric rotor, allowing the rotor to automatically align rotationally with the impeller during assembly without requiring additional alignment procedures or precision machining beyond standard tolerances.
3Reliability
If the resilient element allows axial displacement, then shock absorption is improved, but torque transmission stability deteriorates
Solution Approach 1:
The resilient element is configured to allow axial displacement only under specific conditions: it compresses to absorb shock loads and rotational imbalances, but maintains rigid torque transmission during normal operating conditions. The element's dynamic behavior adapts to the operational state, providing compliance when needed and stiffness when required for stable torque transfer from the impeller to the electric rotor.
Data Source
AI summary
A torque converter for a hybrid module may include a hydraulic coupling arrangement, a front cover, an impeller shell, and an electric rotor. The hydraulic coupling arrangement may include an impeller and a turbine. The front cover may have a first rim extending in a first axial direction. The front cover may at least partially encase the hydraulic coupling arrangement. The impeller shell may be fixed to the front cover and may at least partially encase the hydraulic coupling arrangement. The impeller shell may have a second rim extending in a second axial direction, opposite the first axial direction, a circumferential ring at a distal end of the second rim, and at least one impeller blade. The electric rotor may be fixed to the impeller shell second rim and axially retained by the circumferential ring.