Modular Hybrid Powertrain With Disconnect Clutch And Electric Machine
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Solution Overview
Problem
There is a need for a modular powertrain subassembly for hybrid electric vehicles that can be installed between various engines and transmissions, incorporating a hydraulically actuated disconnect clutch, an electric machine, and suitable power paths, while maintaining low manufacturing and assembly costs and avoiding vehicle body modifications, and ensuring reliable performance.
Innovation Solution
A powertrain module with a disconnect clutch, an electric machine, and hydraulic communication between the transmission, clutch, and electric machine, featuring a torque converter casing driven by the engine or electric machine independently or concurrently, with a design that includes a stator, rotor, bulkheads, and a hydraulic system for fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular powertrain subassembly is designed to be installed between various engines and transmissions, then adaptability is improved, but device complexity increases
Solution Approach 1:
The powertrain module is designed with universal mounting interfaces that can accommodate multiple engine and transmission configurations. The housing includes standardized mounting surfaces and connection points that work with various engine types (V6, V8, inline-6) and transmission models, allowing a single module design to serve multiple vehicle platforms without requiring custom adaptations for each configuration.
Solution Approach 2:
The powertrain system is divided into distinct modular components: the engine, the powertrain module (containing torque converter, clutch, electric machine), and the transmission. This segmentation allows each component to be independently designed, manufactured, and assembled, facilitating adaptability across different vehicle configurations while managing complexity through standardized interfaces between segments.
2Adaptability or versatility
If a hydraulically actuated disconnect clutch and electric machine are integrated into the module, then powertrain functionality is improved, but manufacturing and assembly costs increase
Solution Approach 1:
The disconnect clutch and electric machine are integrated into a single powertrain module housing, combining multiple functions (clutch actuation, electric motor mounting, hydraulic fluid management) into one assembled unit. This merging reduces the total number of separate components that need to be manufactured and assembled, thereby reducing overall manufacturing and assembly costs despite the increased functionality.
Solution Approach 2:
Hydraulic fluid serves as an intermediary medium that connects and actuates multiple components within the module. The same hydraulic fluid that operates the transmission also actuates the disconnect clutch and provides cooling to the electric machine, eliminating the need for separate hydraulic systems and reducing manufacturing complexity.
3Adaptability or versatility
If hydraulic communication is provided from the transmission's hydraulic system to the clutch and electric machine, then system integration is improved, but reliability requirements increase
Solution Approach 1:
The transmission's hydraulic system is designed to serve multiple functions simultaneously: it operates the transmission gears, actuates the disconnect clutch, and provides cooling fluid to the electric machine. This multi-functional hydraulic system reduces the number of separate systems needed while maintaining reliable operation through centralized fluid management and filtering.
Solution Approach 2:
The hydraulic system maintains continuous circulation of fluid through the transmission, clutch, and electric machine, ensuring that all components receive consistent hydraulic pressure and cooling. This continuous action ensures reliable operation of the disconnect clutch and electric machine without interruption, as the hydraulic fluid is constantly replenished and filtered throughout the system.
4Adaptability or versatility
If an oil sump is provided within the module containing hydraulic fluid, then self-containment is improved, but volume of the module increases
Solution Approach 1:
The oil sump is integrated within the powertrain module housing, nesting the fluid reservoir inside the existing structural boundaries of the module. This nesting approach allows the module to be self-contained with its own hydraulic fluid supply while minimizing the overall volume increase, as the sump utilizes the internal cavity space within the housing rather than requiring external mounting.
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
The module provides flexible powertrain configurations with reliable performance, low costs, and no need for vehicle modifications, ensuring continuous hydraulic fluid supply to the transmission pump, enabling efficient operation by either the engine, electric machine, or both.
Implementation Method 1
a torque converter casing 48, which encloses a hydrokinetic torque converter 49
Implementation Method 2
an electric machine 28, which includes a stator 30 bolted to a front bulkhead 32 and a rotor 34 supported by a first leg 36 and a second leg 38 for rotation about an axis 39
Implementation Method 3
a disconnect clutch 22, supported on a clutch hub 24 that is secured by a spline 26 to input shaft 16
Data Source
AI summary
A powertrain module includes an input, first bulkhead supporting the input for rotation, a hub, an electric machine including a stator connected to the first bulkhead and a rotor connected to the hub, a clutch for alternately opening and closing a drive connection between the input and the rotor, and a second bulkhead supporting the input for rotation.