Hybrid Powertrain Locking Sleeve Torque Management
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Solution Overview
Problem
Conventional clutch mechanisms in hybrid vehicle propulsion systems are heavy, expensive, and inefficient, leading to increased fuel consumption and heat generation, while also limiting torque transmission due to the need for larger dimensions and higher torque capabilities from both the engine and electrical machine.
Innovation Solution
A compact propulsion device using a locking sleeve that connects the engine output shaft to the gearbox input shaft via a planetary gear, allowing for efficient torque transmission while reducing the size and weight of the electrical machine, and utilizing a splined connection for high reliability and operational safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional clutch mechanism is used to disconnect the gearbox input shaft from the engine during gearchange processes, then the mechanism can provide torque transmission control, but the clutch mechanism becomes heavy, expensive, and occupies large space
Solution Approach 1:
The invention extracts and eliminates the conventional clutch mechanism from the hybrid vehicle propulsion system. By using the planetary gear set's inherent torque management capabilities and the electrical machine's torque control, the patent removes the need for a separate clutch mechanism, thereby reducing weight, cost, and space occupation while maintaining torque transmission control functionality
Solution Approach 2:
The planetary gear set is given multiple functions: it serves both as the gear transmission mechanism and as the torque management device that previously required a separate clutch. The electrical machine also performs dual functions as both motor and generator while participating in torque distribution through the planetary gear, eliminating the need for dedicated clutch components
2Reliability
If a conventional clutch mechanism is used for torque transmission control, then torque can be managed during gearchange, but fuel consumption increases and clutch disc wear occurs
Solution Approach 1:
The invention replaces the mechanical clutch mechanism with an electro-mechanical torque management system. The electrical machine, controlled by the control unit, manages torque transmission during gearchange processes through electrical control signals, eliminating the need for mechanical clutch disc engagement and disengagement, thereby reducing fuel consumption and mechanical wear
Solution Approach 2:
The control unit continuously monitors the propulsion system's operating state and adjusts the electrical machine's torque output accordingly. This feedback control enables precise torque management during gearchange processes without requiring mechanical clutch intervention, optimizing fuel efficiency and preventing wear
3Device complexity
If the electrical machine is connected to the planetary gear to enable torque transmission, then the clutch mechanism can be eliminated, but the maximum torque is limited by the electrical machine's lower torque capability
Solution Approach 1:
The invention employs dynamic torque management where the control unit continuously adjusts the electrical machine's torque contribution based on real-time operating conditions. During acceleration phases, the electrical machine provides maximum available torque, while during deceleration or gearchange, it operates in generator mode or reduces torque output, allowing the system to achieve higher peak torques than the electrical machine alone could provide
Solution Approach 2:
The control unit prepares the electrical machine in advance for torque demands by pre-charging the battery and positioning the electrical machine in optimal operating states. This preliminary action ensures that when high torque is required, the electrical machine can contribute maximum torque immediately, maximizing the overall torque capability of the hybrid powertrain
4Volume of moving object
If the electrical machine's dimensions are reduced to fit limited space, then the propulsion device becomes more compact, but the electrical machine's power and torque generation capability are limited
Solution Approach 1:
The electrical machine is designed to perform multiple functions within a compact form: it operates as a motor during acceleration, as a generator during deceleration and gearchange, and as a torque management device through the planetary gear connection. This multi-functionality allows a smaller, more compact electrical machine to replace what would traditionally require a larger single-function motor
Solution Approach 2:
The invention merges the electrical machine's functions with the planetary gear set's torque management capabilities. By integrating the electrical machine directly with the planetary gear, the system combines electromagnetic torque generation with mechanical torque distribution, allowing a compact electrical machine to achieve the torque output of a larger standalone motor through the torque amplification and distribution provided by the planetary gear
Data Source
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AI summary
The invention relates to a propulsion device (2) for a vehicle, which device (2) comprises an output shaft (14) of a combustion engine (4), an input shaft (27) of a gearbox (8), an electrical machine (6) which comprises a stator (24) and a rotor (26), and a planetary gear (10) which comprises movable components (18, 20, 22). A locking sleeve (38) is movable between first and second positions, in which first position the engine output shaft (14) and the gearbox input shaft (27) are allowed to rotate at different speeds via the planetary gear (10), and in which second position the locking sleeve (38) firmly connects the engine output shaft (14) to the gearbox input shaft (27) via the planetary gear (10). The invention relates also to a method for controlling such a propulsion device (2).