Modular Hybrid Powertrain Module With Disconnect Clutch
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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 to the transmission system, allowing the module to be driven by either the engine, the electric machine, or both concurrently, with a design that includes a stator connected to a bulkhead and a rotor connected to a hub, supported by a servo for actuating the clutch, and a torque converter casing that can be driven independently by either power source.
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 as a universal subassembly that can be installed between various engines and transmissions. The module includes a clutch assembly with a clutch hub, clutch plates, and a release mechanism that can accommodate different engine and transmission configurations. The housing is designed with standardized mounting interfaces that allow the same module to be adapted to multiple vehicle platforms without requiring vehicle body modifications.
Solution Approach 2:
The powertrain system is segmented into distinct modular components: the engine, the modular powertrain subassembly (containing clutch, electric machine, and hydraulic systems), and the transmission. This segmentation allows each module to be independently designed, manufactured, and assembled, improving adaptability while managing complexity through standardized interfaces between segments.
2Ease of operation
If a hydraulically actuated disconnect clutch is included in the module, then ease of operation is improved, but device complexity increases
Solution Approach 1:
A hydraulic actuator serves as an intermediary between the clutch release lever and the clutch plates. The actuator converts hydraulic pressure from the transmission's hydraulic system into mechanical force that moves the clutch release lever, thereby disengaging the clutch. This intermediary mechanism provides precise and reliable clutch actuation while utilizing the existing hydraulic infrastructure of the transmission.
Solution Approach 2:
The clutch actuation system utilizes hydraulics by connecting the clutch actuator to the transmission's hydraulic system. Hydraulic fluid under pressure is directed to the actuator piston, which moves the clutch release lever to disengage the clutch. This hydraulic actuation method provides smooth, controlled, and reliable clutch engagement and disengagement with minimal driver input.
3Ease of operation
If hydraulic communication from the transmission's hydraulic system to the clutch is provided, then ease of operation is improved, but reliability may worsen due to potential fluid supply issues
Solution Approach 1:
The clutch actuator is designed to be self-servicing by directly utilizing the transmission's existing hydraulic system. The actuator includes hydraulic passages that are in direct communication with the transmission's hydraulic circuit, allowing it to automatically receive hydraulic fluid and pressure without requiring separate fluid storage or pumping systems. This self-service approach ensures reliable operation as long as the transmission's hydraulic system is functioning.
Solution Approach 2:
The hydraulic actuator serves as an intermediary that bridges the transmission's hydraulic system and the clutch mechanism. By positioning the actuator within the powertrain module and providing direct hydraulic communication, it ensures reliable fluid supply while maintaining ease of clutch operation. The actuator's design includes provisions for continuous fluid circulation and pressure regulation.
4Ease of manufacture
If the module is designed to require low manufacturing and assembly costs, then ease of manufacture is improved, but manufacturing precision may worsen
Solution Approach 1:
The powertrain system is divided into separate modular components (engine, modular powertrain subassembly with clutch and electric machine, transmission) that can be manufactured independently using standardized processes. This segmentation allows each module to be produced in high volumes with optimized manufacturing techniques, reducing costs while maintaining precision through dedicated manufacturing cells for each module.
Solution Approach 2:
The modular powertrain subassembly is designed as a universal component that can be manufactured once and installed in multiple vehicle configurations. This universality allows for economies of scale in manufacturing, as the same module design can be produced in large quantities with standardized tolerances and assembly procedures, reducing both manufacturing costs and the need for high-precision custom fabrication for each application.
5Ease of manufacture
If the module is designed to avoid vehicle body modifications, then ease of manufacture is improved, but adaptability may worsen
Solution Approach 1:
The powertrain module is designed as a universal subassembly with standardized mounting interfaces that can be installed in various vehicle platforms without requiring modifications to the vehicle body. The module's housing includes standardized bolt patterns and mounting flanges that accommodate different engine and transmission configurations, allowing the same module design to be adapted to multiple vehicle applications through simple mechanical installation rather than body modifications.
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 operation with reliable hydraulic fluid management, ensuring continuous transmission pump fluid supply and enabling efficient energy transfer between the engine and electric machine, thus supporting a variety of vehicle applications without requiring vehicle body modifications.
Implementation Method 1
A torque converter 49 is encased in the torque converter casing 48
Implementation Method 2
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, a 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, a servo for actuating the clutch and supported on the input, and a second bulkhead supporting the hub for rotation.