Hybrid Powertrain Electric Motor Module Integration
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Solution Overview
Problem
Hybrid powertrains face challenges in integrating an electric motor with existing powertrains, particularly in addressing axial length, housing constraints, clutch actuation, cooling, and integration with existing components, especially when removing the torque converter.
Innovation Solution
A hybrid powertrain design incorporating an engine, electric motor module with a coast clutch, one-way clutch, launch clutch, and hydraulic pump, where the electric motor is connected to the transmission through a flywheel and planetary gear sets, allowing torque transmission from the flywheel to the electric motor while preventing reverse torque flow, and enabling independent pump operation with the coast and launch clutches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the torque converter is removed to improve fuel economy and reduce complexity, then the hybrid powertrain becomes simpler and more efficient, but the integration of the electric motor with existing powertrain components becomes more difficult
Solution Approach 1:
The patent combines the electric motor module with the transmission input shaft assembly, merging previously separate components (electric motor, clutches, pump) into an integrated module that directly couples to the transmission, eliminating the torque converter and reducing overall system complexity while improving fuel economy
Solution Approach 2:
The electric motor module is designed to perform multiple functions: providing launch torque, enabling regenerative braking, driving the hydraulic pump, and interfacing with the transmission through multiple clutch arrangements, thereby replacing the torque converter's functions while adding regenerative capability
2Device complexity
If the electric motor module integrates multiple clutches and the hydraulic pump to reduce component count, then device complexity is reduced, but the axial length and housing space requirements increase
Solution Approach 1:
The patent arranges the electric motor, clutches, and hydraulic pump in a nested configuration where components are stacked axially and radially within the electric motor module housing, with the pump driven directly by the motor shaft, allowing multiple functions in a compact footprint
Solution Approach 2:
The design transitions from radial to axial arrangement of components, utilizing the axial dimension efficiently by stacking the electric motor, clutch assemblies, and pump in sequence along the input shaft axis, thereby reducing the overall housing outside diameter while maintaining functional integration
3Adaptability or versatility
If the one-way clutch allows torque transmission from flywheel to electric motor but prevents reverse torque flow, then regenerative braking is enabled, but torque transmission reliability becomes more complex to control
Solution Approach 1:
The one-way clutch acts as an intermediary device between the flywheel and electric motor, automatically engaging to allow torque transmission during motor starting and regenerative braking, while preventing reverse torque flow, thereby simplifying control logic while maintaining reliability through passive mechanical means
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
This design enhances fuel efficiency by eliminating the need for an auxiliary pump, supports regenerative braking, and facilitates smooth engine starts and vehicle launches, while maintaining performance and reducing the complexity of integrating the electric motor with existing powertrain components.
Implementation Method 1
The one-way clutch is further connected or coupled to the electric motor and allows torque to be transmitted from the flywheel to the electric motor, but not from the electric motor to the flywheel
Implementation Method 2
The rotor of the electric motor is interconnected to the one-way clutch, the launch clutch and to a hydraulic pump
Implementation Method 3
first, second, and third planetary gear sets each having a sun gear, a carrier member and a ring gear
Implementation Method 4
Flywheel includes a damper
Data Source
AI summary
A transmission is provided having an input member, an output member, three planetary gear sets, a plurality of coupling members and a plurality of torque transmitting devices. Each of the planetary gear sets includes first, second and third members. The torque transmitting devices include clutches and brakes.