Hybrid-Electric Powertrain Layout for Compact Torque Integration
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Solution Overview
Problem
Existing hybrid-electric powertrains face challenges in reducing manufacturing costs and improving compactness without compromising performance characteristics.
Innovation Solution
The hybrid-electric powertrain design includes a parallel arrangement of the rotor shaft of the electric machine to the transmission input shaft, with a coaxial connection to the transmission output shaft, allowing for a compact and cost-effective configuration that integrates with conventional transmissions, utilizing a combination housing and dual shift units for efficient torque transmission and modular component arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electric machine is arranged far away from the output gear, then the manufacturing cost and compactness are improved, but the practicality and integration with conventional transmission deteriorate
Solution Approach 1:
The transmission system is segmented into distinct functional modules: the existing conventional transmission (housing, input shaft, main shaft, output gear) and the new electric machine assembly (electric machine, connection housing, output shaft). This segmentation allows the electric machine to be integrated at a distance from the output gear while maintaining compatibility with conventional transmissions, reducing manufacturing complexity and cost.
Solution Approach 2:
The connection housing acts as an intermediary component between the electric machine and the transmission system. It provides the necessary mounting interface and torque transmission path, enabling the electric machine to be positioned away from the output gear while still effectively integrating with the conventional transmission system.
2Volume of moving object
If the electric machine is arranged far away from the output gear, then the compactness is improved, but the torque transmission efficiency deteriorates
Solution Approach 1:
Instead of arranging components along a single axial line (which would require close proximity and reduce compactness), the invention utilizes a three-dimensional arrangement where the electric machine is positioned laterally offset from the transmission axis. The torque is transmitted through the connection housing to the output shaft, achieving efficient torque transmission while maximizing spatial compactness through multi-dimensional positioning.
3Ease of manufacture
If the rotor shaft is arranged parallel to the transmission input shaft, then the manufacturing cost is reduced, but the device complexity increases
Solution Approach 1:
The connection housing serves multiple functions simultaneously: it mounts the electric machine, transmits torque from the electric machine to the output shaft, provides structural support, and facilitates the parallel shaft arrangement. This multi-functionality reduces the need for additional complex components, thereby lowering manufacturing cost while managing the complexity of the parallel shaft configuration.
Data Source
AI summary
A hybrid-electric powertrain includes an internal combustion engine, a transmission, and an electric machine, where the electric machine is connected to the transmission for transmitting torque. The transmission has a transmission housing, within which there is disposed an output-side gear set assembly, and also a transmission housing cover disposed on an output side of the transmission as seen in an axial direction. The electric machine has a stator, a rotor, a rotor shaft connected to the rotor for conjoint rotation, and an electric machine housing. In addition, the electric machine has a connection housing for connecting the electric machine to the transmission housing. The rotor shaft of the electric machine is disposed parallel to a transmission input shaft of the transmission.