Integrated Electric Machine Adapter for Transmission Weight Reduction
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Solution Overview
Problem
Hybrid vehicle drive trains with separate modules for dual-clutch transmissions and electric machines face increased weight and installation space due to individual housings, as well as the need for multiple cooling circuits, which complicates installation and reduces efficiency.
Innovation Solution
An electric machine design where the rotor is mounted on an axle with a bearing device, and a stator is positioned circumferentially, both partially covered by an adapter device that serves as a partial housing, allowing for integration within a transmission housing, reducing weight and installation space, and utilizing a laminated core rotor carrier with a cooling channel for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate modules with individual housings are used for dual-clutch transmission and electric machine, then functional independence is improved, but weight and installation space increase
Solution Approach 1:
The patent combines the electric machine with the dual-clutch transmission housing, integrating the electric machine housing into the transmission housing structure. This merging eliminates the need for separate housings for each module, reducing overall weight and installation space while maintaining functional independence through internal separation of components.
Solution Approach 2:
The transmission housing serves multiple functions: it houses the dual-clutch transmission components and simultaneously serves as the electric machine housing. This multi-functional design reduces the number of separate housing components needed, thereby reducing weight and installation space requirements.
2Adaptability or versatility
If separate modules with individual housings are used for dual-clutch transmission and electric machine, then functional independence is improved, but installation space increases
Solution Approach 1:
The patent combines the electric machine with the dual-clutch transmission housing, integrating the electric machine housing into the transmission housing structure. This merging eliminates the need for separate housings for each module, reducing overall weight and installation space while maintaining functional independence through internal separation of components.
Solution Approach 2:
The electric machine is nested within the transmission housing structure, with the electric machine components arranged inside the housing that also contains the dual-clutch transmission. This nesting arrangement allows compact integration and reduces installation space.
3Temperature
If separate cooling circuits are provided for each module, then thermal management is improved, but device complexity increases
Solution Approach 1:
The patent integrates the cooling circuit into the housing structure, creating a shared cooling system that serves both the dual-clutch transmission and the electric machine. This merged cooling approach reduces device complexity by eliminating separate cooling circuits while maintaining effective thermal management through the unified cooling channels in the housing.
4Reliability
If complete housing surrounds the rotor and stator, then structural protection is improved, but weight and installation space increase
Solution Approach 1:
The housing is segmented into functional zones: the transmission housing contains the dual-clutch transmission components, while the integrated electric machine housing contains the electric machine components. This segmentation provides structural protection where needed while reducing overall housing material and weight.
Solution Approach 2:
The patent extracts the electric machine from a separate complete housing and integrates it into the transmission housing structure. Only the necessary protective structures are retained, eliminating redundant housing material while maintaining structural protection for critical components.
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 reduces the weight and installation space of the electric machine and the drive train, enhances dynamics by lowering the rotor's mass moment of inertia, and simplifies installation while providing efficient cooling and reduced manufacturing costs.
Implementation Method 1
a rotor (20) arranged on the axle (18) so as to be rotatable about the axle (18) via a bearing device (22)
Implementation Method 2
the rotor carrier (26) has a cooling channel (72)
Implementation Method 3
the rotor carrier (26) has a cooling channel (72)
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to an electric machine (12) for arranging in a transmission housing (14), having an adapter device (16), an axle (18) which is connected to the adapter device (16), a rotor (20) which is arranged on the axle (18) in a rotatable manner about the axle (18) via a bearing device (22), and a stator (24) which surrounds the rotor (20) in the circumferential direction and which can be arranged and at least partly secured in the adapter device (16) at a distance from the rotor (20), wherein the adapter device (16) partly covers the rotor (20) and/or the stator (24).