Integrated Flex Plate Torque Converter for Hybrid Powertrain
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Solution Overview
Problem
There is a need for a modular hybrid electric powertrain module that can be installed between various engines and transmissions without increasing the axial length of the powertrain, while incorporating a hydraulically actuated disconnect clutch and providing hydraulic communication to the transmission's hydraulic system, and ensuring reliable fluid supply to the transmission pump.
Innovation Solution
The powertrain module includes a torque converter concentric with a rotor hub, a coupler for rotational and axial connections, and an integrated flex plate that eliminates the need for conventional attachment bolts, allowing the torque converter to elastically expand and contract without damaging the transmission pump, and maintains a compact axial design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flex plate attachment bolts or nuts are used, then secure connection is achieved, but the torque converter cannot elastically expand and contract without risk of damage to the transmission pump
Solution Approach 1:
The flex plate is integrated directly with the torque converter assembly, merging two previously separate components. This integration eliminates the need for separate attachment bolts or nuts while allowing the torque converter to elastically expand and contract without risking damage to the transmission pump, as the flexible connection is built into the torque converter structure itself
2Adaptability or versatility
If the front module is installed between engine and transmission, then modular hybrid powertrain is achieved, but the axial length of the powertrain increases
Solution Approach 1:
The flex plate is nested within the torque converter assembly rather than being a separate external component. This nesting approach allows the front module to be installed between the engine and transmission while minimizing the increase in axial length, as the flex plate integration does not add significant external dimension to the powertrain
3Length of moving object
If integrated flex plate design is used, then axial length is reduced and installation is simplified, but conventional attachment method is eliminated
Solution Approach 1:
The flex plate and torque converter are merged into a single integrated assembly, which simplifies the overall manufacturing process by reducing the number of separate parts that need to be produced and assembled. This integration eliminates the need for separate flex plate attachment bolts or nuts, reducing assembly complexity despite requiring precision in the integrated component manufacturing
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 solution enables easy installation of the front module to the transmission without lengthening the powertrain, ensures reliable hydraulic communication, and allows for elastic expansion of the torque converter, preventing damage to the transmission pump and maintaining efficient power transmission.
Implementation Method 1
allows the torque converter to elastically expand and contract without risk of damage to the transmission pump
Data Source
AI summary
An assembly includes a torque converter concentric with an axis, a rotor hub drivably connected for rotation about the axis to an electric machine and selectively to an engine through a disconnect clutch, a coupler located between the rotor hub and torque converter, providing a rotational connection and an axial connection between the coupler and the rotor hub, and a flex plate providing second rotational and axial connections between the coupler and the torque converter.