Magnetic Coupling Device for Hybrid Vehicle Powertrain
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Solution Overview
Problem
Conventional hybrid vehicle powertrains experience undesirable shift feel and torque interruption during gear changes, leading to uncomfortable driving experiences due to momentary torque loss and delayed reconnection of the engine with the drivetrain.
Innovation Solution
A powertrain system with a magnetic coupling device and non-friction controllable coupling assemblies that synchronize angular velocities and transfer torque without hydraulic control, utilizing magnetic torque converters and controllable mechanical diodes to manage gear shifts smoothly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional hybrid vehicle powertrains use traditional friction-based coupling assemblies with hydraulic control for gear changes, then the transmission can achieve gear ratio changes, but torque interruption and undesirable shift feel occur during gear changes
Solution Approach 1:
The patent replaces traditional friction-based mechanical coupling assemblies with magnetic coupling assemblies. The magnetic coupling assembly uses magnetic fields to couple and decouple the input shaft from the output shaft, eliminating the need for friction-based engagement that causes torque interruption. The magnetic coupling provides seamless transition during gear changes, maintaining continuous torque delivery to the drivetrain while enabling smooth gear ratio changes.
Solution Approach 2:
The magnetic coupling assembly acts as an intermediary between the input shaft and output shaft. During gear changes, the magnetic coupling can be gradually weakened and re-established, providing a buffer that smooths out the transition. This intermediary magnetic field connection allows for controlled torque transfer during gear shifts, preventing the abrupt disconnection and reconnection that occurs with traditional friction-based systems.
2Ease of operation
If hydraulic control systems are used for traditional friction-based coupling assemblies, then gear changes can be achieved, but shift shock and delayed reconnection occur
Solution Approach 1:
The patent replaces hydraulic control mechanisms with direct magnetic control. The magnetic coupling assembly is controlled by adjusting the strength of the magnetic field, which can be modulated electronically without the delays and complexities of hydraulic systems. This direct magnetic control eliminates the hydraulic response lag and provides more precise control over the coupling engagement, reducing shift shock and improving gear shift quality.
3Loss of energy
If engine and electric motors are connected to transmission with independent torque control, then overall vehicle efficiency is improved, but complex control coordination is required during gear changes
Solution Approach 1:
The magnetic coupling assembly serves as a mediator that simplifies the control coordination between the engine, electric motors, and transmission. During gear changes, the magnetic coupling can be independently controlled to maintain torque flow, allowing the engine and electric motors to operate independently for efficiency while the magnetic coupling handles the coordination of torque transfer during shifts. This reduces the control complexity by providing a passive magnetic buffer that automatically manages torque coordination.
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 solution provides improved shift feel and reduced torque interruption, enhancing driving comfort by ensuring continuous torque delivery during gear changes and minimizing shift shock.
Implementation Method 1
A magnetic coupling device magnetically transfers a portion of rotating mechanical energy of the electric powerplant to the transmission output shaft
Implementation Method 2
synchronize angular velocities of the shafts during a change in state of the coupling assembly
Data Source
AI summary
Drive systems or powertrains including transmissions for electric and hybrid electric vehicles are provided. 3-position linear motor, 2-way clutches (i.e. CMDs) are included in the transmissions. An electric 3-speed AMT having a magnetic coupling device such as a magnetic torque converter is provided to magnetically transfer a portion of rotating mechanical energy of an electric powerplant or motor to a transmission output shaft in response to an electrical signal to synchronize angular velocities of the transmission output shaft and an output shaft of the electric powerplant during a change in state of one of the CMDs. Torque is transferred to the transmission output shaft during the change in state.