Modular Hybrid Transmission Centering Plate Bushing Assembly

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Solution Overview

Problem

The assembly of modular hybrid transmissions is complex and prone to damage due to the tilting of the electric motor clutch, which can contact and damage the needle bearing and clutch seals, requiring extensive rework.

Innovation Solution

A method involving a centering assembly with a press-fit bushing in a stamped sheet metal centering plate, connected to the torque converter, which maintains the clutch shaft's centering within the transmission housing, eliminating the need for a needle bearing and providing support through a single rolling bearing and the torque converter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a needle bearing is used to support the clutch shaft during assembly, then the clutch shaft can be supported, but the clutch may tilt and contact the needle bearing, causing damage to the clutch seals and bearing components

Engineering Contradiction:

Improveclutch shaft support reliabilityVSAvoiddamage to clutch seals and needle bearing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the needle bearing from the assembly process entirely. Instead of using a needle bearing to support the clutch shaft, the invention uses a centering plate with a bushing that is press-fit into the torque converter housing, eliminating the harmful interaction between the clutch and needle bearing that causes damage to seals and bearing components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The centering plate with bushing acts as an intermediary component between the torque converter housing and the clutch shaft. This centering assembly provides the necessary support and alignment without requiring direct contact between the clutch and the bearing surface, thereby preventing damage to both the clutch seals and bearing components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the clutch assembly is inserted into the transmission housing without a centering mechanism, then the assembly process is simpler, but the clutch shaft cannot be properly centered, leading to misalignment and potential damage

Engineering Contradiction:

Improveassembly simplicityVSAvoidclutch shaft centering precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The centering plate with bushing is pre-installed into the torque converter housing before the clutch assembly is inserted. This preliminary centering action ensures that when the clutch shaft is inserted, it is automatically guided into the correct centered position, maintaining both assembly simplicity and manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The centering plate serves as an intermediary component that provides the necessary alignment between the torque converter housing and the clutch shaft. The bushing in the centering plate guides the clutch shaft into proper centering, ensuring manufacturing precision while keeping the assembly process relatively simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multiple components (needle bearing, clutch seals, locking ring) are used to support the clutch shaft, then the support is more comprehensive, but the assembly becomes more complex and prone to damage

Engineering Contradiction:

Improveclutch shaft support comprehensivenessVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the centering and support functions into a single integrated component: the centering plate with bushing. This merged component eliminates the need for separate needle bearings, locking rings, and clutch seals, reducing assembly complexity while maintaining comprehensive support through the torque converter and transmission housing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The centering plate with bushing performs multiple functions: it centers the clutch shaft, supports the clutch assembly, and provides alignment between components. This multi-functional component replaces several separate parts, reducing overall device complexity while maintaining comprehensive support.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11465485B1Modular hybrid transmission with shaft centering feature connected to torque converter

Publication Date: 2022.10.11 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A method of assembling a modular hybrid transmission (MHT) is provided including (a) assembling an emotor clutch on a clutch shaft to form a clutch assembly, (b) press-fitting a bushing into a centering plate to form a centering assembly, (c) connecting the centering assembly to a torque converter, (d) assembling the torque converter to the clutch assembly with the bushing on an end of the clutch shaft, and (e) inserting the clutch assembly and the torque converter into a transmission housing while maintaining the centering of the clutch shaft to the transmission housing via the centering assembly connected to the torque converter. The assembled MHT is also provided which eliminates the needle bearing according to the prior art, avoiding the potential for damage during assembly.