Modular Hybrid Powertrain with Disconnect Clutch and Bulkhead
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Solution Overview
Problem
There is a need for a modular powertrain subassembly for hybrid electric vehicles that can be installed between various engines and transmissions, incorporating a hydraulically actuated disconnect clutch, electric machine, and suitable power paths, while maintaining low manufacturing and assembly costs and avoiding vehicle body modifications, and ensuring reliable performance.
Innovation Solution
A powertrain module comprising an input, bulkhead, rotor support, torque converter casing, electric machine with a stator and rotor, clutch hub, and a clutch that allows drive connection alternation between the clutch hub and rotor support, enabling independent operation of the engine, electric machine, or both, with hydraulic communication and fluid management for reliable transmission operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular powertrain subassembly is designed to be compatible with multiple engines and transmissions, then adaptability is improved, but device complexity increases
Solution Approach 1:
The modular powertrain subassembly is designed with universal mounting interfaces and standardized connection points that allow it to be installed on various engine and transmission models. The bulkhead structure incorporates multiple mounting patterns and the input/output shafts are designed to accommodate different torque and speed specifications, enabling a single module design to serve multiple vehicle platforms.
Solution Approach 2:
The powertrain system is divided into discrete modular components including the electric machine, disconnect clutch, torque converter, and bulkhead assembly. Each component is independently designed and can be assembled in different configurations depending on the specific engine-transmission combination, reducing overall system complexity while maintaining versatility.
2Reliability
If hydraulic communication is provided from transmission hydraulic system to clutch and electric machine, then reliability is improved, but device complexity increases
Solution Approach 1:
The hydraulic system for actuating the disconnect clutch and powering the electric machine is integrated with the transmission's existing hydraulic system. A single hydraulic pump in the transmission provides fluid to both the transmission components and the modular subassembly components, eliminating the need for separate hydraulic systems and reducing overall complexity while ensuring reliable operation.
Solution Approach 2:
The bulkhead structure incorporates hydraulic passages and mounting features that serve as intermediaries between the transmission hydraulic system and the modular components. These integrated hydraulic pathways allow fluid communication without requiring complex external routing or additional hydraulic control units.
3Ease of manufacture
If the module is designed for easy installation between engine and transmission, then ease of manufacture is improved, but manufacturing precision requirements increase
Solution Approach 1:
The modular subassembly is pre-assembled as a complete unit with all internal components (electric machine, clutch, torque converter) mounted and configured before installation in the vehicle. Mounting surfaces, alignment features, and connection points are pre-positioned and precision-machined on the bulkhead, allowing for accurate alignment when the entire module is installed between the engine and transmission, while simplifying the vehicle assembly process.
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 module provides a versatile, cost-effective, and reliable powertrain solution that can be used across different vehicles, ensuring efficient torque transmission and hydraulic fluid management without requiring vehicle body modifications, thus addressing the need for adaptability and low manufacturing costs.
Implementation Method 1
a torque converter, with the torque converter impeller secured to the torque converter casing and the torque converter turbine secured to the transmission input shaft
Implementation Method 2
a hydraulically actuated disconnect clutch
Data Source
AI summary
A powertrain module includes an input, a bulkhead supporting the input, a rotor support, a torque converter casing driveably connected to the rotor support, an electric machine including a stator supported on the bulkhead and a rotor connected to the rotor support, a clutch hub driveably connected to the input, and a clutch for alternately opening and closing a drive connection between the clutch hub and the rotor support.