Powertrain Interface Module With Torsional Damping for Gear Shifts
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Solution Overview
Problem
Conventional friction-type and interference-type clutches used in vehicle powertrains for torque modulation are impractical for heavy vehicles and high-speed electric machines, as they tend to slip under heavy loads, are expensive, and have short lifespans, making it difficult to efficiently and reliably modulate torque during gear changes.
Innovation Solution
A powertrain interface module with a torsional damper assembly and an overload clutch assembly, which includes an input drum, output shaft, and a torsional damper assembly with a ramp arrangement and a preload member, and an overload clutch with inner and outer clutch plates, allowing for efficient torque modulation by absorbing torque spikes and limiting maximum torque transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction-type clutches are used for torque modulation, then torque can be modulated, but the clutch slips under heavy loads and has short lifespan
Solution Approach 1:
The patent replaces friction-type clutches with a torsional damper assembly that uses elastic deformation of a damper element and ramp arrangements to modulate torque. This mechanical substitution eliminates slipping by using elastic energy storage and controlled engagement surfaces, thereby improving reliability and reducing energy loss.
Solution Approach 2:
The torsional damper assembly incorporates a damper element that can elastically deform to absorb torque spikes before they reach critical levels. The ramp arrangements are pre-configured to engage at specific torque thresholds, providing beforehand cushioning that prevents slip and extends component lifespan.
2Reliability
If interference-type clutches are used for torque modulation, then torque can be modulated, but the components are expensive and have short lifespan
Solution Approach 1:
The torque modulation function is segmented into distinct components: the torsional damper assembly for absorbing torque variations and the overload clutch assembly for limiting maximum torque. This segmentation allows each component to be optimized independently, using simpler and more cost-effective materials and manufacturing processes compared to complex interference-type clutches.
Solution Approach 2:
The overload clutch assembly uses simple clutch plates and spring elements that can be easily manufactured and replaced if needed. These components are designed to be more economical than expensive interference-type clutches, providing a cost-effective solution for torque limitation while maintaining reliability.
3Reliability
If conventional clutches are used in high-speed applications, then torque modulation is possible, but the clutches slip and fail under high-speed conditions
Solution Approach 1:
The patent replaces conventional friction clutches with a torsional damper assembly that uses elastic deformation and controlled mechanical engagement. This substitution enables reliable operation at high speeds by eliminating slip through elastic energy storage and precisely engineered ramp arrangements that maintain engagement integrity under high-speed conditions.
Solution Approach 2:
The torsional damper assembly incorporates dynamic elements including a spring-based damper element and movable ramp arrangements that adapt to varying torque and speed conditions. This dynamic design allows the system to maintain reliable torque modulation across a wide speed range, including high-speed applications where conventional clutches fail.
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
Enables smooth, efficient, and reliable torque modulation in heavy and high-speed applications without the need for expensive components or complex control systems, effectively managing torque differentials and extending the life of the powertrain components.
Implementation Method 1
a torsional damper assembly with a ramp arrangement and a preload member
Implementation Method 2
an output-side damper body coupled to the output shaft and having a second ramp arrangement disposed in resilient engagement with the first ramp arrangement
Implementation Method 3
a damper preload member abutting the output-side damper body to urge the output-side damper body arrangement toward the first engagement position
Implementation Method 4
an overload clutch including an inner clutch plate mounted to the drive hub and an outer clutch plate mounted to the input-side damper body
Data Source
AI summary
Vehicles that are relatively heavy and/or configured to transport heavy loads may utilize a powertrain comprising an electric machine capable of operating at high speeds and a multispeed transmission to propel the vehicle. An interface module is configured to modulate torque between the electric machine and the multispeed transmission allowing the electric machine to smoothly match speed as the multispeed transmission shifts between gears. The interface module facilitates efficient, predictable, and reliable modulation of torque between an input and an output of the powertrain of the vehicle.