Resolver Carrier and Impeller Shell Assembly for Axial Space Saving
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Solution Overview
Problem
Hybrid modules face challenges in packaging and fitting all necessary components, such as e-motors, torque converters, and resolvers, due to axial constraints within the limited spacing of the hybrid module envelope.
Innovation Solution
A hybrid module design that integrates a resolver assembly with a torque converter assembly by using a resolver carrier with tabs that engage slots in the impeller shell, allowing for a combined assembly without the need for welded connections, which reduces distortion and space constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional separate packaging of resolver and torque converter is used, then each component can be independently manufactured and assembled, but the hybrid module envelope requires excessive axial space
Solution Approach 1:
The patent merges the resolver assembly and torque converter assembly into a single integrated hybrid module. The resolver carrier is directly coupled with the impeller shell, combining two previously separate components into one unified structure that reduces axial space while maintaining functional independence of both subsystems
Solution Approach 2:
The resolver assembly is nested within the torque converter assembly structure. The resolver carrier with tabs is positioned inside the impeller shell, with tabs extending through slots to create a nested configuration where the resolver is housed within the torque converter envelope, optimizing space utilization
2Strength
If welded connections are used to attach resolver carrier to impeller shell, then strong mechanical connection is achieved, but distortion and assembly costs increase
Solution Approach 1:
The connection structure is segmented into discrete tabs on the resolver carrier that engage with slots in the impeller shell. This segmentation allows for non-welded attachment through interference fit or riveting, avoiding the distortion and complexity associated with welding while maintaining connection strength
Solution Approach 2:
The tabs and slots act as an intermediary mechanical interface between the resolver carrier and impeller shell. This intermediate structure provides a standardized, repeatable connection method that eliminates the need for welding operations while ensuring adequate mechanical strength through precise geometric engagement
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 design effectively combines the resolver assembly with the torque converter assembly, optimizing space usage within the hybrid module while maintaining durability and performance requirements, and reducing assembly costs by avoiding welding processes.
Implementation Method 1
a resolver carrier (156). The resolver carrier (156) includes a plurality of tabs (164) circumferentially spaced from each other. Each of the tabs (164) being arranged to engage one respective slot (146) of the impeller shell (134)
Implementation Method 2
each tab may be connected to the impeller shell via brazing
Data Source
AI summary
A hybrid module includes a rotor carrier including an axially extending portion. The hybrid module further includes a torque converter assembly having an impeller. The impeller includes an impeller shell non-rotatably connected to the axially extending portion. The impeller shell includes a row of slots extending axially through the impeller shell. The hybrid module further includes a resolver assembly having a resolver carrier. The resolver carrier includes a plurality of tabs circumferentially spaced from each other. Each of the tabs being arranged to engage one respective slot of the impeller shell.