Resolver Assembly Integrated with Torque Converter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hybrid modules face challenges in packaging and fitting components like e-motors, crank dampers, torque converters, and resolvers due to axial and radial constraints, limiting available space within the module architecture.
Innovation Solution
A hybrid module design that integrates a resolver assembly with the torque converter, where the resolver rotor is attached to the impeller hub via a press-fit, snap-ring, or bonding method, and the stator is fixed to the housing, optimizing space usage by leveraging the torque converter's rotational motion to provide the necessary rotational function for the resolver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If all desired components (e-motor, crank damper, torque converter, torque converter clutch, disconnect clutch, and resolver) are packaged within the hybrid module architecture, then the functionality and performance of the hybrid module are improved, but the axial and radial constraints make it difficult to fit all components due to limited space
Solution Approach 1:
The patent combines the resolver assembly with the torque converter by mounting the resolver rotor on the impeller hub and the resolver stator on the torque converter housing. This merging of previously separate components (resolver and torque converter) into a single integrated assembly reduces the total volume required and eliminates the need for separate mounting spaces, thereby resolving the space constraint while maintaining all required functionalities.
2Volume of moving object
If the resolver assembly is integrated with the torque converter to optimize space usage, then the available space within the hybrid module is increased, but the complexity of the integration and assembly process increases
Solution Approach 1:
The resolver assembly is segmented into distinct components ( rotor, stator, housing) that can be manufactured and assembled separately. The rotor is mounted on the impeller hub while the stator is mounted on the torque converter housing, allowing for modular assembly. This segmentation reduces integration complexity by enabling independent manufacturing and simplifying the assembly process, while still achieving the space optimization benefits of integration.
3Measurement precision
If the rotor is attached to the impeller hub using press-fit, snap-ring, or bonding methods, then the rotational positioning accuracy for the e-motor rotor is maintained, but the manufacturing precision requirements increase
Solution Approach 1:
The patent introduces an intermediary mounting structure (impeller hub and torque converter housing) that facilitates the attachment of the resolver components. The impeller hub serves as an intermediary between the torque converter and the resolver rotor, while the torque converter housing serves as an intermediary for mounting the resolver stator. These intermediaries provide standardized mounting interfaces that reduce the direct precision requirements between the resolver components, while still maintaining the required rotational positioning accuracy through proper design of the mounting features.
Data Source
AI summary
A hybrid module comprising a housing, a torque converter, and a resolver assembly is provided. The torque converter comprises a turbine having a turbine shell including at least one blade attached thereto; an impeller having an impeller shell including at least one blade attached thereto; and an impeller hub attached to a radially extending end of the impeller shell. The resolver assembly comprises a rotor connected to an outer surface of the impeller hub and a stator connected to the housing.