Stamped Rotor Hub for Modular Hybrid Powertrain
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Solution Overview
Problem
There is a need for a modular hybrid electric powertrain module that can be installed between various engines and transmissions, incorporating a hydraulically actuated disconnect clutch, an electric machine, and suitable power paths, while maintaining low manufacturing and assembly costs and ensuring reliable performance without vehicle body modifications.
Innovation Solution
The powertrain module includes a rotor hub formed from low-cost stamped components, comprising a sheet metal cylinder with spline teeth, a cylindrical tube, and a hub, which supports a torque converter and flex plate, allowing for efficient heat dissipation and hydraulic fluid circulation, enabling reliable operation and packaging improvements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a wet disconnect clutch is nested inside the motor rotor to improve packaging, then packaging efficiency is improved, but manufacturing cost increases due to the expensive rotor hub required to hold the rotor, clutch piston and clutch plates
Solution Approach 1:
The rotor hub is divided into three separate stamped components (cylinder, tube, and hub) that are assembled together, replacing the traditional single-piece expensive rotor hub while maintaining the nested wet clutch configuration inside the motor rotor
Solution Approach 2:
The stamped components are designed with specific local features including spline teeth on the cylinder and tube for torque transmission, and integrated clutch plates with friction material only where needed, optimizing material usage and manufacturing cost
2Strength
If a single-piece rotor hub is used to hold the rotor, clutch piston and clutch plates, then structural integrity is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The rotor hub is segmented into three simple stamped components that are easily assembled together through interference fits and splines, reducing manufacturing cost and assembly complexity while maintaining structural integrity through proper design of connection interfaces
Solution Approach 2:
The cylinder, tube, and hub components are combined to form an integrated rotor hub assembly that supports the rotor, clutch piston, and clutch plates, achieving structural integrity through the collaborative function of multiple simple components rather than a single complex piece
3Adaptability or versatility
If a modular powertrain module is designed to be installed between various engines and transmissions, then adaptability is improved, but device complexity increases
Solution Approach 1:
The powertrain module is designed with universal interfaces including a torque converter compatible with various engine outputs and a transmission input interface that can connect to different transmission types, allowing the same module to be adapted to multiple vehicle configurations without redesign
Solution Approach 2:
The module is segmented into distinct functional components (disconnect clutch, electric machine, torque converter, rotor hub) that can be independently designed and assembled, facilitating adaptability to different engine and transmission combinations while keeping individual component complexity manageable
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 cost-effective, reliable, and modular powertrain solution that efficiently transmits torque and manages hydraulic fluid circulation, enhancing packaging and performance while maintaining low manufacturing costs and avoiding vehicle modifications.
Implementation Method 1
Centrifugal force causes automatic transmission fluid (ATF) to flow radially continually outward through the cylinder, tube and rotor, thereby carrying heat from clutch plates, cylinder and tube away from the module
Implementation Method 2
ATF that exits the assembly falls due to gravity to a sump at the bottom of the module
Data Source
AI summary
A method for forming a rotor hub that includes a sheet metal cylinder including spline teeth including angularly spaced crests and valleys, a tube surrounding the cylinder, secured to the crests and supporting a rotor thereon, a hub secured to the cylinder and supported for rotation, a torque converter, and a flex plate secured to the hub and the torque converter.