Support Disc Multi-Clutch Assembly for Compact Hybrid Shifting
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Solution Overview
Problem
Existing dual-clutch transmissions in hybrid vehicles face issues with shifting in purely electric mode without interrupting traction, leading to emission problems and increased manufacturing and assembly costs due to limited installation space, especially in P2 hybrid systems.
Innovation Solution
A multi-plate clutch arrangement with radially offset plate packs and a support disc made of sheet metal between clutch outputs and inputs, featuring a compact design with centrifugal oil compensation chambers and optimized components for cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a triple-plate clutch is used to optimize installation space in P2 hybrid systems, then the installation space is optimized, but manufacturing and assembly costs increase
Solution Approach 1:
The support disc is divided into multiple separate components (first support disc component, second support disc component, third support disc component) rather than using a single integrated triple-plate structure. This segmentation allows each component to be manufactured and assembled independently, reducing overall manufacturing and assembly costs while maintaining the compact installation space required for P2 hybrid systems.
2Ease of manufacture
If a one-piece sheet metal support disc is used, then manufacturing complexity is reduced, but structural optimization is limited
Solution Approach 1:
The support disc is segmented into multiple components that can be manufactured using simple sheet metal forming processes, yet when assembled together with the clutch plates, they create an optimized structural configuration. Each segment can be independently formed and then assembled to achieve the desired structural optimization without requiring complex one-piece manufacturing.
3Reliability
If centrifugal oil compensation chambers are provided to counteract centrifugal force effects, then actuation reliability is improved, but device complexity increases
Solution Approach 1:
The centrifugal oil compensation chambers are integrated into the existing support disc components and clutch structure rather than being added as separate external systems. The support disc components themselves form the boundaries of these chambers, merging the structural support function with the oil compensation function, thereby improving actuation reliability without proportionally increasing device complexity.
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 shifting in purely electric mode without traction interruption, reduces costs, and optimizes installation space in hybrid vehicles, particularly in P2 configurations.
Implementation Method 1
the aim is to counteract the sometimes disruptive effects of centrifugal force on rotating actuating pistons—namely, pressure increases caused by the cooling oil, intended for clutch actuation, being flung outwards by centrifugal force during rotation—by providing corresponding compensation chambers in which a corresponding counter-pressure is generated
Implementation Method 2
a support disc is arranged between the clutch output of one clutch and the clutch input of another clutch, which serves as a support when actuating at least one of the clutches
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed is a multi-disc clutch arrangement having at least two friction clutches (K1, K2, K0) which have disc stacks that are radially offset relative to each other and disposed on disc carriers (9, 10, 11, 12), and which have pistons (13, 14, 15) for actuating the friction clutches, a supporting disc (7) being arranged between the clutch output of one clutch (K1) and the clutch input of another clutch (K0) and serving as a support when at least one of the clutches (K1, K2, K0) is actuated. The supporting disc (7) is a sheet metal part consisting of at least one piece.