Torque Converter Thrust Bushing for Compact Hybrid Module Packaging
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Solution Overview
Problem
Hybrid modules face challenges in packaging and fitting all necessary components, such as an e-motor, crank damper, torque converter, and resolver, due to axial and radial constraints within the limited hybrid module envelope, while maintaining durability and performance requirements.
Innovation Solution
The introduction of a thrust bushing connected to the impeller hub of the torque converter, which includes an axial portion in contact with the impeller hub and a radial portion extending radially outward to axially constrain the torque converter, allowing for efficient packaging within the hybrid module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components (e-motor, crank damper, torque converter, torque converter clutch, K0 clutch, resolver) are packaged within the hybrid module, then the functionality and performance of the hybrid module are improved, but the device complexity and packaging difficulty increase due to axial and radial constraints
Solution Approach 1:
The thrust bushing combines multiple functions into a single component: it provides axial positioning for the torque converter, supports the impeller hub, and enables the lock-up clutch to engage between the impeller and turbine. This merging of functions reduces the number of separate components needed and simplifies the overall packaging arrangement within the hybrid module.
Solution Approach 2:
The thrust bushing serves multiple purposes simultaneously: it acts as a bearing surface for the impeller hub, provides axial constraint for the torque converter, and creates the engagement interface for the lock-up clutch. This multi-functionality allows the hybrid module to achieve complex functionality while maintaining a compact and simplified structural arrangement.
2Reliability
If traditional multiple-component arrangements are used for positioning the torque converter, then the durability and performance requirements can be met, but the axial and radial spacing requirements increase, making it difficult to fit all components within the hybrid module envelope
Solution Approach 1:
The thrust bushing merges the positioning and support functions into a single integrated component that contacts both the impeller hub and the lock-up clutch assembly. This consolidation eliminates the need for separate positioning components, thereby reducing the axial and radial spacing required while maintaining the durability and performance needed for reliable torque converter operation.
Data Source
AI summary
A hybrid module includes a rotor carrier, a torque converter, and a thrust bushing. The rotor carrier includes an axially extending portion and a radially extending portion extending radially inward from the axially extending portion. The torque converter includes an impeller having an impeller shell fixed to the rotor carrier and an impeller hub fixed to the impeller shell. The impeller hub extends in an axial direction away from the radially extending portion of the rotor carrier to a distal end. The thrust bushing is connected to the impeller hub. The thrust bushing includes an axial portion in contact with the impeller hub and a radial portion extending radially outward from the axial portion. The radial portion is in contact with the distal end.