Hybrid Powertrain Module With Wet Cavity Torque Converter
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Solution Overview
Problem
The industry lacks a modular subassembly for hybrid electric vehicle powertrains that can be easily integrated with various engines and transmissions, requiring a hydraulically actuated disconnect clutch and efficient oil management without increasing manufacturing or assembly costs, and without modifying the vehicle body.
Innovation Solution
Incorporating a torque converter with a rotor hub and electric machine into the powertrain module, which converts the bell housing from a dry to a wet cavity, simplifying oil management and hydraulic fluid supply through the transmission input shaft, reducing parts and axial length, and integrating the hydraulic system with the disconnect clutch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular subassembly is designed to integrate with various engines and transmissions, then versatility and adaptability are improved, but device complexity increases due to the need for multiple connection interfaces and configurations
Solution Approach 1:
The powertrain module is designed with universal connection interfaces that can accommodate multiple engine and transmission types. The module includes standardized mounting points, hydraulic connections, and torque converter interfaces that allow it to be integrated with various vehicle configurations without requiring custom design for each application.
2Ease of operation
If hydraulic fluid management is simplified by converting the bell housing to a wet cavity, then ease of operation and maintenance are improved, but the risk of fluid contamination and leakage increases
Solution Approach 1:
The patent merges the transmission fluid sump with the bell housing cavity, creating a unified wet environment. This integration eliminates the need for separate fluid reservoirs and transfer systems, simplifying fluid management while incorporating seals and baffles to prevent contamination and leakage.
3Ease of manufacture
If the number of parts is reduced and axial length is shortened, then manufacturing and assembly costs are reduced, but reliability may be compromised due to fewer independent components for isolation
Solution Approach 1:
The patent combines multiple functions into integrated components: the bell housing serves as both structural support and fluid sump, the torque converter is directly mounted to the module reducing coupling components, and hydraulic passages are integrated into existing structural elements. This consolidation reduces part count and assembly steps while maintaining reliability through robust integrated design.
Data Source
AI summary
An assembly includes a torque converter including a casing supported for rotation about an axis, a rotor hub secured to the torque converter casing for rotation about the axis, a leg member secured to and supporting the rotor hub for rotation about the axis, and an electric machine including a rotor secured to the rotor hub.