DE102015100282A1 - Modular hybrid electric car rotor hub - Google Patents

Abstract

A rotor hub includes a metal cylinder having teeth that include angularly spaced protrusions and depressions, a tube surrounding the cylinder that is fixed to the protrusions that supports a rotor, a hub that is fixed to the cylinder and fixed for rotation, a torque converter and a flex plate fixed to the hub and torque converter.

Description

REFER TO RELATED APPLICATIONS

This is a continuation-in-part application of US Application No. 13 / 362,018, filed January 31, 2012.

BACKGROUND OF THE INVENTION

This invention relates to a powertrain of hybrid electric vehicles, more particularly to a powertrain module that can be installed and fixed between an engine output and a transmission input.

Hybrid electric vehicles (HEVs) have both an internal combustion engine and an electric machine, which are used alternatively or jointly to drive the vehicle. Various powertrains are used in hybrid vehicles, for example, a parallel configuration in which the engine is connected to the electric motor via a disconnect clutch, the electric motor driving a torque converter input of an automatic power transmission. The transmission has an output connected to a differential coupled to the two drive wheels of the vehicle.

There is a need in the industry for a hybrid electric powertrain that includes a modular subassembly for use with various internal combustion engines and transmissions, such that the module can be installed and fixed between an output of one or more internal combustion engines and an input of one or more transmissions. The composite powertrain can then be used in various vehicles. The module should include a hydraulically actuated disconnect clutch, the electric machine, and appropriate power paths between the engine and the transmission input electrical machine. Preferably, the module provides hydraulic communication from the transmission's hydraulic system to the clutch, an equilibrium lock, and the electric machine. The module must provide an oil sump containing hydraulic fluid supplied to the module and a path for continuously returning the fluid to the transmission sump so that the gear pump is reliably and continuously supplied with fluid.

Most disconnect couplings are dry, but wet clutches are generally easier to control and allow oil cooling of the clutch and the electric motor. If the disconnect clutch is embedded within the motor rotor, the enclosure is facilitated but generally requires an expensive rotor hub since it must hold the rotor, the clutch piston and the clutch plates.

The module should cause low manufacturing and assembly costs, require no changes to the vehicle body and must provide reliable performance.

SUMMARY OF THE INVENTION

A rotor hub includes a metal cylinder having teeth which comprise angularly spaced ridges and recesses, a tube surrounding the cylinder fixed to the ridges and supporting a rotor, a hub fixed to the cylinder and fixed for rotation Torque converter and a flex plate fixed to the hub and torque converter.

A method of forming a rotor hub comprises forming a plate cylinder with serrations defining angularly spaced ridges and valleys, defining a pipe surrounding the cylinder at the ridges, locating a rotor on the pipe, forming a hub fixed to the cylinder, and setting the hub to rotate about an axis.

The rotor hub comprises three simple, low-cost components, a cylinder, a cylindrical tube and a hub. Torque is transmitted between the hub and the torque converter through the flexplate.

Centrifugal force causes automatic transmission fluid (ATF) to continuously flow radially outward through the cylinder, pipe and rotor, transporting heat away from the module from clutch plates, cylinders and pipe. ATF exiting the assembly falls by gravity into a trough at the bottom of the module, passes through a radiator, and returns to the transmission pan, from which it is drawn into the transmission pump to be recirculated through the hydraulic system.

The scope of applicability of the preferred embodiment will be apparent from the following detailed description, claims, and drawings. It should be understood that the description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications of the described embodiments and examples will be apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more readily understood by reference to the following description, taken in conjunction with the accompanying drawings, in which:

1A and 1B a side cross-sectional view of a powertrain module showing a front connection with an engine output and a rear connection with a Getriebedrehmomentwandlereingang;

2 Fig. 3 is a side cross-sectional view of a portion of the powertrain module showing a component serving as a clutch reaction plate and a forward bearing of the rotor of the electric machine; and

3 a side cross-sectional view of a rotor hub, which consists of stamped components;

4 a cross section taken along a plane 4-4 in 3 is;

5 a cross-section along a plane 5-5 in 3 is; and

6 a side view of the rotor and end plates is.

DETAILED DESCRIPTION

1A and 1B show a module 10 of a powertrain for a hybrid electric vehicle having an internal combustion engine with a rotary output 12 ; a torsion damper 14 , which is at the engine output 12 is fixed, an input shaft 16 through a gearing 18 at an exit 20 of the damper 14 is fixed; a separating clutch 22 on a clutch hub 24 is stored by a toothing 26 at the input shaft 16 is fixed; an electric machine 28 holding a stator 30 attached to a front bulkhead 32 screwed, and a rotor 34 that of a first thigh 36 and a second leg 38 is mounted for rotation about an axis comprises; a rotor hub 40 , preferably by a weld on the leg 38 is fixed; and a flex plate 42 , which at one end through a spline connection 44 on a rotor hub 40 is fixed and at the opposite end by bolts 46 on a torque converter housing 48 which is a hydrokinetic torque converter 49 includes. The electric machine 28 may be an electric motor or an electric motor generator.

Torque converters suitable for use in the powertrain are disclosed in U.S. Patent Application No. 13 / 325,101 filed on Dec. 14, 2011, the entire disclosure of which is incorporated herein by reference 4a . 4b . 5 . 12 and 15 described.

The torque converter 49 includes a bladed impeller in the housing 48 is arranged and fixed to it; a bladed turbine, which is hydrokinetic driven by the impeller and by a toothing 50 at the input shaft 52 an automatic transmission 54 is fixed; and a bladed stator wheel disposed between the turbine and stator and on a stator shaft 56 is fixed to a transmission housing 58 is held against rotation.

A rear partition 60 by bolts 62 on the gearbox 58 is set on the radially inner surface with a hydraulic seal 64 provided with the radial outer surface of the rotor hub 40 is in contact.

A flywheel 66 that by bolts 68 at the rotation exit 12 of the internal combustion engine is stored, an internal combustion engine starter pinion 70 that through a disk 72 is fixed, which is welded to the starter pinion and the flywheel.

A warehouse 74 stores the first thigh 36 for rotation on the front partition 32 , A warehouse 76 stores the second leg 38 for rotation on the rotor hub 40 , A pipe 78 that with the axle 39 is aligned and the rotor 34 is stored for rotation about the axis, is on the first leg 36 and on the second leg 38 established. margins 80 . 82 at the front or rear end of the pipe 78 can be rolled radially outward to the rotor 34 on the pipe 78 set and an axial displacement of the rotor 34 to prevent in relation to the pipe. The inner surface of the pipe 78 is with an axial toothing 81 formed into which the thighs 36 . 38 and removable disks 83 the separating clutch 22 intervention. The friction plates 84 the clutch 22 are defined by an axial toothing on the radial outer surface of the clutch hub 24 is trained.

A hydraulic servo control to operate the clutch 22 includes a piston 86 , a balance barrier 88 , a return spring 90 and hydraulic lines for transmitting actuating pressure to the pressure control volume 92 on the right side of the piston 86 and the pressure equilibrium volume 94 on the left side of the piston. The piston 86 moves in a cylinder that passes through the right thigh 38 is formed when actuating pressure and hydraulic fluid to the volume 92 be supplied by the use of seals 151 and 152 to the left, which causes the clutch 22 in the rotor 34 and the engine output 12 through the damper 14 , the input shaft 16 , the clutch hub 24 and the clutch 22 engages and connects them to the drive.

Because the piston 86 , the equilibrium barrier 88 and the return spring 90 on the rotor hub 40 are stored, is the moment of inertia of the piston 86 , the equilibrium barrier 88 and the return spring 90 on the output side, ie the rotor side, the clutch 22 ,

The rotor 34 is continuously drivable with the transmission input shaft 52 connected, via the torque path, the rear leg 38 , the rotor hub 40 , the flex plate 42 , the torque converter housing 48 , which includes hydrodynamic drive connection between the torque converter impeller and the turbine via the teeth 50 with the transmission input shaft 52 connected is.

A pickup 100 A very precise type of electrical rotary transducer used to measure angles of rotation is by bolts 102 on the front partition 32 set on the front partition 32 and a first leg and axially between the front partition plate 32 and the rear partition plate 60 arranged.

The teeth of the spline connection 44 , which provides a rotary drive connection between the flexplate 42 and the rotor hub 40 form, are fitted together so that no play arises when a torque between the flex plate and the rotor hub is transmitted. The flex plate 42 is with a thick wall section 104 formed a threaded hole 106 that's on a jetty 108 ends. The outer teeth of the teeth on the flex plate 42 be by bolts 110 in threaded holes at the right end of the rotor hub 40 engage axially in engagement with the internal teeth of the gear on the rotor hub 40 forced. The teeth engage the spline connection 44 be when removing bolts 110 and screwing a larger bolt into the hole 106 disengaged so that the bolts come into contact with the web, whereby the flex plate is pressed axially to the right.

The rotor hub 40 is with several axially aligned hydraulic passages 120 and laterally aligned passages 122 . 124 . 126 . 128 . 120 provided, the hydraulic fluid and pressure to the module 10 from the hydraulic system of the gearbox 54 transport. The passages 120 . 122 . 124 . 126 . 128 . 129 carry hydraulic fluid and pressure, which is the control volume 92 the servo control of the clutch 22 on the right side of the piston 86 is arranged, over the pressure equilibrium volume 94 between the equilibrium barrier 88 and the piston to a variable force solenoid (VFS) 130 and to the surfaces of the rotor 34 and the stator 30 whose surfaces are cooled by the fluid comprises. The rear partition plate 60 is with a passage 128 fitted hydraulically with the VFS 130 communicated.

The rear partition plate 60 stores a tub 132 that contains fluid from the hydraulic system of the transmission 54 to the module 10 is supplied. The gear 54 includes a tub 136 containing hydraulic fluid from a transmission pump 134 is supplied to the transmission hydraulic system, from where fluid and control pressure to the module 10 , to the torque converter 49 , to gear clutches and brakes, bearings, shafts, gears, etc. supplied.

A warehouse 140 that in the front bulkhead 32 fitted, and a bearing 142 that in the rotor hub 40 is fitted, store an input shaft 16 when rotating around an axis 39 , The front partition 32 also stores the stator 30 in its own axial and radial positions with respect to the rotor 34 , The warehouse 76 that is between the rear bulkhead 60 and a rotor hub 40 fitted, and a bearing 142 store the rotor hub 40 in rotation around the axis 39 , The front and rear dividing wall 32 . 60 store the rotor together 34 in rotation around the axis 39 using a warehouse 74 that in the partition 32 is fitted, and a warehouse 76 that in the partition 60 is fitted.

The seal 64 which are in the rear bulkhead 60 is fitted, and a seal 141 in the front bulkhead 32 is fitted, prevent fluid from module 10 that between the end walls 32 . 60 is arranged, passes through. Another dynamic seal 144 prevents the passage of contaminants between the engine compartment 146 and the module 10 ,

The components of the module 10 are built into the module and assembled in it. The assembled module may then be between the engine output 12 and the torque converter housing 48 installed and connected to it.

During operation, the engine output is 12 Powered by an internal combustion engine, torque is transmitted from the engine through the rotor hub 40 and the flexplate to the torque converter housing 48 transferred, provided that the coupling 22 is engaged. The electric machine 28 of the rotor 34 is through the pipe 78 , the thigh 38 , the rotor hub 40 and the flex plate 42 continuously drivable with the torque converter housing 48 connected. Therefore, the torque converter housing 48 be driven by the internal combustion engine alone, provided the electric machine 28 is switched off and the clutch 22 is engaged; from the electric machine alone, provided the engine is off or the engine is running and the clutch is disconnected; and of the combustion engine and the electric machine at the same time.

As in 2 you can see the rotor 34 the electric machine 28 on a pipe 78 stored, that of a sheath 160 is stored by a weld 162 with the pipe 78 is connected and to the rotor hub 40 is welded and over a thigh 164 by an axial, internal toothing 166 is fixed to the casing 160 is fixed. A single snap ring 168 who is at the sheath 160 is fixed and with the thigh 164 is in contact, limits an axial displacement of the friction plates 84 through a gearing 166 on the jacket 160 are fixed. spacer plates 83 are by an external axial toothing 170 on the clutch hub 24 established.

A thrust bearing 172 is in contact with the clutch hub 24 and a flange 174 on a wave 176 parallel to an axis 19 runs. A bearing supports the clutch hub on the shaft 176 , The engine output 12 is through a flywheel 66 , a damper 20 , an input shaft 16 and a gearing 26 with the clutch hub 24 connected.

A warehouse 182 that is between the front bulkhead 32 and the thigh 164 is fitted, stores the rotor 23 for rotation around the axis 19 and provides a response to axial force between the legs 164 and the partition 32 is transmitted.

During operation, the piston moves 86 to the left against the force of the return spring 90 when pressurized hydraulic fluid passes through the passage 184 to the cylinder 186 is provided, which is the piston 86 contains. The separating clutch 22 is engaged when the friction plates 83 and the spacer plates 84 through the piston 86 be forced into mutual frictional contact, creating a drive connection between the rotor hub 40 and the engine output 12 is produced. The rotor 34 is through the sheath 160 continuously drivable with the rotor hub 40 connected.

The left axial force coming from the piston 86 is exercised through the plates 83 . 84 by 164 , the snap ring 168 and the sheath 160 transfer.

3 - 6 show a rotor hub, which consists of stamped components and a clutch cylinder 200 , a pipe 202 and a hub 204 include. The cylinder 200 includes a hole 204 that has a clutch piston 86 includes, which is preferably formed by a stamping method, and axial teeth 166 used in clutch dividers 84 intervene, the cylinder 200 and the gears 166 formed by any of various methods, including open-die forging.

The rotor 34 the electric machine 28 gets off the pipe 202 stored, the rolled ends 208 has to hold the rotor on the pipe. The pipe 202 can be a seamless pipe or a pipe with a continuous weld. The cylinder 200 is preferably by interference fit on the pipe 202 established.

The hub 40 is preferably by welding on the cylinder 200 established. The hub 40 transmits torque from the electric machine 28 and from the engine through the clutch 22 to the torque converter 49 through the flex plate 42 ,

4 shows that the spline 166 of the cylinder 200 a series of angularly spaced depressions in the bore 206 and raises 210 having. Every increase 210 is at the radial inner surface 212 of the pipe 202 established.

Angularly spaced, axially aligned first channels 214 are through a surface 212 and the gears 166 of the cylinder 200 Are defined. The surfaces of cylinder 200 , which form the recesses, are with a radial hole 216 trained, that with the channel 214 communicates, which is arranged radially outside the respective recess. The cylinder 202 is with a series of axially spaced drain holes 218 trained, each with one of the channels 214 communicate.

5 shows that the rotor 34 with a series of axially aligned second channels 220 is formed, each through a drain hole 218 with one of the channels 214 of the cylinder 200 communicate. Some of the channels 214 get an axially aligned projection 222 which extends radially into the channel, causing the tube 202 , the cylinder 200 and the rotor 34 be connected so as to be a unit around the axis 39 rotate, which prevents the rotor 34 on the outside surface 404 of the pipe 202 rotates.

6 shows that each axial second channel 220 on an end plate 224 . 226 ending at axially opposite ends of the rotor 23 are located. Every end plate 224 . 226 is with a series of radially aligned passages 228 . 230 formed, each passage with one of the second axial channels 220 is aligned.

In operation, centrifugal force causes automatic transmission fluid (ATF) in module 10 through the holes 216 , Channels 214 , Holes 218 , Channels 220 and passages 228 . 230 flows radially outward, thereby removing heat from clutch plates 83 . 84 , from the cylinder 200 , from the pipe 202 and from the rotor 34 from the module 10 is transported away. When the fluid is out of the channels 228 and 230 when the oil is sprayed radially outward due to centrifugal force, the end turns contact the stator 30 and so cool the stator. Due to gravity, ATF falling out of the assembly falls into a sump at the bottom of the module 10 , passes through a radiator and returns to the transmission pan, from which it is drawn into the transmission pump to be recirculated through the hydraulic system.

As required by patent law, the preferred embodiments have been described. It should be understood, however, that alternative embodiments may be practiced other than as specifically illustrated and described.

Claims (20)

Rotor hub comprising: a sheet metal cylinder having gear teeth comprising angularly spaced ridges and valleys; a pipe surrounding the cylinder, which is fixed to the elevations and which supports a rotor; a hub fixed to the cylinder and supported for rotation; a torque converter; a flexplate fixed to the hub and torque converter. The rotor hub of claim 1, wherein the tube and gears define first channels, the cylinder is formed with holes, each hole extends through one of the recesses and communicates with one of the first channels, the tube is formed with drain holes, each drain hole having a hole the first channels communicates. The rotor hub of claim 2, wherein the rotor includes second channels, each second channel communicating with one of the first channels through one of the drain holes. The rotor hub of claim 3, wherein the first channels and the second channels are aligned along a rotational axis. The rotor hub of claim 3, further comprising end plates, each end plate disposed at an opposite end of the rotor and formed with radial passages, each passage communicating with one of the second channels. A rotor hub according to claim 5, wherein the passages are radially aligned with respect to a rotational axis. The rotor hub of claim 1, wherein the tube is one of a seamless tube and a continuous weld tube. A rotor hub according to claim 1, further comprising: a clutch piston disposed in the cylinder; Clutch plates engaged with the gear teeth and capable of being actuated by the piston. Rotor hub comprising: a sheet metal cylinder having gear teeth comprising angularly spaced ridges and valleys; a pipe surrounding the cylinder, which is fixed to the elevations and which supports a rotor; a hub, which is fixed to the cylinder and stored for rotation. The rotor hub of claim 9, wherein the tube and gears define first channels, the cylinder is formed with holes, each hole extends through one of the recesses and communicates with one of the first channels, the tube is formed with drain holes, each drain hole having a hole the first channels communicates. The rotor hub of claim 10, wherein the rotor comprises second channels, each second channel communicating with one of the first channels through one of the drain holes. The rotor hub of claim 11, wherein the first channels and the second channels are aligned along a rotational axis. The rotor hub of claim 11, further comprising end plates, each end plate disposed at an opposite end of the rotor and formed with radial passages, each passage communicating with one of the second channels. The rotor hub of claim 12, wherein the passages are radially aligned with respect to a rotational axis. The rotor hub of claim 9 wherein the tube is one of a seamless tube and a continuous weld tube. A rotor hub according to claim 9, further comprising: a clutch piston disposed in the cylinder; Clutch plates engaged with the gear teeth and capable of being actuated by the piston. A method of forming a rotor hub comprising: Forming a plate cylinder having spline teeth defining angularly spaced ridges and valleys; Defining a pipe surrounding the cylinder at the elevations; Fixing a rotor to the pipe; and Forming a hub which is fixed to the cylinder. The method of claim 17, further comprising securing the tube to the ridges by one of welding and interference fit. The method of claim 17, further comprising forming the cylinder by forging. The method of claim 17, further comprising using a flex plate to connect the hub to a torque converter in a driveable manner.

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