DE102016214514A1 - Hybrid module with fully integrated separating and double clutches - Google Patents

Abstract

The invention relates to a hybrid module (1) for a drive train of a motor vehicle, comprising a electric machine (4) having a stator (2) and a rotor (3), a disconnect clutch (5) with a first clutch component (6) for non-rotatable connection prepared with an output shaft of an internal combustion engine and with a second coupling component (7) rotatably connected to the rotor (3), and one with the rotor (3) operatively connected dual clutch (8), wherein both the separating clutch (5) and the double clutch ( 8) are arranged radially inside the electric machine (4); and a powertrain for a hybrid vehicle having a hybrid module (1).

Description

The invention relates to a hybrid module, i. a hybridized / hybrid multiple clutch, for a powertrain of a motor vehicle, such as a car, truck, bus or other commercial vehicle, with a stator and a rotor having electric machine (also referred to as an electric motor), a separating clutch with a first coupling component for rotationally fixed Connection with an output shaft of an internal combustion engine, such as a diesel or gasoline engine, prepared and rotatably connected to a second coupling component is connected to the rotor, as well as an operatively connected to the rotor dual clutch.

Generic prior art is known from DE 10 2009 059 944 A1 known. Disclosed herein is a hybrid module for a powertrain of a vehicle, which hybrid module includes a first disconnect clutch, an electric motor, and a second disconnect clutch. The first separating clutch is arranged in the torque flow in the drive train between an internal combustion engine and the electric motor and the second separating clutch in the torque flow in the drive train between the electric motor and a transmission.

In the hybrid modules known from the prior art, however, it has proven to be disadvantageous that they are often relatively bulky. Especially in the axial direction most hybrid modules occupy a relatively large amount of space, so that their use for smaller or smallest vehicles is relatively limited so far. In addition, their construction is relatively complex, so that there are disadvantages in terms of manufacturing costs.

It is therefore the object of the present invention to remedy these known from the prior art disadvantages and in particular to provide a hybrid module available, which is designed so space-optimized that it should be as versatile as possible.

This is inventively achieved in that both the separating clutch and the dual clutch (i.e., the two part couplings belonging to the double clutch) are arranged radially inside the electric machine.

By this arrangement of the couplings of the hybrid module to each other, the hybrid module per se in the axial direction designed particularly short construction. The versatility of the hybrid module thus increases significantly.

Further advantageous embodiments are claimed in the subclaims and explained in more detail below.

If the separating clutch and the dual clutch are arranged in a common wet chamber, which in turn is arranged radially and / or axially within the electric machine, the required installation space is further reduced.

If the disconnect clutch and the dual clutch are in the axial direction of the hybrid module within the electric machine, i. arranged within two opposite axial end faces of the electric machine, preferably of the stator and / or the rotor, the hybrid module is further optimized space.

Furthermore, it is advantageous if the separating clutch and the dual clutch in each case have a plurality of mutually rotatably connectable connecting elements which are arranged in the radial direction of the hybrid module (approximately / approximately) at the same height (relative to a rotational axis of the hybrid module). Connecting elements of the separating clutch are preferably arranged at the same radial height as connecting elements of the double clutch. As a result, the space is exploited even more efficiently radially within the electric machine.

If the separating clutch and the dual clutch are arranged side by side in the axial direction of the hybrid module, the structure of the hybrid module is further simplified and the production costs are further reduced.

It is furthermore advantageous if at least one of the clutches, preferably each partial clutch of the double clutch, is / are actuated with a preferably hysteresis-free or hysteresis-poor hydraulic first actuating system. As a result, a particularly direct actuation of the clutches is implemented.

In this context, it is also particularly useful if the first actuating system has a biased by a metal bellows and the position of the respective coupling predetermining first pressure element. As a result, a particularly skilled training of the actuation system is realized. In turn, space can be saved significantly and the hysteresis properties of the actuation system can be further optimized.

If at least one of the clutches, preferably the separating clutch, is actuated with a preferably hysteresis-free or hysteresis-poor hydraulic second actuating system, the operation of the hybrid module is further increased in efficiency.

In this regard, it is particularly advantageous if the second actuation system has a second one Having pressure element forming membrane element. This makes it possible to operate a very short operating hysteresis-free.

In this context, it is again advantageous if the first actuation system and / or the second actuation system (in each case) have / has a centrifugal force compensation unit. As a result, the operation of the hybrid module is made even more efficient.

Furthermore, the invention relates to a powertrain for a hybrid vehicle, i. a hybrid motor vehicle, with a hybrid module according to at least one of the embodiments described above. As a result, the drive train is designed to be particularly effective.

In other words, thus, an actuating system for a separating clutch of a hybrid module of the parallel type, having a small hysteresis, implemented. The solution according to the invention serves, in particular, to further reduce the installation space of the hybrid module and, on the other hand, to enable a simple assembly of the hybrid module according to the parallel type. In a hybrid module of the parallel type, a separating clutch, a first partial clutch and a second partial clutch of a double clutch are arranged in series, viewed in the axial direction, relative to each other and substantially at a common distance to a rotational axis of the hybrid module; Furthermore, the couplings have a substantially common / same dimension in the radial direction. In this case, a wet chamber is preferably arranged completely within the electric machine of the hybrid module according to the parallel type. Furthermore, preferably in the hybrid module of the parallel type, the disconnect clutch has an actuator (first actuation system) that has little or no hysteresis. As a result, a simplified assembly is secured, so that specific sub-assemblies are defined, which are interconnected in a predetermined order. Further, the disconnect clutch as incorporated in the parallel type hybrid module may include an integrated return spring which, in turn, may take on various shapes and configurations of a bellows to implement various spring rates.

The invention will now be explained in more detail below with reference to various figures, in which context also different embodiments are shown in principle.

Show it:

1 a longitudinal sectional view of a hybrid module according to the invention according to a first embodiment, wherein the formation of the hybrid module on the part of his electric machine and clutches is clearly visible,

2 a perspective view of a rigid connected by means of several bolts housing the electric machine, as in the hybrid module according to 1 is used, wherein the housing is shown cut in the longitudinal direction, so that the attachment can be seen via one of the bolts in the form of a bolt,

3 a schematic exploded view of the hybrid module according to 1 wherein the assembly process for assembling the hybrid module is shown schematically,

4 a detailed view of the longitudinally cut hybrid module after 1 in the region of a first partial clutch of the double clutch, wherein a, acting on the first partial clutch acting, first actuating system is shown in the structure,

5 a detailed longitudinal sectional view of a first actuating system in the region of two metal bellows, said first actuating system is used in a hybrid module of a second embodiment, and wherein the respective metal bellows in particular has an additional reinforcement compared to the first embodiment,

6 a detailed longitudinal sectional view of a first actuating system in the region of two metal bellows, which actuating system is used in a hybrid module of a third embodiment, and wherein the cross-sectional shape of the respective metal bellows is now carried out somewhat differently,

7 a detailed longitudinal sectional view of a first actuating system in the region of two metal bellows, which actuating system is used in a hybrid module of a fourth embodiment, with a further variable formations of the respective metal bellows,

8th a detailed view of the hybrid module according to the first embodiment in the region of a (second) actuating system of the separating clutch, wherein the second actuating system is provided with a membrane element,

9 another detail view of the in 8th marked with IX section of the second actuating system, wherein a centrifugal balance unit having additional Recording chamber of the second operating system can be seen in detail, and

10 a detailed longitudinal sectional view of a hybrid module according to a fifth embodiment, wherein a plate spring of the centrifugal balance unit of the second actuating system is rubberized.

The figures are merely schematic in nature and are for the sole purpose of understanding the invention. The same elements are provided with the same reference numerals. Also, the different features of the various embodiments can be combined freely with each other. The various embodiments are essentially the same structure and functioning, which is why below for the second to fifth embodiments, only their differences from the first embodiment are described.

In 1 is a hybrid module according to the invention 1 according to a preferred first embodiment in longitudinal section particularly well recognizable. The hybrid module 1 is in an operating state part of a drive train of a hybrid vehicle and is in particular in the torque flow between an internal combustion engine, which is not shown here for clarity, or an electric machine 4 and a transmission, also not shown here for clarity. The hybrid module 1 basically has several couplings 5 and 8th on that with the electric machine 4 , under formation of the hybrid module 1 , are combined.

A disconnect clutch 5 (Also referred to as the first clutch / K0 clutch) of the hybrid module 1 serves to couple an output shaft of the internal combustion engine with a (rotor) fixed component 23 a rotor 3 the electric machine 4 , This is a first coupling component 6 , preferably in the form of a clutch disc, the clutch 6 , prepared for non-rotatable connection with the output shaft of the internal combustion engine. The first coupling component 6 is in 1 rotatably with a further coupled to the output shaft connection shaft portion 24 connected. A second coupling component 7 the separating clutch 5 is with the rotor fixed component 23 rotatably connected, wherein the rotorfest component 23 a rotor housing 25 of the rotor 3 forms / has. The first coupling component 6 has a first connection element 11a and the second coupling component 7 has a second connecting element 12a on. The connecting elements 11a and 12a are due to the design of the disconnect clutch 5 designed as a friction clutch in the form of friction plates / friction elements. The two connecting elements 11a and 12a are then typically in an engaged position of the disconnect clutch 5 rotatably, under frictional engagement, interconnected and in a disengaged position of the clutch 5 torque transferless to each other, ie freely rotatable relative to each other, arranged.

Also, in the hybrid module 1 a double clutch 8th integrated. The double clutch 8th again has two partial clutches 13 and 14 , here again in the form of a friction clutch, on. The two partial clutches 13 and 14 in turn have a first coupling component 26 . 28 and a second coupling component 27 and 29 on.

A first partial clutch 13 (also referred to as second clutch / K1 clutch) of the dual clutch 8th has a first coupling component 26 on, in the operating state with a first transmission input shaft 30 the transmission is rotatably connected. With a second coupling component 27 is the first part clutch 13 again rotatably with the rotor fixed component 23 coupled / connected. The two clutch components 26 and 27 the first part clutch 13 in turn have first and second fasteners 11b . 12b in the form of friction disks / friction disks, which in an engaged position of the first part clutch 13 reibkraftschlüssig / rotatably connected to each other and are arranged freely rotatable in a disengaged position to each other.

The second part clutch 14 (also referred to as third clutch / K2 clutch) of the dual clutch 8th is according to the first part clutch 13 designed. Here is a first coupling component 28 the second part clutch 14 rotatably with another, second transmission input shaft 31 connected to the transmission. A second coupling component 29 this second part clutch 14 is in turn rotationally fixed with the rotor-fixed component 23 coupled / connected. Also the two clutch components 28 and 29 the second part clutch 14 in turn have first and second fasteners 11c . 12c in the form of friction disks / friction disks, which in an engaged position of the second part clutch 14 reibkraftschlüssig / rotatably connected to each other and are arranged freely rotatable in a disengaged position to each other.

Due to its construction with the various fasteners 11a to 11c . 12a to 12c are the separating clutch 5 , the first part clutch 13 and the second part clutch 14 Also referred to as multi-plate clutches.

The rotor resistant component 23 of the rotor 3 is especially good in connection with 2 to recognize. The rotor resistant component 23 also serves as a receiving housing for the couplings 5 and 8th ,

Coming back to 1 it can be seen that in the assembled state of the hybrid module 1 on a radial outside of the rotor-fixed component 23 one the rotor 3 with forming rotor coil 32 is attached. The rotor coil 32 as well as the rotorfest component 23 form the rotor 3 the electric machine 4 out. A stator 2 the electric machine 4 , opposite to the rotor 3 is rotatably mounted, is fixed in a housing 33 of the hybrid module 1 appropriate. According to the invention, the electric machine 4 with her rotor 3 as well as her stator 2 designed so that both the separating clutch 5 as well as the double clutch 8th integral radial and axial within the electric machine 4 are arranged. In particular, the couplings 5 and 8th integral radially within the rotor coil 32 of the rotor 3 arranged. The separating clutch 5 as well as the double clutch 8th are in the axial direction of the hybrid module 1 seen within two opposite axial end faces 9 and 10 the electric machine 4 arranged. The two front sides 9 and 10 be through two axial ends of the stator 2 , namely by the side of a stator coil 34 of the stator 2 arranged electronic connections, formed.

Within the axial dimensions of the stator 2 is a wet chamber 35 that the couplings 5 and 8th picks up, completely arranged. The wet chamber 35 is again sealed / closed to the environment. The wet chamber 35 thus serves to form the clutches 5 and 8th as wet-running couplings.

Also is in 1 to realize that the fasteners 11a . 11b . 11c . 12a . 12b . 12c the couplings 5 and 8th are arranged in total on a same radial height. In particular, the connecting elements 11a . 11b . 11c . 12a . 12b . 12c all have a same radial outer and a radial inner diameter. Thus, the first connecting elements 11a to 11c each have a specific first inner diameter and a specific first outer diameter, and the second connecting elements 12a to 12c each have a certain second inner diameter and a certain second outer diameter. It can also be seen that the connecting elements 11a to 11c and 12a to 12c are lined up next to each other in the axial direction.

Combined with 3 is particularly well a schematic assembly principle of the hybrid module 1 illustrated according to the preferred first embodiment. This is an assembly of housing 33 and stator 2 compiled. The rotor 3 is on an intermediate assembly, which is the disconnect clutch 5 as well as the first part clutch 13 has, applied. An actuator unit comprising the actuation systems 15 . 36 the two partial clutches 13 and 14 the double clutch 8th , is also provided. In addition, another intermediate assembly, the second part clutch 14 has provided. After assembly of the individual components of the hybrid module 1 These are connected one after another, so that the holistic assembly after 1 results.

Combined with 4 is a further aspect of the invention illustrated. 4 shows a detailed representation of a (first) actuating system 15 the first part clutch 13 , The first actuation system 15 is essentially very similar to another, third actuation system 36 constructed and functioning, the third operating system 36 the second part clutch 14 assigned.

The first actuation system 5 has a first pressure element 17 on that in the axial direction of the hybrid module 1 ie along a rotation axis 37 of the hybrid module 1 , is arranged displaceably. The first actuation system 15 is designed as a piston-less actuator and has an axially fixed support 38 on. The first printing element 17 is by means of two metal bellows 16a and 16b relative to the support element 38 resiliently biased in the axial direction. The first printing element 17 serves as an actuator of the first part clutch 13 and thus for engagement or disengagement of the first part clutch 13 , The first actuation system 15 is designed so hydraulically that when a force applied between the support element 38 , the first printing element 17 as well as the metal bellows 16a and 16b trained (first) pressure chamber 39 (the first operating system 15 ) the first pressure element 17 in the axial direction against the connecting elements 11b and 12b is pressed and this pushes into the engaged position. In the disengaged position of the first part clutch 13 is the first printing element 17 again arranged without pressure and by the connecting elements 11b and 12b spaced or unpressurized to these adjacent. To reset the first pressure element 17 relative to the support element 38 serve the metal bellows 16a . 16b that train return springs.

In the first operating system 15 is also a first centrifugal balancing unit 21 intended. The first centrifugal balance unit 21 acts holistically at increasing speeds so shifting on the first pressure element 17 in that the restoring force of the metal bellows 16a . 16b is supported. For this purpose, a compensation adjustment element 40 the first centrifugal balance unit 21 to one of the fasteners 11b and 12b facing axial side of the first pressure element 17 supported. Also the balancing actuator 40 is by means of a (third) metal bellows 16c , this metal bellows 16c again serves as a return spring, axially biased. When increasing the speed of the hybrid module, a centrifugal force compensation is implemented. It will be in another (second) pressure chamber 41 the first centrifugal balance unit 21 , between an axially fixed component and the Ausgleichsstellelement 40 built up an increased pressure and due to the prevailing centrifugal forces reduced contact pressure of the first pressure element 17 at the connecting elements 11b and 12b causes. This ensures that the first pressure element 17 Reliable openable even at high speeds.

Also the third operating system 36 the second part clutch 14 is with two metal bellows serving as return springs 16d and 16e to form a (third) pressure chamber 42 fitted. The metal bellows 16d and 16e tension for actuating the second part clutch 14 Serving, further (third) pressure element 43 resetting relative to an axially fixed component.

In conjunction with the 5 to 7 are alternative forms of metal bellows 16a to 16e listed. Exemplary are the two metal bellows 16a and 16b of the first actuation system 15 however, these are also principal design alternatives of metal bellows 16c to 16e represent. In principle, it can be seen that the individual metal bellows 16a and 16b can also have more than just two folds, about three / three and a half folds.

The metal bellows 16a and 16b can according to 5 also one reinforcement each 44 have as an additional stiffening plate. The reinforcement 44 can extend over the entire length of the respective metal bellows 16a . 16b However, in its axial extent, it is limited here and in particular extends only substantially over two folds. The reinforcement 44 always has an additional restoring effect on the geometry of the metal bellows 16a and 16b ,

According to 6 It is also possible, the cross-sectional shape of the metal bellows 16a and 16b to shape differently. While at least a first fold of the respective metal bellows 16a . 16b When viewed in cross-section is Ω-shaped, at least one further fold is U / V-shaped.

Also, as in 7 recognizable, it is possible the individual folds of the metal bellows 16a and 16b In the radial direction in their dimension to perform differently.

In conjunction with the 8th and 9 is then an area of the hybrid module 1 after the 1 to 4 on a second actuation system 18 shown. The second actuation system 18 serves to actuate the separating clutch 5 , For this purpose, the second actuating system 18 a membrane element 19 / a diaphragm spring in the form of a second pressure element 20 on. The membrane element 19 is supported on the one hand fixed to the housing, on the other hand on the connecting elements 11a and 12a the separating clutch 5 created in the axial direction. Depending on a pressure state in a fourth pressure chamber 45 becomes the membrane element 19 pivots and accordingly the separating clutch 5 actuated.

Furthermore, it can be seen that the second actuating system 18 a (second) centrifugal force compensation unit 22 having. The second centrifugal balance unit 22 works in principle like the first centrifugal force compensation unit 21 , For this purpose is a receiving chamber 46 , which in turn has a fifth pressure chamber 48 forms, radially within the membrane element 19 and the fourth pressure chamber 45 arranged. In addition, a plate spring 47 as a return element in the receiving chamber 46 arranged.

Combined with 10 It can be seen that it is also possible in principle, this disc spring 47 to rubberize, ie to design with a rubberized coating. Also, the receiving chamber 46 is something different ausgestaltbar.

In other words, according to the invention is thus an axial or radial dual clutch assembly 8th with an integrated coupling K0 5 in the wet area 35 for hybridization (decoupling or connection of the combustor) implemented. Here is a direct return spring 16a to 16e integrated. The design of the restoring forces is implemented by a different bellows geometry. This different spring rate can be achieved by the following changes in the characteristics: a) different wall thicknesses, b) variable bellows profiles, c) partial double walling through two sheet thicknesses. The K1 / K2 13 . 14 is preferably with a low hysteresis actuation system 15 designed. In this case, a simple pre-assembly in a unit as sub-assembly is possible. The K0 5 can be directly in the wet room 35 the double clutch 8th be arranged. In addition, a simple assembly with clamping ring and diaphragm spring, which press the module constantly possible. A membrane-based construction on a modular basis has the advantage that an actuation module 18 can be configured, which is particularly hysteresis-free. An integrated centrifugal oil balance is optional. In this case, the arrangement with in the membrane module 18 including Fliehölkompensation be configured as a sub-assembly or the arrangement with membrane module 18 including centrifugal oil compensation and rubberized diaphragm spring 47 be configured as Fliehölraumtrennung.

LIST OF REFERENCE NUMBERS

1

 hybrid module

2

 stator

3

 rotor

4

 electric machine

5

 separating clutch

6

 first coupling component of the separating clutch

7

 second coupling component of the separating clutch

8th

 Double coupling

9

 first end face

10

 second end face

11a

 first connecting element of the separating clutch

11b

 first connecting element of the first part coupling

11c

 first connecting element of the second partial coupling

12a

 second connecting element of the separating clutch

12b

 second connecting element of the first part clutch

12c

 second connecting element of the second partial coupling

13

 first part clutch

14

 second part clutch

15

 first actuation system

16a

 first metal bellows

16b

 second metal bellows

16c

 third metal bellows

16d

 fourth metal bellows

16e

 fifth metal bellows

17

 first pressure element

18

 second actuation system

19

 membrane element

20

 second pressure element

21

 first centrifugal force compensation unit

22

 second centrifugal force compensation unit

23

 rotor-resistant component

24

 Connection shaft section

25

 Rotor receiving housing

26

 first coupling component of the first part clutch

27

 second coupling component of the first part clutch

28

 first coupling component of the second part clutch

29

 second coupling component of the second part clutch

30

 first transmission input shaft

31

 second transmission input shaft

32

 rotor coil

33

 casing

34

 stator

35

 wet chamber

36

 third actuation system

37

 axis of rotation

38

 supporting

39

 pressure chamber

40

 Compensating actuator

41

 second pressure chamber

42

 third pressure chamber

43

 third pressure element

44

 reinforcement

45

 fourth pressure chamber

46

 receiving chamber

47

 Belleville spring

48

 fifth pressure chamber

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102009059944 A1 [0002]

Claims (10)

Hybrid module ( 1 ) for a drive train of a motor vehicle, with a stator ( 2 ) and a rotor ( 3 ) having electric machine ( 4 ), a separating clutch ( 5 ) fitted with a first coupling component ( 6 ) for the rotationally fixed connection with an output shaft of an internal combustion engine and with a second coupling component ( 7 ) rotatably with the rotor ( 3 ), as well as one with the rotor ( 3 ) Actively connected double clutch ( 8th ), characterized in that both the separating clutch ( 5 ) as well as the double clutch ( 8th ) radially inside the electric machine ( 4 ) are arranged. Hybrid module ( 1 ) according to claim 1, characterized in that the separating clutch ( 5 ) and the double clutch ( 8th ) in the axial direction of the hybrid module ( 1 ) within two opposite axial end faces ( 9 . 10 ) of the electric machine ( 4 ) are arranged. Hybrid module ( 1 ) according to claim 1 or 2, characterized in that the separating clutch ( 5 ) and the double clutch ( 8th ) in each case a plurality of non-rotatably connectable connecting elements ( 11a . 11b . 11c . 12a . 12b . 12c ), which in the radial direction of the hybrid module ( 1 ) are arranged at the same height. Hybrid module ( 1 ) according to one of claims 1 to 3, characterized in that the separating clutch ( 5 ) and the double clutch ( 8th ) in the axial direction of the hybrid module ( 1 ) are arranged side by side. Hybrid module ( 1 ) according to one of claims 1 to 4, characterized in that at least one of the couplings ( 5 . 8th ) with a, preferably hysteresis-free or hysteresis-poor, hydraulic first actuation system ( 15 ) is actuated. Hybrid module ( 1 ) according to claim 5, characterized in that the first actuating system ( 15 ) by means of a metal bellows ( 16a . 16b ) biased and the position of the respective coupling ( 8th ) predetermining first pressure element ( 17 ) having. Hybrid module ( 1 ) according to one of claims 1 to 6, characterized in that at least one of the clutches ( 5 ) with a, preferably hysteresis-free or hysteresis-poor, hydraulic second actuation system ( 18 ) is actuated. Hybrid module ( 1 ) according to claim 7, characterized in that the second actuating system ( 18 ) a second pressure element ( 20 ) forming membrane element ( 19 ) having. Hybrid module ( 1 ) according to one of claims 5 to 8, characterized in that the first actuating system ( 15 ) and / or the second actuating system ( 18 ) a centrifugal force compensation unit ( 21 . 22 ) exhibit. Drive train for a hybrid vehicle with a hybrid module ( 1 ) according to one of claims 1 to 9.

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