Hybrid drive module having a rotor secured to a hub via staking

Patent metadata

Field	Value
Publication number	US-9917482-B2
Application number	US-201514872664-A
Country	US
Kind code	B2
Filing date	Oct 1, 2015
Priority date	Oct 9, 2014
Publication date	Mar 13, 2018
Grant date	Mar 13, 2018

Abstract

A hybrid drive module including: a torque converter with a cover, an impeller and a turbine; a rotor for an electric motor; a hub non-rotatably connected to the rotor and the cover and including a circumferential surface and a plurality of protrusions extending radially outward from the circumferential surface; and an end plate disposed between the plurality of protrusions and the rotor and engaged with the end plate and the rotor. The plurality of protrusions is formed of a material forming the hub and restrains the end plate and the rotor, with respect to the hub, in an axial direction.

First claim

What is claimed is:

1. A hybrid drive module, comprising:
a torque converter including:
a cover;
an impeller; and,
a turbine;

a rotor for an electric motor, the rotor including a magnet;
a hub non-rotatably connected to the rotor and the cover and including:
a first circumferential surface; and,
a first plurality of protrusions:
extending radially outward from the first circumferential surface; and,
formed of a material forming the hub; and,

an end plate:
not part of the rotor;
made of a non-magnetic material;
disposed between the first plurality of protrusions and the rotor; and,
engaged with the rotor, wherein:
the first plurality of protrusions restrains the end plate and the rotor, with respect to the hub, in a first axial direction; and,
the end plate blocks movement of the magnet in the first axial direction.

2. The hybrid drive module of claim 1 , wherein the first plurality of protrusions fixes an axial position of the rotor on the hub.

3. The hybrid drive module of claim 1 , wherein:
the material forming the hub, with the exception of the first plurality of protrusions and material adjoining the first plurality of protrusions, has a first number of lattice defects including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume; and,
the material forming the first plurality of protrusions has a second number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume greater than the first number of lattice defects per unit of volume.

4. The hybrid drive module of claim 1 , wherein the first plurality of protrusions is in contact with the end plate and urges the end plate into contact with the rotor in a second axial direction, opposite the first axial direction.

5. The hybrid drive module of claim 1 , wherein the hub includes:
a second circumferential surface; and,
a second plurality of protrusions:
extending radially outward from the second circumferential surface; and,
formed of the material forming the hub, the hybrid drive module further comprising:

a resolver rotor engaged with the second circumferential surface, wherein the second plurality of protrusions fixedly secures the resolver rotor to the hub.

6. The hybrid drive module of claim 1 , further comprising:
an input part arranged to receive torque; and,
a disconnect clutch including:
at least one first clutch plate non-rotatably connected to the hub;
an inner carrier non-rotatably connected to the input part;
at least one second clutch plate non-rotatably connected to the inner carrier; and,
a piston plate axially displaceable to open and close the disconnect clutch.

7. A hybrid drive module, comprising:
a torque converter including:
a cover;
an impeller; and,
a turbine;

a rotor for an electric motor;
an end plate;
a hub non-rotatably connected to the rotor and the cover and including:
a first circumferential surface; and,
a first plurality of protrusions:
extending radially outward beyond the first circumferential surface;
formed of the material forming the hub; and,
restraining the rotor, with respect to the hub, in a first axial direction; and,

a spring located between the rotor and the first plurality of protrusions for the hub and urging the rotor in a second axial direction, opposite first axial direction.

8. The hybrid drive module of claim 7 , wherein:
the first plurality of protrusions are in contact with the end plate; and,
the spring reacts against the end plate to urge the rotor in the second axial direction.

9. The hybrid drive module of claim 7 , wherein:
the material forming the hub, with the exception of the first plurality of protrusions and material adjoining the first plurality of protrusions, has a first number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume; and,
the material forming the first plurality of protrusions has a second number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume greater than the first number of lattice defects per unit of volume.

10. The hybrid drive module of claim 7 , wherein:
the rotor includes at least one magnet;
the end plate is made of a non-magnetic material; and,
the end plate restrains the at least one magnet in the first axial direction.

11. The hybrid drive module of claim 7 , further comprising:
an input part arranged to receive torque; and,
a disconnect clutch including:
at least one first clutch plate non-rotatably connected to the hub;
an inner carrier non-rotatably connected to the input part;
at least one second clutch plate non-rotatably connected to the inner carrier; and,
a piston plate axially displaceable to open and close the disconnect clutch.

12. The hybrid drive module of claim 11 , wherein:
for a first mode:
the disconnect clutch is open to enable independent rotation of the hub and the inner carrier; and,
the rotor is the only source of torque for the torque converter;

for a second mode:
the disconnect clutch is closed to non-rotatably connect the hub and the inner carrier; and,
the input part is the only source of torque for the torque converter; and,

for a third mode:
the disconnect clutch is closed to non-rotatably connect the hub and the inner carrier; and,
the rotor provides torque to the input part via the disconnect clutch.

13. A method of securing components to a hub of a hybrid drive module including a torque converter and a disconnect clutch, comprising:
non-rotatably connecting a rotor for an electric motor to a first circumferential surface of a hub;
placing an end plate on the first circumferential surface;
inserting a spring between the end plate and the rotor;
compressing, using a first punch, the spring between the end plate and the rotor;
urging, with the spring, the rotor in a first axial direction;
deforming, using a second punch, material forming the hub to form a first plurality of protrusions extending radially outward from the first circumferential surface;
contacting the end plate with the first plurality of protrusions; and,
restraining, with the first plurality of protrusions, displacement of the end plate and the rotor, with respect to the hub, in a second axial direction, opposite the first axial direction.

14. The method of claim 13 , further comprising:
engaging a resolver rotor with a second circumferential surface of the hub;
deforming, using the second punch or a third punch, the material forming the hub to form a second plurality of protrusions extending radially outward from the second circumferential surface; and,
fixedly securing the resolver rotor to the hub with the second plurality of protrusions.

15. The method of claim 13 , further comprising:
deforming the material forming the hub such that:
the material forming the hub, with the exception of the first plurality of protrusions and material adjoining the first plurality of protrusions, has a first number of lattice defects including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume; and,
the material forming the first plurality of protrusions has a second number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume greater than the first number of lattice defects per unit of volume.

16. The method of clai

Assignees

• Schaeffler Technologies Ag

Inventors

• Lindemann Patrick M
• Steinberger Markus
• Payne Matthew

Classifications

• B60K2006/4825

  Electric machine connected or connectable to gearbox input shaft · CPC title

• Y10S903/902

  Prime movers comprising electrical and internal combustion motors · CPC title

• B60K6/48

  Parallel type · CPC title

• B60K6/40

  characterised by the assembly or relative disposition of components · CPC title

• H02K7/108 Primary

  with friction clutches · CPC title