TECHNICAL FIELD

[0001] The present disclosure relates generally to a hybrid module, and more specifically to a rotor carrier assembly.

BACKGROUND

[0002] Rotor assemblies are known. One example is shown and described in commonly -assigned United States Patent Publication No. 2016/0105060, hereby incorporated by reference as if set forth fully herein.

BRIEF SUMMARY

[0003] Example aspects broadly comprise a rotor assembly including a torque converter having a housing forming a hydraulic chamber, a rotor for an electric motor, a rotor carrier non-rotatably connected to the rotor, wherein the rotor carrier is fixed to the torque converter housing. The rotor assembly also includes a seal disposed between the rotor carrier and the torque converter housing for sealing the torque converter housing to the rotor carrier. In some embodiments, at least one bolt is provided for fixing the torque converter housing to the rotor carrier. The rotor carrier may include a first aperture formed in an end of the rotor carrier facing the torque converter housing, and the torque converter may include a second aperture. The first aperture is axially aligned with the second aperture, and the at least one bolt is disposed within the first and second apertures to fix the torque converter housing to the rotor carrier.

[0004] In an example embodiment, the seal is a compressible gasket. In an example embodiment, the rotor assembly includes a hardened plate with an aperture and the at least one bolt is disposed in the aperture. The hardened plate is disposed between a head of the bolt and the torque converter housing. In some example embodiments, the rotor carrier is formed from a non-magnetic material or a non-ferrous metal. In other embodiments, the rotor carrier is formed from gold, aluminum, beryllium, lead, magnesium, nickel, platinum, zinc, copper or stainless steel.

[0005] In another embodiment, a rotor assembly includes a torque converter having a torque converter housing, an impeller having a plurality of impeller blades fixed to the torque converter housing, a turbine, and a stator. The rotor assembly further includes a rotor for an electric motor and a rotor carrier having an outer diameter. The rotor is non-rotatably connected to the rotor carrier outer diameter, and the rotor carrier is connected to the torque converter housing by a bolt disposed within a first aperture formed in an axial end of the rotor carrier. In some embodiments the torque converter housing includes a second aperture axially aligned with the first aperture of the rotor carrier such that when the rotor carrier is connected to the torque converter housing, the bolt is disposed within both the first and second apertures.

[0006] In an example embodiment, the rotor assembly has at least one clutch plate drivingly engaged with the rotor carrier. In an example embodiment, at least a portion of the rotor is axially aligned with a stator for the electric motor. Rotor assembly includes a torque converter with the torque converter housing, a plurality of impeller blades fixed to the torque converter housing, and a turbine assembly, stator assembly, and damper assembly disposed within the torque converter housing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The nature and mode of operation of the present disclosure will now be more fully described in the following detailed description taken with the accompanying drawing figures, in which:

[0008] Figure 1 is a partial cross-sectional view of a hybrid module according to an example aspect;

[0009] Figure 2 is a detailed view of Area B of the hybrid module shown in Figure 1 ;

[0010] Figure 3 is a detailed view of an alternative embodiment of Area B of the hybrid module shown in Figure 1.

DETAILED DESCRIPTION

[0011] Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations. [0012] In general, it is important that the rotor of an electric motor does not move relative to its position at the time of calibration to prevent degradation of performance and to prevent excessive imbalance. Embodiments disclosed herein provide a two-piece design that uses a rotor carrier fixed to a torque converter cover by bolts sealed to the cover. The disclosed embodiments provide several advantages that include maintaining the position of the rotor within a hybrid module, thereby improving performance characteristics and preventing imbalance that results from undesirable rotor movement.

[0013] The following description is made with reference to Figures 1-2. Figure 1 is a partial cross-sectional view of a hybrid module 100 according to an example aspect. Figure 2 is a detailed view of Area B of the hybrid module 100 shown in Figure 1. Hybrid module 100 includes housing 102 with stator 104, electric motor 1 16, shaft 106, and rotor assembly 1 10. Rotor assembly 1 10 includes rotor 114 axially aligned with stator 104 of electric motor 1 16, rotor carrier 132, clutch assembly 108, and a launch device such as torque converter 162. Torque converter 162 includes a torque converter housing 1 12 forming a hydraulic chamber 1 13, impeller blades 164 fixed to the torque converter housing 1 12, turbine assembly 166, stator assembly 168, and damper assembly 170.

[0014] Rotor 1 14, for electric motor 1 16, is non-rotatably connected to an outer diameter 172 of rotor carrier 132 and includes at least one rotor segment 130. Although rotor 1 14 is shown to include a plurality of rotor segments, one of ordinary skill in the art would understand that rotor 1 14 may include a single large rotor segment in other embodiments depending on the application and individual system constraints. Rotor carrier 132 includes annular ring 134 extending from rotor carrier 132 outer diameter 172. Annular ring 134 may be integrally formed with rotor carrier 132. By integral, it is meant that the rotor carrier 132 and the annular ring 134 are formed from a single piece of material. Other embodiments (not shown) may include a rotor carrier with a separate annular ring axially retained on the rotor carrier by a snap ring, for example. Rotor carrier 132 may be formed from cast steel, for example. Rotor 1 14 is axially clamped between the torque converter housing 1 12 and the rotor carrier 132 annular ring 134 to prevent movement of the rotor 1 14 for improved performance and reduced imbalance.

[0015] Rotor carrier 132 is fixed to torque converter housing 1 12 by bolt 120. Thus, a fixed connection is established between the rotor carrier 132 and torque converter housing 1 12. Torque is then transmitted from electric motor 1 16 and a combustion engine (not shown) through clutch assembly 108 to torque converter housing 1 12 via this fixed connection. Although only a single bolt 120 is shown, a plurality of bolts disposed about a circumference may be used to fix rotor carrier 132 to torque converter housing 1 12. Seal 1 18 is disposed between the torque converter housing 1 12 and the rotor carrier 132 for sealing the torque converter housing 1 12 to the rotor carrier 132. Seal 1 18 may be a compressible gasket, for example. Seal 1 18 is configured to seal around an aperture 122 formed in an axial end of rotor carrier 132. Torque converter housing 112 includes an aperture 129 formed therein that is aligned axially with the aperture 122 formed in the end of the rotor carrier 132. Rotor assembly 1 10 includes hardened plate 124. Hardened plate 124 is positioned on an inner surface 131 of torque converter housing 1 12 and includes aperture 126 axially aligned with aperture 122 of rotor carrier 132 and aperture 129 of torque converter housing 1 12. Bolt 120 is configured to be threaded through the aperture 126 of hardened plate 124, aperture 129 of torque converter housing 1 12, and then through aperture 122 of rotor carrier 132 for fixing torque converter housing 1 12 to rotor carrier 132 to prevent movement of rotor 1 14. In this manner, hardened plate 124 is disposed axially between head 128 of bolt 120 and an inner surface 131 of the torque converter housing 1 12.

[0016] Rotor assembly 110 further includes non-magnetic annular ring 144, annular ring 136, and non-magnetic annular ring 140 positioned on, or extending from, the outer diameter 172 of rotor carrier 132. Non-magnetic annular ring 144 is disposed axially between rotor 114 and rotor carrier 132 annular ring 134. Non-magnetic annular ring 144 is configured to prevent short circuit of the magnets in rotor 1 14. Annular ring 136 and non- magnetic annular ring 140 are disposed axially between rotor 1 14 and torque converter housing 1 12. Annular ring 136 has a thickness 138 that is selected to ensure that rotor 1 14 is clamped securely between the torque converter housing 1 12 and the rotor carrier 132 annular ring 134. That is, the thickness 138 is selected such that, when the bolt 120 is tightened, a force from the bolt 120 ensures a friction fit such that the rotor 114 does not rotate relative to the rotor carrier 132 or the torque converter housing 1 12. In some embodiments (not shown), annular rings 136 and 140 may be combined into a single non-magnetic annular ring with a thickness selected to ensure that the rotor 1 14 is clamped securely between rotor carrier 132 annular ring 134 and torque converter housing 1 12. Torque converter housing 1 12 includes machined support surface 142 and non-magnetic annular ring 140 contacts the machined support surface 142. Annular rings 144, 136, 140 and rotor 1 14 are slip fit to the rotor carrier 132 outer diameter 172.

[0017] With continual reference to Figure 1, clutch assembly 108 includes clutch plate 148 drivingly engaged with rotor carrier 132. For example, the clutch plate 148 and rotor carrier 132 include complementary splines 146 and 150, respectively, in driving engagement. The rotor carrier spline 150 includes castellated portion 152. Rotor assembly 1 10 also includes rotor carrier flange 154, spring 156, snap ring 158, and retention element 155. Spring 156 may be a diaphragm spring, for example. The spring 156 is disposed axially between the snap ring 158 and the rotor carrier flange 154. Rotor carrier 132 includes groove 160 and the snap ring 158 is disposed in the groove 160. The spring 156 clamps the rotor carrier flange 154 between the snap ring 158 and the castellated portion 152. Retention element 155 is disposed between the spring 156 and the snap ring 158. Retention element 155 may be a shim having at least one tab 157 bent toward the snap ring 158 such that the at least one tab 157 contacts at least a portion of the snap ring 158 to secure the snap ring 158 in the groove 160. Rotor carrier 132 is arranged to non-rotatably engage rotor resolver 159.

[0018] The following description is made with reference to Figure 3. Figure 3 is a detailed view of an alternative embodiment of Area B of hybrid module 100 shown in Figure 1. Rotor assembly 210 is similar to rotor assembly 1 10 and 2XX labels generally correspond to 1XX labels except as described below. Rotor carrier 232 is formed from a non-magnetic or non-ferrous material. For example, rotor carrier 232 may be formed of gold, aluminum, beryllium, lead, magnesium, nickel, platinum, zinc, copper and/or stainless steel. The use of a non-magnetic material for rotor carrier 232 obviates the need for non-magnetic ring 144 shown in rotor assembly 1 10 of Figures 1 and 2. Rotor carrier 232 further includes integral annular ring 234.

[0019] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments outside the scope of the disclosure and can be desirable for particular applications.

[0020] LIST OF REFERENCE CHARACTERS

[0021] 100 Hybrid Module

[0022] 102 Housing

[0023] 104 Stator

[0024] 106 Shaft

[0025] 108 Clutch Assembly

[0026] 110 Rotor Assembly

[0027] 112 Torque Converter Housing

[0028] 1 13 Hydraulic Chamber

[0029] 1 14 Rotor

[0030] 1 16 Electric Motor

[0031] 1 18 Seal

[0032] 120 Bolt

[0033] 122 Aperture

[0034] 124 Hardened Plate

[0035] 126 Aperture

[0036] 129 Aperture

[0037] 128 Head of Bolt

[0038] 130 Rotor Segment

[0039] 131 Inner Surface

[0040] 132 Rotor Carrier

[0041] 134 Annular Ring

[0042] 136 Annular Ring

[0043] 138 Thickness

[0044] 140 Non-Magnetic Annular Ring

[0045] 142 Machined Support Surface

[0046] 144 Non-Magnetic Annular Ring

[0047] 146 Spline

[0048] 148 Clutch Plate

[0049] 150 Spline

[0050] 152 Castellated Portion

[0051] 154 Rotor Carrier Flange [0052] 155 Retention Element

[0053] 156 Spring

[0054] 157 Tab

[0055] 158 Snap Ring

[0056] 159 Resolver

[0057] 160 Groove

[0058] 162 Torque Converter

[0059] 164 Impeller Blades

[0060] 166 Turbine Assembly

[0061] 168 Stator Assembly

[0062] 170 Damper Assembly

[0063] 172 Outer Diameter

[0064] 210 Rotor Assembly

[0065] 232 Rotor Carrier

[0066] 234 Integral Annular Rin;