Overload clutch for e-motor rotor
A hybrid drive assembly having an e-motor with a housing fixed stator and a rotor that connects to a transmission. The e-motor rotor includes a rotor support having a mounting flange with a stop at one end. A diaphragm spring clamps a second rotor ring, a rotor stack, and a first rotor ring against the stop to rotationally fix the rotor stack to the mounting flange. A drive plate assembly for connection to a crankshaft includes an output flange that is: (a) frictionally engaged to the diaphragm spring and/or the second rotor ring such that upon application of a torque spike the output flange rotates relative to the diaphragm spring and/or the second rotor ring, or (b) rotationally fixed to the diaphragm spring such that upon application of a torque spike the diaphragm spring rotates relative to the mounting flange, forming in each case an overload clutch.
1. A hybrid drive assembly for a motor vehicle, the hybrid drive assembly comprising:
a housing;
a stator mounted to the housing;
a rotor connected to an input shaft that is adapted to be connected to a transmission, the rotor being rotatably mounted within the stator;
the rotor including a rotor support connected to the input shaft, the rotor support including an axially extending mounting flange with a stop located at one axial end region of the mounting flange, a rotor stack located on the mounting flange, first and second rotor rings located on respective first and second axial sides of the rotor stack, and a diaphragm spring located on the mounting flange on an opposite axial end region from the stop that clamps the second rotor ring, the rotor stack, and the first rotor ring against the stop in order to rotationally fix the rotor stack to the mounting flange; and
a drive plate assembly configured to be connected to a crankshaft of an internal combustion engine, the drive plate assembly including an output flange that (a) is frictionally engaged to at least one of the diaphragm spring or the second rotor ring such that upon application of a torque spike the output flange rotates relative to the at least one of the diaphragm spring or the second rotor ring, or (b) is rotationally fixed to the diaphragm spring such that upon application of a torque spike the diaphragm spring rotates relative to the mounting flange, to form an overload clutch.
2. The hybrid drive assembly of claim 1 , wherein the output flange is rotationally fixed to the diaphragm spring via one or more projections on the output flange engaging in teeth on the diaphragm spring.
3. The hybrid drive assembly of claim 1 , wherein the drive plate assembly includes an input plate that is configured to be connected to the crankshaft, and damper springs located between the input plate and the output flange.
4. The hybrid drive assembly of claim 1 , wherein the input shaft is configured to be supported on one axial end in an opening in an end of the crankshaft.
5. The hybrid drive assembly of claim 1 , further comprising a resolver rotor connected to the rotor and a position sensor connected to the housing.
6. The hybrid drive assembly of claim 5 , wherein the resolver rotor is located on a radially inner side of the mounting flange.
7. The hybrid drive assembly of claim 1 , wherein the input shaft is configured to be connected to a torque converter.
8. The hybrid drive assembly of claim 1 , wherein the drive plate assembly comprises the output flange that is frictionally engaged to the at least one of the diaphragm spring or the second rotor ring, and the drive plate assembly includes an input plate that is configured to be connected to the crankshaft, and the output flange is rotationally fixed to the input plate.
9. The hybrid drive assembly of claim 1 , wherein the drive plate assembly comprises the output flange that is frictionally engaged to the at least one of the diaphragm spring or the second rotor ring, and the drive plate assembly includes an input plate that is configured to be connected to the crankshaft, and damper springs are located between the input plate and the output flange.
10. A method of forming an overload clutch for protecting a hybrid drive arrangement that includes a housing, a stator mounted to the housing, and a rotor connected to an input shaft that is adapted to be connected to a transmission, with the rotor being rotatably mounted within the stator, the method comprising:
providing the rotor with a rotor support connected to the input shaft, the rotor support including an axially extending mounting flange with a stop located at one axial end region of the mounting flange, a rotor stack located on the mounting flange, first and second rotor rings located on respective first and second axial sides of the rotor stack;
pressing a diaphragm spring on the mounting flange on an opposite axial end region from the stop, clamping the second rotor ring, the rotor stack, and the first rotor ring against the stop in order to rotationally fix the rotor stack to the mounting flange; and
providing a drive plate assembly configured to be connected to a crankshaft of an internal combustion engine, the drive plate assembly including an output flange, and one of:
(a) frictionally engaging the output flange to at least one of the diaphragm spring or the second rotor ring such that application of a torque spike causes the output flange to rotate relative to the at least one of the diaphragm spring or the second rotor ring, or
(b) rotationally fixing the output flange to the diaphragm spring such that application of a torque spike causes the diaphragm spring to rotate relative to the mounting flange.
11. The method of claim 10 , wherein the rotationally fixing includes engaging one or more projections on the output flange in teeth on the diaphragm spring.
12. The method of claim 10 , wherein the frictionally engaging includes locating the output flange between the diaphragm spring and the second rotor ring.