Axle assembly with lubricant reservoir

Abstract

An axle assembly having a lubricant reservoir. The lubricant reservoir may be positioned above a differential assembly and may capture lubricant splashed by the differential assembly. The lubricant reservoir may have at least one tank. The lubricant reservoir may optionally supply lubricant to a lubricant dispensing tank.

Description

Technical Field

[0001] This disclosure relates to an axle assembly with a lubricant reservoir. background

[0002] U.S. Patent Publication No. 2020 / / 0047613 discloses an axle assembly having an upper lubricant reservoir disposed inside the differential mount.

[0003] Overview

[0004] In at least one embodiment, an axle assembly is provided. The axle assembly may include a differential assembly, a housing assembly, a lubricant reservoir, a first conduit, and a second conduit. The differential assembly is rotatable about an axis and has a ring gear. The housing assembly receives the differential assembly. The lubricant reservoir is disposed above the differential assembly and collects lubricant splashed by the ring gear. The lubricant reservoir has a first canister and a second canister spaced apart from the first canister. The first conduit delivers lubricant from the first canister to an input shaft bearing. The second conduit delivers lubricant from the second canister to an output shaft bearing.

[0005] In at least one embodiment, an axle assembly is provided. The axle assembly may include a differential assembly, a housing assembly, a lubricant reservoir, and a lubricant distribution slot. The differential assembly is rotatable about an axis and has a ring gear. The housing assembly receives the differential assembly. The lubricant reservoir is disposed above the differential assembly and collects lubricant splashed by the ring gear. The lubricant distribution slot receives lubricant from the lubricant reservoir. The lubricant distribution slot includes a first slot, a second slot, and a baffle. The first slot receives lubricant from the lubricant reservoir. The second slot is disposed below the first slot. The baffle separates the first slot from the second slot. Attached Figure Description

[0006] Figure 1 This is a 3D view of an example axle assembly.

[0007] Figure 2 This is a cross-sectional view of the axle assembly along section line 2-2.

[0008] Figure 3 This is a cross-sectional view of a portion of the axle assembly along section line 3-3.

[0009] Figure 4 This is a 3D view of a lubricant reservoir.

[0010] Figure 5 This is a side view of the lubricant reservoir.

[0011] Figure 6 This is an enlarged side view of a portion of the axle assembly, including the lubricant reservoir and lubricant distribution channel. Detailed Implementation

[0012] As requested, detailed embodiments of the invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of how the invention can be implemented in various forms and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but rather serve only as a representative basis for teaching those skilled in the art to employ the invention in various ways.

[0013] refer to Figure 1 An example of axle assembly 10 is shown. Axle assembly 10 can be supplied to any suitable type of vehicle, such as trucks, buses, farm equipment, mining equipment, military transport or armed vehicles, or cargo loading equipment for land, air, or sea vessels. In one or more embodiments, the motor vehicle may include a trailer for transporting cargo.

[0014] Axle assembly 10 may be part of a vehicle drivetrain that provides torque to one or more traction wheel assemblies, which may include tires mounted on wheels. One or more axle assemblies 10 may be provided to the vehicle. For example, axle assembly 10 may be a single drive axle assembly or may be configured as part of a tandem axle configuration or a multi-axle configuration that may include multiple axle assemblies connected in series. An axle assembly 10 operatively connected to at least one torque source (such as an electric motor or internal combustion engine) may be referred to as a first axle assembly. An axle assembly receiving propulsion torque from a torque source via the first axle assembly may be referred to as a second axle assembly. Figure 1 In the image, axle assembly 10 is depicted as a first axle assembly.

[0015] The axle assembly 10 can provide torque to its associated wheel assembly and can also provide torque to the second axle assembly. In at least one embodiment and as referenced Figure 1 and Figure 2 As best shown, the axle assembly 10 may include a housing assembly 20, an input yoke 22, an input shaft 24, a reduction gear set 26, a clutch collar 28, a drive pinion 32, a differential assembly 34, at least one half-shaft 36, an inter-axle differential unit 38, an output shaft 40, an output yoke 42, or combinations thereof. These components are shown to facilitate a brief discussion of the operation of the axle assembly 10. The axle assembly 10 may also include a lubricant reservoir 50, a first conduit 52, and a second conduit 54.

[0016] refer to Figure 1The housing assembly 20 can accommodate various components of the axle assembly 10. Additionally, the housing assembly 20 can facilitate the mounting of the axle assembly 10 to the vehicle. In at least one configuration, the housing assembly 20 may include an axle housing 60 and a differential mount 62.

[0017] The axle housing 60 can receive and support the half-shaft 36. In at least one configuration, the axle housing 60 may include a central portion 70 and at least one arm portion 72.

[0018] The central portion 70 can be positioned close to the center of the axle housing 60. For example... Figure 2 As best shown, the center portion 70 may define an internal cavity that may at least partially receive the differential assembly 34. The internal cavity may also receive a lubricant reservoir 50. A lower region of the center portion 70 may at least partially define an oil pan portion 80 that may contain or collect lubricant 82. Lubricant 82 in the oil pan portion 80 may be splashed by the differential assembly 34 during rotation. Some of the splashed lubricant 82 may be captured or collected by the lubricant reservoir 50, as will be discussed in more detail below. The center portion 70 may also include a bowl-shaped cover 84 that may be configured opposite to the differential mount 62. In at least one configuration, the bowl-shaped cover 84 may be configured as a spherical cap or dome and may surround the side of the center portion 70 configured opposite to the differential mount 62.

[0019] Lubricant 82 (which can be a liquid such as oil) lubricates components of axle assembly 10, such as differential assembly 34 and various bearings. Figure 2 In the diagram, the level of lubricant 82 in the oil pan portion 80 is indicated by a dashed line. The lubricant level is merely an example and may be higher or lower than the depicted level.

[0020] refer to Figure 1 One or more arm portions 72 may extend from the central portion 70. For example, two arm portions 72 may extend from the central portion 70 in opposite directions and away from the differential assembly 34. The arm portions 72 may have similar configurations. For example, each arm portion 72 may have a hollow or tubular configuration that extends around a corresponding half-shaft 36 and helps to separate or isolate the half-shaft 36 from its surroundings. An arm portion 72 or a portion thereof may be integrally formed with the central portion 70. Alternatively, the arm portion 72 may be separate from the central portion 70. In this configuration, each arm portion 72 may be attached to the central portion 70 in any suitable manner, such as by welding or by one or more fasteners. Each arm portion 72 may define an arm cavity that can receive a corresponding half-shaft 36. The arm portions 72 and arm cavities may be positioned above the oil pan portion 80.

[0021] Main reference Figure 2 The differential mount 62 can be mounted to the central portion 70 of the axle housing 60. The differential mount 62 can support the differential assembly 34. In at least one configuration, the differential mount 62 may include a flange portion 90. The differential mount 62 may also include at least one differential bearing support 92, such as... Figure 3 As best shown.

[0022] refer to Figure 2 The flange portion 90 can facilitate mounting the differential mount 62 to another component of the axle assembly 10 (such as the axle housing 60). For example, the flange portion 90 can be positioned close to and engage with the center portion 70 of the axle housing 60, and can have a set of holes that can receive fasteners (such as bolts) that can connect the differential mount 62 to the axle housing 60.

[0023] refer to Figure 3 The differential bearing support 92 can receive the bearing 100, which can rotatably support the differential assembly 34. Figure 3 For clarity, the bearing cap that may arch over the bearing 100 is omitted. The bearing 100 can have any suitable configuration. For example, the bearing 100 can be a roller bearing assembly. In the configuration shown, two differential bearing supports 92 are provided to the differential mount 62. The differential bearing supports 92 can be received inside the central portion 70 of the axle housing 60 and can be positioned close to opposite ends of the differential assembly 34.

[0024] refer to Figure 1 and Figure 2 The input yoke 22 facilitates the connection of the axle assembly 10 to the torque source. The input yoke 22 is operatively connected to the input shaft 24. (As...) Figure 2 As best shown, the input seal 110 can be positioned adjacent to the input yoke 22. The input seal 110 can be at least partially received within a bore in the differential mount 62 and can surround the input yoke 22. It is conceivable that, for example, when a torque source (e.g., an electric motor) is coupled to the axle assembly 10, the input yoke 22 and the input seal 110 can be omitted.

[0025] refer to Figure 2An example of an input shaft 24 is shown. The input shaft 24 may extend along a first axis 120 and may rotate about this first axis. For example, the input shaft 24 may be rotatably supported by one or more bearings (such as input shaft bearing 130) that may be disposed on the housing assembly 20. The input shaft bearing 130 may be mounted to the differential mount 62 and may surround the input shaft 24. Furthermore, the input shaft bearing 130 may be positioned close to the input seal 110. The input shaft 24 may be operatively connected to the inter-axle differential unit 38.

[0026] The reduction gear set 26 is operatively connected to the input shaft 24 and the drive pinion 32. The reduction gear set 26 may include a first gear 140 and a second gear 142.

[0027] A first gear 140 (which may also be referred to as a drive gear) is rotatably mounted on an input shaft 24. Furthermore, the first gear 140 can be selectively engaged with the input shaft 24 via a clutch collar 28. For example, when the clutch collar 28 engages the first gear 140 with the input shaft 24, the first gear 140 can rotate about a first axis 120 with the input shaft 24, and when the clutch collar 28 does not engage the first gear 140 with the input shaft 24, the first gear 140 can rotate about the first axis 120 relative to the input shaft 24. In at least one configuration, the first gear 140 may have a central bore and an optional bearing that receives the input shaft 24 and rotatably supports the first gear 140 on the input shaft 24. In at least one configuration, the first gear 140 may include external gear teeth 150, face gear teeth 152, and side gear teeth 154.

[0028] The external gear teeth 150 can engage and mesh with the teeth on the second gear 142. The external gear teeth 150 can extend away from the first axis 120 and can be arranged around the outer diameter of the first gear 140.

[0029] The face gear teeth 152 may include a set of teeth that may be arranged on one side or one side of the first gear 140 that is away from the inter-axle differential unit 38 and faces the clutch collar 28. The face gear teeth 152 may selectively engage the teeth on the clutch collar 28, for example, when the clutch collar 28 connects the first gear 140 to the input shaft 24.

[0030] Side gear teeth 154 may be disposed on the side of the first gear 140 opposite to the face gear teeth 152. Side gear teeth 154 may be arranged around the first axis 120 and may face one or more pinions 196 and may mesh with one or more pinions, which may be disposed inside the inter-axle differential unit 38.

[0031] The second gear 142 (which may also be referred to as the driven gear) is rotatable about the second axis 160. For example, a drive pinion 32 may be received in the center hole of the second gear 142, and the second gear 142 may be fixedly mounted on or connected to the drive pinion 32 such that the second gear 142 and the drive pinion 32 can rotate together about the second axis 160. The second gear 142 may include a plurality of teeth that may be arranged generally around the outer diameter of the second gear 142 and may engage or mesh with the teeth of the external gear teeth 150 of the first gear 140. The second axis 160 may be configured to be substantially parallel to the first axis 120. As used herein, the term “substantially parallel” means parallel or very close to parallel, and includes features or axes that are parallel to each other within ±2°.

[0032] refer to Figure 2 The clutch collar 28 (if provided) may be movable along the first axis 120 to engage or disengage the first gear 140. For example, the clutch collar 28 may have a spline that can mate with a corresponding spline on the input shaft 24, such that the clutch collar 28 can rotate about the first axis 120 with the input shaft 24 and can be movable relative to the input shaft 24 along the first axis 120. The clutch collar 28 may have a clutch collar face gear that can selectively engage with the face gear teeth 152 of the first gear 140.

[0033] The drive pinion 32 can operatively connect a torque source to the differential assembly 34. The drive pinion 32 can be spaced apart from the input shaft 24 and can be configured to rotate about an axis, such as a second axis 160. The drive pinion 32 can rotate with the second gear 142. It is also conceivable that, in other configurations, such as when the first gear 140 and the second gear 142 are omitted, or when the output shaft 40 extends through the drive pinion 32, the drive pinion 32 can rotate about a first axis 120. The gear portion can be located at one end of the drive pinion 32.

[0034] refer to Figure 2 and Figure 3The differential assembly 34 may be received within the housing assembly 20. For example, the differential assembly 34 may be at least partially received within the axle housing 60. The differential assembly 34 may be rotatable about an axis (e.g., differential axis 170). In at least one configuration, the differential axis 170 may be arranged substantially perpendicular to the second axis 160. The term "substantially perpendicular" is used herein to refer to a feature or axis that is the same as or very close to perpendicular to the axis, and includes features within ±2° of each other. The differential assembly 34 may transmit torque to the half-shaft 36 and the wheels. For example, the differential assembly 34 may be operatively connected to the half-shaft 36 and may allow the half-shaft 36 to rotate at different speeds of rotation in a manner known to those skilled in the art. The differential assembly 34 may have a ring gear 180 having teeth that can engage or mesh with the teeth of the gear portion of the drive pinion 32. Thus, the differential assembly 34 may receive torque from the drive pinion 32 via the ring gear 180 and transmit torque to the half-shaft 36. For example, the ring gear 180 can be fixedly mounted to the housing of the differential assembly 34. The housing can receive a gear operatively connected to the half-shaft 36. The ring gear 180 can rotate about the differential axis 170 with the housing, and when the ring gear rotates, it can splash lubricant 82 that has accumulated in the oil pan portion 80.

[0035] refer to Figure 1 The half-shaft 36 can transmit torque from the differential assembly 34 to the corresponding hub and wheel. The half-shaft 36 can extend along an axis and be rotatable about that axis, which can be the differential axis 170. Each half-shaft 36 can have a first end and a second end. The first end is operatively connected to the differential assembly 34. The second end can be arranged opposite to the first end and is operatively connected to the wheel.

[0036] refer to Figure 2 An example of an inter-axle differential unit 38 is shown. The inter-axle differential unit 38 can accommodate or compensate for rotational speed differences between different drive axle assemblies, such as the speed difference between axle assembly 10 and a second axle assembly connected in series with axle assembly 10. The inter-axle differential unit 38 can be positioned in various locations. Figure 3In this configuration, the inter-axle differential unit 38 is disposed within the differential mount 62 on the input shaft 24; however, it is conceivable that the inter-axle differential unit 38 may be disposed in other locations, such as closer to the output yoke 42 or together with the second axle assembly. It is also conceivable that the inter-axle differential unit 38 may be disposed on a shaft other than the input shaft 24. In at least one configuration, the inter-axle differential unit 38 may include a housing 190 that can receive an inter-axle differential unit gear nest. The inter-axle differential unit gear nest may include a plurality of gears that operatively connect the input shaft 24 to the output shaft 40. In at least one configuration, the inter-axle differential unit gear nest may include a side gear 192, a spoke 194, and one or more pinions 196.

[0037] The side gear 192 may extend partially into the housing 190. The side gear 192 may be mounted to the output shaft 40. Thus, the side gear 192 may be able to rotate about the first axis 120 with the output shaft 40.

[0038] The spoke 194 may be fixedly mounted on the input shaft 24. For example, the spoke 194 may include a center bore that may include a plurality of splines that can mate with corresponding splines on the input shaft 24 to help align and secure the spoke 194 to the input shaft 24. Thus, the spoke 194 can rotate about a first axis 120 with the input shaft 24. The spoke 194 may also include one or more pins that can extend away from the center bore of the spoke 194.

[0039] One or more pinions 196 may be rotatable relative to the spokes 194. For example, pinions 196 may be rotatably mounted on pins of the spokes 194. Pinions 196 may include a plurality of teeth that may mesh or engage with the side gear teeth 154 of the first gear 140 and may mesh or engage with the teeth of the side gear 192.

[0040] refer to Figure 2 The output shaft 40 may extend along an axis (e.g., the first axis 120) and may be configured to rotate about that axis. For example, the output shaft 40 may be supported by one or more bearings (e.g., output shaft bearing 200) that may be disposed on the axle housing 60. The output shaft bearing 200 may be mounted to the axle housing 60 and may surround the output shaft 40. The output shaft 40 may be fixedly coupled to the side gear 192.

[0041] refer to Figure 1 and Figure 2The output yoke 42 can facilitate the coupling of axle assembly 10 to another axle assembly. For example, the output yoke 42 can be fixedly coupled to the output shaft 40 and can be operatively connected to a second axle assembly in any suitable manner (e.g., via a driveshaft). Figure 2 As best shown, the output seal 210 can be positioned adjacent to the output yoke 42. For example, the output seal 210 can be at least partially received within a bore in the axle housing 60 and can surround the output yoke 42. It is conceivable that, in various configurations, the output yoke 42 and the output seal 210 can be omitted.

[0042] refer to Figure 2 and Figure 3 A lubricant reservoir 50 may be disposed above the differential assembly 34. The lubricant reservoir 50 can trap lubricant 82 splashed by the differential assembly 34. For example, when the ring gear 180 rotates about the differential axis 170, the lubricant reservoir 50 can trap lubricant 82 splashed by the ring gear 180. The lubricant reservoir 50 may be positioned above the first axis 120. Furthermore, the lubricant reservoir 50 may be received within the axle housing 60, such that the lubricant reservoir 50 can be spaced apart from the cup-shaped cover 84. The lubricant reservoir 50 may have an integral configuration or may be configured as a one-piece component. In at least one configuration and as referenced... Figure 4 As best shown, the lubricant reservoir 50 may have a first tank 220, a second tank 222, a main board 224, a bridge 226, and a lip 228.

[0043] refer to Figure 3 The first canister 220 can be positioned above the output shaft 40 and the first axis 120. In at least one configuration, the teeth of the ring gear 180 can face the first canister 220. For example... Figure 4 As best shown, the first can 220 may have an upward-facing inlet 230 and at least one outlet 232, the inlet being able to receive splashed lubricant. The first can 220 may be defined by a plurality of plates. For example, the first can 220 may be at least partially defined by a main plate 224, and may be further defined by an end plate 240, a base plate 242, a ramp plate 244, a boss plate 246, an inner side plate 248, an outer side plate 250, or a combination thereof.

[0044] End plate 240 can be configured opposite to and spaced apart from main plate 224. Thus, end plate 240 can be opposite to axle housing 60, differential mount 62, or both. End plate 240 can extend upward from base plate 242. In at least one configuration, end plate 240 can be configured substantially parallel to main plate 224.

[0045] The base plate 242 can extend between the main plate 224 and the end plate 240. For example, the base plate 242 can extend from the main plate 224 to the end plate 240. The base plate 242 can be positioned closer to the differential axis 170 than the other plates of the first plate 220. Figure 5 Ideally, the base plate 242 can be tilted downwards from the end plate 240 toward the main plate 224.

[0046] refer to Figure 4 and Figure 5 The ramp plate 244 can extend between the base plate 242 and the boss plate 246. In at least one configuration, the ramp plate 244 can extend at an angle such that the ramp plate 244 can extend further from the differential axis 170 or further upward as the distance from the ring gear 180 increases.

[0047] The boss plate 246 may extend between the ramp plate 244 and the outer plate 250. The boss plate 246 may be positioned above the differential axis 170 relative to the base plate 242. The boss plate 246 may be positioned directly above the output shaft 40 and the first axis 120. In at least one configuration, the boss plate 246 may extend substantially parallel to the first axis 120.

[0048] Main reference Figure 3 and Figure 4 The inner side plate 248 can extend from the main plate 224 to the end plate 240. Furthermore, the inner side plate 248 can extend from the base plate 242 to the bridge member 226. The inner side plate 248 can face the ring gear 180.

[0049] The outer side plate 250 can be configured opposite to and spaced apart from the inner side plate 248. The outer side plate 250 can extend from the main plate 224 to the end plate 240. Furthermore, the outer side plate 250 can extend from the boss plate 246 to the upward-facing inlet 230 and to the lip 228. The outer side plate 250 can follow the curvature of the inner side of the central portion 70 of the axle housing 60.

[0050] Main reference Figure 3 and Figure 4The second can 222 may be spaced apart from the first can 220. The ring gear 180 may be positioned between the first can 220 and the second can 222 and may extend therebetween. The second can 222 may be disposed above the differential bearing support 92. Compared to the first can 222, the second can 220 may hold the same volume of lubricant 82 or a different volume of lubricant 82. In the illustrated configuration, the second can 222 has a larger volume than the first can 220. The second can 222 may have an upward-facing inlet 230' and at least one outlet 232', the inlet being able to receive splashed lubricant. The second can 222 may be defined by multiple plates. For example, the second can 222 may be at least partially defined by a main plate 224, and may be further defined by an end plate 240', a bottom plate 242', a ramp plate 244', an inner side plate 248', an outer side plate 250', or a combination thereof.

[0051] End plate 240' can be configured opposite to and spaced apart from main plate 224. Thus, end plate 240' can be opposite to axle housing 60, differential mount 62, or both. End plate 240' can extend upward from base plate 242'. In at least one configuration, end plate 240' can be configured substantially parallel to main plate 224 and coplanar with end plate 240 of first tank 220. In the illustrated configuration, outlet 232' of second tank 222 is provided to end plate 240'; however, it is contemplated that outlet 232' can be provided to other plates of second tank 222.

[0052] The base plate 242' can extend between the main plate 224 and the end plate 240'. For example, the base plate 242' can extend from the main plate 224 to the end plate 240'. The base plate 242' can be positioned closer to the differential axis 170 than the other plates of the second tank 222. In at least one configuration, the base plate 242' can be positioned directly above the differential bearing support 92. Figure 5 As best shown, the base plate 242' can be inclined downwards from the main plate 224 toward the end plate 240'. Furthermore, compared to the arrangement of the base plate 242' of the second tank 222 relative to the oil pan portion 80, the base plate 242 of the first tank 220 can be positioned higher than the oil pan portion 80. In one or more configurations, the base plate 242 can be positioned above the first axis 120, while the base plate 242' can be positioned below the first axis 120.

[0053] refer to Figure 3 and Figure 4 The ramp 244' can extend between the base plate 242' and the outer plate 250'. In at least one configuration, the ramp 244' can extend at an angle such that the ramp 244' can extend further from the differential axis 170 or further upward as the distance from the ring gear 180 increases.

[0054] The inner side plate 248' can extend from the main plate 224 to the end plate 240'. Furthermore, the inner side plate 248' can extend from the base plate 242' to the bridge member 226. The inner side plate 248' can face the ring gear 180. In at least one configuration and as shown... Figure 3 As best shown, the inner side plate 248' may have a non-planar configuration and may be configured such that at least a portion of the inner side plate 248' extends toward the first tank 220 as the distance from the differential axis 170 increases.

[0055] The outer side plate 250' can be configured opposite to and spaced apart from the inner side plate 248'. The outer side plate 250' can extend from the main plate 224 to the end plate 240'. Furthermore, the outer side plate 250' can extend from the ramp plate 244' to the upward-facing inlet 230' and to the lip 228. The outer side plate 250' can follow the curvature of the inner side of the central portion 70 of the axle housing 60.

[0056] Main reference Figure 3 and Figure 4 Main plate 224 may partially define first canister 220 and second canister 222. Main plate 224 may face differential mount 62 and may engage the central portion 70 of axle housing 60. Furthermore, main plate 224 may extend vertically from bridge 226 to lip 228. In at least one configuration, main plate 224 may be positioned substantially perpendicular to the first axis 120 and may include one or more recesses that may receive the ends of fasteners that can engage the differential mount 62 to the axle housing 60. In the illustrated configuration, an outlet 232 of the first canister 220 is provided to end plate 224; however, it is contemplated that outlets 232 may be provided to other plates of the first canister 220.

[0057] Bridging member 226 interconnects the first can 220 and the second can 222. Bridging member 226 can extend above and beyond the ring gear 180. Furthermore, bridging member 226 can guide lubricant 82 splashed by the ring gear 180 and falling onto the top of bridging member 226 to the first can 220 and the second can 222. For example, as... Figure 3 As best shown, the bridging member 226 may protrude or may project upward at a position positioned directly above the ring gear 180, and thus at least a portion of the bridging member 226 may be away from the protrusion and tilted toward the first can 220, the second can 222, or both.

[0058] Main reference Figure 4The lip 228 can be positioned near the top of the lubricant reservoir 50. The lip 228 can extend from the main plate 224 in a direction extending over the first reservoir 220, the second reservoir 222, the bridging member 226, or a combination thereof. The lip 228 can engage the inner side of the central portion 70 of the axle housing 60 and can extend from the first reservoir 220 to the second reservoir 222. For example, the lip 228 can extend from the outer side plate 250 of the first reservoir 220 over the bridging member 226 and to the outer side plate 250' of the second reservoir 222.

[0059] refer to Figure 2 and Figure 4 The first conduit 52 can be fluidly connected to the outlet 232 of the first tank 220. From Figure 2 From the angle shown, the first conduit 52 is concealed behind the output shaft 40. The first conduit 52 can have any suitable configuration. For example, the first conduit 52 can be configured as a tube, pipe, conduit, channel, hose, etc. In at least one configuration, the first conduit 52 can deliver lubricant along a route from the first reservoir 220 to the input seal 110, the input shaft bearing 130, or a combination thereof. For example, the first conduit 52 can extend between the main plate 224 and the input shaft bearing 130.

[0060] The second conduit 54 can be fluidly connected to the outlet 232' of the second tank 222. From Figure 2 From the angle shown, the second conduit 54 is concealed behind the output shaft 40. The second conduit 54 can have any suitable configuration as previously discussed with respect to the first conduit 52. In at least one configuration, the second conduit 54 can deliver lubricant 82 along a route from the second reservoir 222 to the output shaft bearing 200, the output seal 210, or a combination thereof. For example, the second conduit 54 can extend between the end plate 240' of the second reservoir 222 and the output shaft bearing 200. In one or more configurations, the first conduit 52, the second conduit 54, or both can be angled downwards away from the lubricant reservoir 50 to further facilitate the flow of lubricant 82. Thus, the first reservoir 220 and the first conduit 52 can lubricate components different from the second reservoir 222 and the second conduit 54. This can be achieved by having a single conduit extending from each reservoir 220, 222.

[0061] refer to Figure 6 This illustrates another configuration for distributing lubricant in axle assemblies. Figure 6 Similar to Figure 2 However, it is shown as a side view rather than a cross-sectional view, and the periphery of the housing assembly 20 is omitted for clarity. This configuration may include a lubricant reservoir 50' and a lubricant dispensing channel 260.

[0062] The lubricant reservoir 50' may have a configuration similar to or the same as the lubricant reservoir 50 discussed previously. For example, the lubricant reservoir 50' may have one or more tanks and may receive lubricant 82 splashed by the differential assembly 34. At least one tank of the lubricant reservoir 50' may supply lubricant 82 to the lubricant distribution tank 260 via a conduit (such as the first conduit 52').

[0063] The lubricant dispensing tank 260 can receive lubricant 82 from the lubricant reservoir 50'. The lubricant dispensing tank 260 can be positioned at a lower height than the lubricant reservoir 50'. In at least one configuration, the lubricant dispensing tank 260 may include a first tank 270, a second tank 272, and a dam 274. The lubricant level in the lubricant dispensing tank 260 is exemplary and may be higher or lower than the depicted level.

[0064] The first groove 270 can receive lubricant 82 from the lubricant reservoir 50'. For example, lubricant 82 exiting the first conduit 52' can flow into the first groove 270. The first groove 270 may have an outlet that can supply or direct lubricant 82 to the input seal 110, the input shaft bearing 130, or both. The flow of lubricant through the outlet is indicated by an arrow extending from the left end of the first groove 270.

[0065] The second groove 272 can be located below the first groove 270. Thus, the bottom of the second groove 272, or a portion thereof, can be located at a lower height than the bottom of the first groove 270. In the illustrated configuration, the bottom of the second groove 272 is located below the first axis 120, while the bottom of the first groove 270 is located above the first axis 120. The second groove 272 can provide lubricant 82 to components that may be located between the input shaft bearing 130 and the differential assembly 34. For example, the second groove 272 can provide lubricant 82 to the reduction gear set 26, the inter-axle differential unit 38, or both. In at least one configuration, the second groove 272 can be divided into an upper portion 280 and a lower portion 282.

[0066] The upper portion 280 extends from the baffle 274 to the lower portion 282. The upper portion 280 can be raised relative to the lower portion 282. For example, the upper portion 280 can be positioned at a height lower than the first groove 270 and a height higher than the lower portion 282. In at least one configuration, the upper portion 280 can have an outlet that supplies lubricant 82 to the reduction gear set 26, the inter-axle differential unit 38, the bearings supporting these components, or combinations thereof. The outlet is indicated by an arrow line extending downward from the bottom of the upper portion 280.

[0067] The lower portion 282 (if provided) may extend from the upper portion 280 toward the differential assembly 34. In at least one configuration, the lower portion 282 may receive lubricant 82 splashed by the differential assembly 34, as indicated by the curved arrow line near the right end of the lower portion 282.

[0068] A baffle 274 separates the first slot 270 from the second slot 272. The baffle 274 protrudes upwards from the bottom of the first slot 270. Thus, lubricant 82 entering the first slot 270 can be temporarily stored in the first slot 270. The lubricant 82 can exit the first slot 270 in two main ways. First, as previously discussed, the lubricant 82 can exit the first slot 270 through an outlet to lubricate the input seal 110, the input shaft bearing 130, or both. Furthermore, when the level of lubricant 82 exceeds the volume of lubricant 82 that can be stored behind the baffle 274, the lubricant 82 can flow across the top of the baffle 274. When the differential assembly 34 rotates at medium to high speeds, the volume of lubricant 82 supplied to the first slot 270 can exceed the storage capacity of the first slot 270, causing the lubricant 82 to overflow from the top of the baffle 274 and flow into the second slot 272. Excess lubricant 82 can exit the second reservoir 272 and flow into the oil pan portion 80. When the differential assembly 34 is stationary and lubricant 82 has not splashed into the lubricant reservoir 50', the lubricant reservoir 50' can be empty. Therefore, the flow of lubricant 82 from the lubricant reservoir 50' to the first reservoir 270 can be reduced at lower rotational speeds, and this flow can stop once the lubricant reservoir 50' is empty. Even without splash lubrication to the first reservoir 270, lubricant 82 trapped behind the baffle 274 can exit through the outlet to lubricate components (such as the input shaft bearing 130) instead of exceeding the baffle 274. Alternatively, lubricant 82 can be routed to the lubricant distribution reservoir 260 to lubricate various components for a limited period of time, such as during low-speed operating conditions, during which splash lubrication is minimal.

[0069] The flow rate through any of the outlets of the lubricant distribution channel 260 can be actively or passively controlled to help supply lubricant 82 to various components over an extended period of time.

[0070] Optionally, the lubricant reservoir 50', the second tank 272, or both may have a second conduit 54' that can supply lubricant to the output shaft bearing 200, the output seal 210, or both. It is also conceivable that the second conduit 54' may be omitted and the second tank 272 may be open. It is also conceivable that the second conduit may be as follows: Figure 2 It is configured in that way and can accept lubricant from lubricant reservoir 50' instead of lubricant dispensing tank 260.

[0071] The axle assembly described above allows for the placement of a lubricant reservoir in a raised position to trap splashed lubricant. Trapping the lubricant in a reservoir located outside the oil pan helps reduce drag and churning losses on the differential assembly, which in turn helps improve the operating efficiency of the axle assembly. The trapped lubricant can be distributed to components located away from the differential assembly and in areas where splashed lubricant cannot reach in sufficient quantity. Furthermore, the axle assembly described above can store lubricant and aid in lubricating components when the differential assembly is not rotating. For example, if torque is not supplied to the differential assembly, such as by disengaging torque transmission via the reduction gear set and by disconnecting the differential assembly from its associated wheels, the differential assembly cannot rotate and lubricant cannot splash. However, when torque is transferred from one axle assembly to another, components such as the input shaft, output shaft, inter-axle differential unit, and associated bearings can still rotate. This invention can store lubricant and distribute it to these components and the bearings associated with them to help reduce friction, wear, and operating temperature, which can help increase component life.

[0072] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terminology used herein is descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the invention. Furthermore, features of various implementations of the embodiments can be combined to form other embodiments of the invention.

Claims

1. An axle assembly, comprising: A differential assembly, the differential assembly being rotatable about an axis and having a ring gear; A housing assembly having an axle housing and a differential mount supporting the differential assembly, wherein the differential mount is mounted to the axle housing and the axle housing receives the differential assembly; A lubricant reservoir, disposed above the differential assembly inside the axle housing and capturing lubricant splashed by the ring gear, the lubricant reservoir having a first tank and a second tank spaced apart from the first tank; A first conduit, which follows a route to deliver lubricant from the first tank to the input shaft bearing; and The second conduit, following a specific route, delivers lubricant from the second tank to the output shaft bearing.

2. The axle assembly as claimed in claim 1, wherein, The ring gear extends between the first tank and the second tank.

3. The axle assembly as claimed in claim 1, wherein, The first tank is positioned above the output shaft.

4. The axle assembly as claimed in claim 1, wherein, The second tank is positioned above the differential bearing support, which receives a bearing capable of rotatably supporting the differential assembly.

5. The axle assembly as claimed in claim 1, wherein, The lubricant reservoir includes a bridging member that extends above the ring gear and interconnects the first tank and the second tank.

6. The axle assembly as claimed in claim 5, wherein, The bridging component guides the lubricant splashed by the ring gear to the first and second tanks.

7. The axle assembly as claimed in claim 5, wherein, The lubricant reservoir has a lip that engages the axle housing and extends over the bridge member, wherein the lip extends from the first reservoir to the second reservoir.

8. The axle assembly as claimed in claim 7, wherein, The lubricant reservoir has a main board extending from the bridging member to the lip and partially defining the first and second cans.

9. The axle assembly as claimed in claim 7, wherein, The lubricant reservoir has a main plate that partially defines the first and second tanks and faces the differential mount.

10. The axle assembly of claim 9, wherein, The first tank has an end plate configured opposite to the main board and a bottom plate sloping downward from the end plate toward the main board.

11. The axle assembly of claim 10, wherein, The first conduit extends from the main board.

12. The axle assembly of claim 10, wherein, The second tank has an end plate configured opposite to the main board and a bottom plate sloping downward from the main board toward the end plate.

13. The axle assembly of claim 12, wherein, The second conduit extends from the end plate.

14. The axle assembly of claim 12, wherein, Compared to the second tank, where the bottom plate is positioned relative to the oil pan portion, the first tank's bottom plate is positioned further away from the oil pan portion of the axle housing.

15. An axle assembly, comprising: A differential assembly, the differential assembly being rotatable about an axis and having a ring gear; A housing assembly that receives the differential assembly; A lubricant reservoir is disposed above the differential assembly and collects the lubricant splashed by the ring gear; as well as A lubricant dispensing tank, the lubricant dispensing tank receiving lubricant from the lubricant reservoir, the lubricant dispensing tank comprising: A first slot receives lubricant from the lubricant reservoir; A second slot, wherein the second slot is disposed below the first slot; and A baffle that separates the first slot from the second slot.

16. The axle assembly of claim 15, wherein, The first groove provides lubricant to the input shaft bearing that rotatably supports the input shaft.

17. The axle assembly of claim 16, wherein, The second groove provides lubricant to the inter-axle differential unit and the reduction gear set, which is operatively connected to the input shaft and the drive pinion that meshes with the ring gear of the differential assembly.

18. The axle assembly of claim 15, wherein, The second groove receives lubricant splashed up by the differential assembly.

19. The axle assembly of claim 15, wherein, The second groove is divided into an upper portion and a lower portion, wherein the upper portion extends from the baffle to the lower portion and is raised relative to the lower portion.

20. The axle assembly of claim 19, wherein, The upper portion provides lubricant to the inter-axle differential unit and reduction gear set, and the lower portion receives lubricant splashed by the differential assembly.

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