Drive unit assembly and drive train

Abstract

The utility model relates to a driving unit assembly. In some examples, an assembly includes an oil shroud element (214) configured to surround a lower portion of at least one rotating gear of a transmission, and an oil inlet element (216) having an oil filter and an oil outlet (222) configured to be coupled to a pump (122) of an oil recirculation circuit, where the oil inlet element (216) is in face-to-face common contact with the oil shroud element (214). In addition, the utility model further relates to a transmission system.

Description

Technical Field

[0001] The utility model relates to a drive unit assembly in a vehicle, more specifically, to a drive unit assembly with a lubricant shield and lubricant pickup features, and further, to a transmission system. Background Art

[0002] Various transmission systems are used to transfer a certain amount of rotational power generated by a rotational power source to one or more driven components. For example, the rotational power source can be an engine or motor that generates a certain amount of rotational power required to drive one or more wheel assemblies. Typically, a vehicle transmission system includes one or more drive unit assemblies that transfer a certain amount of rotational power generated by the engine to one or more wheel assemblies of the vehicle. A conventional drive unit assembly includes one or more gears meshed together in a housing. In order to increase the overall life and durability of the drive unit assembly, a certain amount of lubricating fluid (e.g., oil) is contained in the housing to lubricate the gears of the drive unit assembly. Conventional drive unit assemblies may be subject to various parasitic and / or churning losses, which are caused by the resistance provided by the gears rotating through the lubricating fluid. This reduces the overall efficiency of the drive unit assembly and reduces the size of the rotational power transmitted from the engine to the vehicle wheels.

[0003] Other attempts to address lubrication churning losses include shielding at least one gear of the drive unit assembly from excess lubricating fluid. Tanaka et al. show an example approach in U.S. Pat. No. 9,309,958. Therein, a lubricant shield is configured to cover a gear train within a housing. The housing includes an extraction port that directs the exhausted lubricating fluid to a passageway disposed outside the housing before being pumped through a lubricating fluid recirculation circuit.

[0004] However, the inventors herein have recognized potential problems with such a system. A drive unit assembly including a shielding element within a housing and a pump lubricating fluid (e.g., oil) pickup element external to the housing may require a large vertical packaging space. The large vertical packaging space required at the bottom of the drive unit assembly may reduce the ground clearance of a vehicle in which the drive unit assembly is positioned. Simply moving the pump oil pickup element into the drive unit assembly housing may not reduce the required vertical packaging space because the housing may have to be made larger to accommodate both the shielding element and the pump oil pickup element. Utility Model Content

[0005] In one example, the above problem can be solved by an assembly including an oil shield element configured to surround a lower portion of at least one rotating gear of a gearbox, and an oil inlet element having an oil filter and an oil outlet, the oil outlet configured to be connected to a pump of an oil recirculation circuit, wherein the oil inlet element is in common contact with the oil shield element surface. In this way, the oil shield element and the oil inlet element can be combined into a single component, which is configured to be vertically positioned below the rotating gear of the drive unit assembly, wherein the gear, the oil shield element, the oil pick-up of the oil inlet element, and the oil outlet of the oil inlet element are all laterally aligned along a common axis. By combining the oil shield element and the oil inlet element into a single / common component, the oil shield element can provide structural aspects to facilitate packaging the oil inlet element into an existing space in the housing of the drive unit assembly while maintaining an appropriate gap above the bottom inner surface of the housing to allow oil pickup. For example, the bottom surface of the oil shield element can form a portion of the top of the oil inlet element and can support a cantilevered oil pick-up to allow oil to be picked up at the center of the housing. In doing so, the vertical packaging space required for the drive unit assembly can be reduced while maintaining sufficient clearance within the housing of the drive unit assembly. In addition, by positioning the oil shielding element, the oil pick-up, and the oil outlet of the oil sucking element along a common lateral axis, the lateral space occupied by the oil shielding element and the oil sucking element can be minimized to facilitate incorporation into the housing of the drive unit assembly.

[0006] It should be understood that the above utility model summary is provided to introduce a selection of concepts further described in the detailed description in a simplified form. It is not meant to identify key or essential features of the claimed subject matter, and the scope of the claimed subject matter is uniquely defined by the claims following the detailed description. In addition, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic diagram of the vehicle powertrain;

[0008] Figure 2 is an example transmission with an integrated oil guard and pump oil pickup;

[0009] Figure 3 yes Figure 2 Front view of the integrated oil guard and pump oil pickup;

[0010] Figure 4 yes Figure 2 Bottom perspective view of the integrated oil shield and pump oil pickup;

[0011] Figure 5 yes Figure 2 a top perspective view of the front side of the integrated oil shield and pump oil pickup of FIG. 1 ; and

[0012] Figure 6 yes Figure 2 A second top perspective view of the rear side of the integrated oil shroud and pump oil pickup. DETAILED DESCRIPTION

[0013] The following description relates to a drive unit assembly having a single component that provides both oil shielding features and pump oil pick-up features. Figure 1 A vehicle having a powertrain including a drive unit assembly and a lubrication system for supplying lubricant to the drive unit assembly to reduce component wear is depicted. Figure 2 An example drive unit assembly is shown having an integrated oil shield and pump oil pickup positioned near the bottom of the drive unit assembly housing. Figure 3-6 Shows Figure 2 Different views of the integrated oil guard and pump oil pickup in. Figure 2-6 Shown to scale, but other relative dimensions may be used.

[0014] Figure 1 A vehicle 100 with a powertrain 102 according to the present disclosure is schematically shown. In different embodiments, the vehicle 100 can take a variety of forms, such as light, medium or heavy vehicles. In order to generate power, the powertrain 102 may include a prime mover 104. The prime mover 104 may include an internal combustion engine, an electric motor, a combination thereof, or other suitable devices designed to generate rotational energy. The internal combustion engine may include conventional components, such as one or more cylinders, one or more pistons, valves, a fuel delivery system, an intake system, an exhaust system, etc. In addition, in some cases, the electric motor may include conventional components, such as a rotor, a stator, a housing, etc., for generating mechanical power and electricity during a regeneration mode. Therefore, the powertrain 102 can be used in a hybrid or electric vehicle (e.g., a battery electric vehicle). Therefore, in some cases, the powertrain 102 may have a parallel, series or series-parallel hybrid configuration. However, in other examples, the vehicle 100 can use an internal combustion engine alone to generate electricity.

[0015] The motive power source 104 may provide mechanical power to the differential 108 via the transmission 106. The power path may continue through the differential 108 and reach the first drive wheel 110 and the second drive wheel 112 via the first axle shaft 114 and the second axle shaft 116, respectively. In this way, during certain operating conditions, the differential 108 may distribute the rotational drive force received from the transmission 106 to the first drive wheel 110 and the second drive wheel 112 of the first axle shaft 114 and the second axle shaft 116, respectively.

[0016] The transmission 106 may have a gear reducer that provides a speed-torque conversion function. Specifically, the transmission 106 may be a gearbox capable of shifting gears, a continuously variable transmission, a continuously variable transmission, etc. The transmission 106 may utilize mechanical components such as shafts, gears, bearings, etc. to achieve the aforementioned gear reduction function.

[0017] The differential 108 may be designed to allow speed deviations between the axle shafts during certain conditions, such as during cornering. However, to increase vehicle traction, the differential 108 may be a limited slip differential designed to limit speed deviations between the first axle shaft 114 and the second axle shaft 116 during certain conditions. To achieve this speed limiting function, the differential 108 may include a housing, a set of pinion gears, and side gears.

[0018] Figure 1 Also shown is a lubrication system 118 designed to supply lubricant (e.g., natural and / or synthetic oil) to components of the transmission 106. In one example, to distribute the lubricant, the lubrication system 118 may include a reservoir 120 (e.g., an oil sump), a pump 122 for driving the flow of lubricant through the system, a plurality of conduits 124, and / or other suitable lubricant distribution components such as nozzles, valves, injectors, etc. In the illustrated example, the plurality of conduits 124 lead from the pump 122 to the transmission 106 and from the transmission 106 to the reservoir 120. In addition, the differential 108 may include a closed splash lubrication arrangement. In such an example, as the differential 108 rotates, lubricant may be picked up from the reservoir 126 in the differential 108 and distributed to various components of the differential 108. Thus, in one example, the lubricant in the differential 108 may be self-contained and may not be in fluid communication with the lubricant conduits in the transmission 106. However, in other examples, lubricant may be directed between the transmission 106 and the differential 108 and from the differential 108 to the reservoir 120. In yet other examples, the reservoir 120 may not be an external reservoir, but may be incorporated into the transmission 106. Furthermore, in some examples, the differential 108 may be housed within the transmission 106. Thus, lubricant may be passively supplied (e.g., splashed) from the reservoir 120 to the transmission 106 and / or the differential 108. In some examples, lubricant may also be directed between the transmission 106 and the prime mover 104, and from the prime mover 104 to the reservoir 120. Other lubricant directing schemes have been envisioned, such as a conduit arrangement that causes lubricant to flow in parallel through the transmission 106 and the differential 108.

[0019] The vehicle 100 may include a control system 128 having a controller 130. The controller may include a processor 132 and a memory 134 having instructions stored therein, which when executed by the processor 132 causes the controller 130 to perform various methods, control techniques, etc. described herein. The processor 132 may include a microprocessor unit and / or other types of circuits. The memory 134 may include known data and storage media, such as random access memory, read-only memory, keepalive memory, combinations thereof, etc. The memory 134 may also include non-transitory memory.

[0020] The control system 128 may receive various signals from sensors 136 located at various locations in the vehicle 100 and the powertrain 102. Conversely, the controller 130 may send control signals to a plurality of actuators 138 coupled at various locations in the vehicle 100 and the powertrain 102.

[0021] For example, the controller 130 can send a signal to the prime mover 104. In response to the received command signal, the actuator in the prime mover 104 can adjust the output speed or torque. Other controllable components in the vehicle and transmission system can function in a similar manner based on the received command signal and actuator adjustment. For example, the pump 122 can receive a control signal that triggers the adjustment of the pump actuator to change the output flow of the pump 122. In addition, during the driving mode, for example, the controller 130 can adjust the prime mover 104 to achieve the desired vehicle speed. In contrast, during the gliding mode, the prime mover 104 can be inactive and power can travel from at least one of the first drive wheel 110 and the second drive wheel 112 to the differential 108, etc.

[0022] Figure 2 2 shows a drive unit assembly 200 according to the present disclosure. Figure 2 as well as Figure 3-6 Each of the axes includes a Cartesian coordinate system 299 to orient the view. In one example, the y-axis can be a vertical axis (e.g., parallel to the gravity axis), the x-axis can be a longitudinal axis (e.g., a horizontal axis), and / or the z-axis can be a transverse axis. However, in other examples, these axes can have other orientations.

[0023] The drive unit assembly 200 is Figure 1 The transmission 106 of the embodiment of the present invention is a non-limiting example of a gearbox. The drive unit assembly 200 can provide a speed / torque conversion between the prime mover power source of the vehicle and the drive wheels. The drive unit assembly 200 can utilize gear reduction or any other suitable speed / torque conversion method by using a gear assembly 204.

[0024] The drive unit assembly 200 may include a housing 202 having an inner surface defining a hollow interior portion of the drive unit assembly 200. The housing 202 may have a size and shape that surrounds at least a portion of the gear assembly 204. The housing 202 may have a bottom inner surface 203 that is flat (e.g., without a depression or curvature) along the zx plane. Figure 2 In the view shown, the side covers of the housing 202 have been removed to facilitate viewing of the internal components of the drive unit assembly (eg, the gear assembly 204).

[0025] The gear assembly 204 may include at least a first rotating gear and a second rotating gear, wherein the teeth of the first rotating gear and the second rotating gear may mesh together. In some examples, the gear assembly 204 may include a plurality of rotating gears, such as a first rotating gear 206, a second rotating gear 208, and a third rotating gear 210. In other examples, the gear assembly 204 may include a different number of suitable rotating gears, such as four or more rotating gears. The gear assembly 204 may be used to transfer rotational power from a prime mover to at least one axle shaft.

[0026] The drive unit assembly 200 can have an integrated oil shield and pump oil pickup 212 housed within the housing 202. The integrated oil shield and pump oil pickup 212 includes an oil shield element 214 and an oil inlet element 216 coupled to the oil shield element 214 and formed integrally with the oil shield element 214. The integrated oil shield and pump oil pickup 212 can be a continuous component produced by injection molding or another suitable construction method. In one example, the continuous component can be integral and without any seams, connectors, and any other connecting features. By integrally forming the oil shield element 214 and the oil inlet element 216, the vertical packaging space required for the drive unit assembly 200 and the complexity of manufacturing can be reduced.

[0027] The oil shield element 214 can have a shape similar to the gears of the gear assembly 204 that are located below the operating oil level (e.g., the first rotating gear 206 and the second rotating gear 208), and extend along the bottom of the gear and partially up the side of the gear to surround the lower portion of the first rotating gear 206 and the second rotating gear 208. In some examples, the oil shield element 214 can extend around a portion of the entire periphery below the operating oil level of all rotating gears (e.g., the oil shield element 214 can be shaped and positioned to extend around the portion of each gear that is below the operating oil level). The bottom inner surface of the oil shield element 214 (e.g., Figure 5The oil shield element 214 (shown) can be positioned an appropriate distance below the lowest gear of the gear assembly 204 of the drive unit assembly 200, for example, in the range of 1-5 mm. In this way, the oil shield element 214 can be configured to collect oil for lubricating the lowest rotating gear by collecting oil distributed within the wall of the oil shield element 214. The oil shield element 214 separates the corresponding gear assembly 204 from excess oil collected at the bottom of the housing 202, thereby reducing the amount of excess oil that the gear may have to rotate through.

[0028] The housing 202 of the drive unit assembly 200 can act as an oil reservoir, with excess oil collecting at the bottom of the housing 202. The excess oil collected at the bottom of the housing 202 can then be pumped out by a pump (e.g. Figure 1 The pump 122) is directed to other components in the oil recirculation circuit, although in Figure 2 The pump is not shown in the drawings, but the pump can be directly coupled to the exterior of the housing 202 (e.g., on the exterior surface of the side cover). The oil inlet element 216 can play a passive role in pumping excess oil out of the bottom of the housing 202 by using an oil pick-up 218. The oil pick-up 218 can be located at the bottom of the oil inlet element 216 and can include one or more orifices through which oil can be drawn and directed to the oil outlet 222 of the oil inlet element 216, which in turn is fluidly coupled to the inlet of the pump (e.g., the oil outlet 222 can be directly coupled to the pump so that the oil outlet 222 extends through the side cover and terminates at the pump). The bottom surface of the oil inlet element 216 can face the bottom inner surface 203 of the housing 202 and can extend in a plane parallel to the plane of the bottom inner surface 203 (e.g., the zx plane). The bottom surface of the oil inlet element 216 may be positioned an appropriate distance C1, such as within 0.1-1 cm, above the bottom inner surface 203 of the housing 202, which may allow the oil pick-up 218 to be immersed in and / or contact excess oil in the bottom of the housing 202. The excess oil may travel through the oil pick-up 218, across the magnet 220 positioned along the bottom of the oil inlet element 216, and through the oil outlet 222 before being directed to other components in the oil recirculation circuit via a pump.

[0029] The oil inlet element 216 may be positioned a distance C1 above the bottom inner surface 203 of the housing 202 to prevent the integrated oil shield and pump oil pickup 212 from blocking excess oil at the bottom of the housing 202 to allow efficient pumping of the oil in the housing 202. In addition, when a vehicle in which the housing 202 is positioned accelerates in any direction, excess oil at the bottom of the housing 202 may move around the bottom of the housing 202 (e.g., toward at least one wall of the housing 202). Therefore, the oil pickup 218 may be positioned at a midpoint of the bottom of the housing 202 (e.g., approximately midway between the side edges of the bottom inner surface 203 along the x-axis) to help the oil pickup 218 remain continuously submerged in excess oil even when the oil is displaced toward one side of the housing 202.

[0030] Although the integrated oil shield and pump oil pick-up 212 is described herein as being positioned in the gearbox of the transmission, it should be understood that Figure 2 The integrated oil shield and pump oil pickup 212 may also be used with other drive unit components, including but not limited to at least a portion of a single-speed transmission, a multi-speed transmission, a differential, a power transfer unit, a transfer case, or an inter-axle differential. In some examples, the integrated oil shield and pump oil pickup 212 may be used in a vehicle in which the prime mover power source is an internal combustion engine, an electrical energy storage device, or a combination of an internal combustion engine and an electrical energy storage device.

[0031] Figure 3-6 Various perspective views of the integrated oil shield and pump oil pick-up 212 are shown and will be described primarily. Figure 3 A front view of the integrated oil shield and pump oil pickup 212 is shown; Figure 4 A front view of the integrated oil shield and pump oil pick-up 212 is shown. Figure 5 A top perspective view of the front side of the integrated oil shield and pump oil pickup 212 is shown. Figure 6 A top perspective view of the rear side of the integrated oil shield and pump oil pickup 212 is shown.

[0032] The oil inlet element 216 may be formed by a body 301 and a bottom plate 303 coupled to the body 301. The body 301 of the oil inlet element 216 may include a top portion including a first top surface 306 and a second top surface 308, the first top surface 306 and the second top surface 308 being opposite to the bottom plate 303 forming a bottom 304 of the oil inlet element 216. The body 301 of the oil inlet element 216 may also include a first side 506, the first side 506 being opposite to the second side 402 of the body 301 of the oil inlet element 216. The body 301 of the oil inlet element 216 may also include a front portion 302, the front portion 302 being opposite to a rear portion 602 of the body 301 of the oil inlet element 216. The oil shield element 214 may include a bottom portion 312, a front side 314, and a rear side 502 opposite to the front side 314.

[0033] The oil shield element 214 may have a suitable curvature to match the size and shape of at least a portion of a gear assembly, such as a gear assembly. Figure 2 Thus, the oil shield element 214 may include two curved portions, wherein the front side 314, the rear side 502, and the bottom 312 may all curve downward (e.g., in the direction of gravity) and then return upward to accommodate and shield the lower portion of at least one rotating gear of the gear assembly in the concave area. Figure 3-6 As shown, the two curved portions can accommodate and shield the bottoms of the first gear and the second gear of the gear assembly.

[0034] The two curved portions may include a first curved portion 320 configured to be positioned below the first rotating gear 206 and a second curved portion 322 configured to be positioned below the second rotating gear 208. The first curved portion 320 may transition to the second curved portion 322 at an intersection region 324 positioned between the first curved portion 320 and the second curved portion 322. Because the second rotating gear 208 is smaller than the first rotating gear 206, the second curved portion 322 may have a smaller radius of curvature than the first curved portion 320. In addition, because the second rotating gear 208 is vertically positioned lower than the first rotating gear 206 within the housing 202, the lowest point of the second curved portion 322 may be vertically lower than the lowest point of the first curved portion 320. Thus, the top surface 326 of the front side 314 of the oil shield element 214 (as well as the top surface of the rear side of the oil shield element) may include a first flat section transitioning to the first curved portion (forming the top surface of the first curved portion 320), a second flat section in the intersection area 324, and a second curved section transitioning to a third flat section (forming the top surface in the second curved portion 322).

[0035] In addition, the front side 314 at the first curved portion 320 can have a first radial height RH1 that is approximately equal to the intersection height IH of the intersection area 324 and greater than the second radial height RH2 of the second curved portion 322 (for example, because the second rotating gear 208 is smaller than the first rotating gear 206). The rear side 502 at the first curved portion 320 can have a third radial height RH3 that is less than the first radial height RH1 and the second radial height RH2 to provide clearance between the integrated oil shield and the pump oil pickup 212 and other components within the drive unit assembly housing. In some examples, the first radial height RH1 can be approximately 30% of the radius of the first rotating gear 206. Similarly, the second radial height RH2 can be approximately 30% of the radius of the second rotating gear 208. The third radial height RH3 can be approximately 10% of the radius of the first rotating gear 206. The intersection height IH can be configured such that the top of the intersection area 324 relative to the y-axis is positioned above the operating oil level in the bottom of the housing 202. The first curved portion 320 and the second curved portion 322 may be aligned along the x-axis such that the two curved portions may be aligned along a common axis and not offset from one another along the z-axis.

[0036] The oil inlet element 216 may be positioned below (e.g., in the direction of gravity) the oil shield element 214 and be integral with the oil shield element 214. As previously described, the top of the oil inlet element 216 may include a first top surface 306 and a second top surface 308 and a common middle portion 404 extending between the first top surface 306 and the second top surface 308. The oil inlet element 216 may be seamlessly connected (e.g., without a seam or joint) to the bottom 312 of the oil shield element 214 at the common middle portion 404. The common middle portion 404 may be a surface without voids, and the inner surface of the bottom 312 of the oil shield element 214 may not open to the interior volume of the oil inlet element 216. The common middle portion 404 may form a portion of the top of the oil inlet element 216 and a portion of the bottom of the second curved portion 322 of the oil shield element 214.

[0037] The oil pick-up 218 may be included in the bottom plate 303 and may extend horizontally from approximately the midpoint of the bottom of the second curved portion 322 (e.g., the lowest point of the second curved portion 322) to approximately the midpoint of the bottom of the intersection region 324, and may be cantilevered from the oil shield element 214 so as to be positioned at the midpoint / center of the housing 202, as described above. The oil inlet element 216 and the oil shield element 214 may also be permanently joined together by a reinforcement plate 310, which may extend vertically from the bottom 312 of the oil shield element 214 to the second top surface 308 of the oil inlet element 216. The reinforcement plate 310 may be positioned closer to the rear of the oil inlet element 216 than to the front 302 of the oil inlet element 216 (e.g., Figure 4322). The reinforcing plate 310 may be flat and have a relatively thin thickness along the z-axis (e.g., 1-3 mm), and may be continuously coupled to the bottom 312 of the oil shield element 214 from the terminating edge of the common middle portion 404 to the midpoint of the bottom of the intersection region 324, such that the top edge of the reinforcing plate 310 has a curvature that matches the curvature of the second curved portion 322. The reinforcing plate 310 may be positioned between the oil pick-up 218 and the bottom 312 of the oil shield element 214 to provide structural support (e.g., to reduce potential beam vibrations) for a portion of the oil inlet element 216 that extends horizontally toward the center of the integrated oil shield and pump oil pick-up 212.

[0038] The first top surface 306 and the second top surface 308 of the oil inlet element 216 may have a second width W2 along the z-axis (eg, Figure 5 As shown), such as in the range of 3-6 centimeters, and the first curved portion 320, the second curved portion 322 and the intersection area 324 of the oil shield element 214 can have a common first width W1 along the z-axis, and the first width W1 is greater than the second width W2, such as in the range of 6-10 centimeters. The first width W1 may be approximately 12 millimeters wider than the face width of the first rotating gear 206 and the second rotating gear 208. As shown, the first width W1 may be greater than the second width W2, and the oil shield element 214 may be cantilevered out of the front portion 302 of the oil inlet element 216 along the z-axis by a third width W3. In some examples, the oil shield element 214 may not be cantilevered out of the rear portion 602 of the oil inlet element 216. In some examples, the outer surface of the rear portion 602 of the oil inlet element 216 may be flush with the rear portion 502 of the oil shield element 214 at the common middle portion 404, such as Figure 6 As shown. In other examples, the outer surface of the rear portion 602 of the oil inlet element 216 can extend further along the z-axis at the common middle portion 404 than the rear side 502 of the oil shield element 214. In still other examples, the oil shield element 214 can be cantilevered out of the rear portion 602 of the oil inlet element 216, similar to the front side. Because the oil shield element 214 can be positioned independently of the center of the gear width, the oil shield element 214 can be positioned at a location based on the packaging constraints of the housing (e.g., the housing 202 of the drive unit assembly) in which the integrated oil shield and oil pickup are positioned.

[0039] The bottom 304 of the oil inlet element 216 may be opposite to the first top surface 306 and the second top surface 308 of the oil inlet element 216. Figure 3 and Figure 4As shown, the bottom 304 of the oil inlet element 216 may include an oil pick-up 218 and a magnet 220. The oil pick-up 218 may protrude downward from the bottom 304 of the oil suction element 216, which may allow the oil pick-up 218 to contact a small amount of excess oil in the bottom of the housing 202 while still maintaining a desired gap between the bottom 304 of the oil inlet element 216 and the bottom inner surface 203 of the housing 202 in the area of ​​the oil outlet 222. The oil pick-up 218 may include at least one aperture through which excess oil in the drive unit assembly housing, such as a drive unit assembly housing, may flow. Figure 2 The housing 202. Figure 4 As shown, the oil pick-up 218 may include four rectangular apertures that may support an oil screen or filter while allowing as much open area as possible for the desired oil flow. In some examples, the oil pick-up 218 may include a different number of rectangular apertures. In other examples, the oil pick-up 218 may include apertures of different shapes, such as triangular or elliptical. In some examples, the oil pick-up 218 may include an oil screen or filter positioned to cover at least one or all apertures of the oil pick-up 218. The oil filter or screen may filter debris from the oil flowing through the oil pick-up 218. In other examples, the oil pick-up 218 may not have an oil filter or screen. As the oil is pumped through the oil inlet element 216, the magnet 220 on the oil inlet element 216 may remove metallic and / or magnetic debris from the oil. The magnet 220 may fit into a slot present on the bottom 304 of the oil inlet element 216. The magnet 220 may face the interior volume of the oil inlet element 216. In some examples, the magnet 220 may be located at a different location on the bottom 304 of the oil inlet element 216 , or the magnet 220 may not be present on the oil inlet element 216 at all.

[0040] The front portion 302 of the oil inlet member 216 may have a length L1 extending continuously along the x-axis from the first side 506 to the second side 406 (in Figure 3 As shown in Figure 3 As shown, the first side 506 of the oil inlet element 216 can be positioned beyond the terminal edge of the second curved portion 322 in the negative x-direction, which can allow the oil outlet 222 to be positioned so that the oil outlet 222 is aligned with and can be coupled to the pump. The second side 402 of the oil inlet element 216 can be positioned below the longitudinal center of the oil shield element 214 (e.g., below the intersection area 324). In this way, the oil inlet element 216 can extend longitudinally (e.g., in the horizontal direction along the x-axis) from the center of the oil shield element 214 to beyond the first terminal edge of the oil shield element 214. The common middle portion 404 can include a portion of the length L1, such as 50% or less of the length L1.

[0041] In some examples, the front portion 302 can have a first height H1 along the y-axis (at Figure 4 304 to the first top surface 306. The first height H1 may be constant along the first portion of the oil inlet element 216 from the first side 506 of the oil inlet element 216 to the common middle portion 404. The height H1 may be selected to both position the oil outlet 222 to align with the pump and provide a planar coupling surface to the body 301 of the oil inlet element 216, which may be advantageous in simplifying the manufacture and coupling of the base plate 303 to the body 301.

[0042] The front portion 302 may also have a second height H2 along the y-axis, such as in the range of 1-3 centimeters, extending from the bottom 304 to the second top surface 308. The second height H2 may be constant along the second portion of the oil inlet element 216 from the common middle portion 404 to the second side 402 of the oil inlet element 216. As shown, the first height H1 may be greater than the second height H2. The height H2 may be selected so that the oil inlet element 216 is positioned at a desired height above the bottom of the housing 202 to facilitate picking up oil at a target height relative to the y-axis from the bottom of the housing 202 and facilitating the flow of oil to the oil outlet 222. The oil inlet element 216 may have a variable height below the common middle portion 404, such as between the second height H2 and the first height H1. The rear portion 602 of the oil inlet element 216 opposite the front portion 302 may have similar dimensions, but mirrored on the xy plane of the Cartesian coordinate system 299.

[0043] like Figure 3-5 As shown, the front portion 302 of the oil inlet element 216 may include an oil outlet 222. The oil outlet 222 may extend through the housing 202 and connect to the pump directly or through intermediate piping or another suitable connection. In this way, the oil outlet 222 helps provide suction from the pump to pull oil into the oil pickup 218 and through the magnet 220. Figure 5 As shown, the oil outlet 222 may include a port extending outwardly (eg, along the z-axis) from the front portion 302 of the oil inlet element 216. The center of the oil outlet 222 may be positioned at the lowest point of the bottom of the oil shield element 214 (eg, Figure 3 The oil picker 218 may be located at the same height (eg, position along the y-axis) as the bottom of RH2 in FIG. 1 , and may also be located at a third height H3 above the bottom surface of the oil picker 218 (eg, Figure 3 shown).

[0044] The first side 506 of the oil inlet element 216 and the second side 402 of the oil inlet element 216 may have the same width as the top of the oil inlet (eg, first width W1). The first side 506 of the oil inlet element may have a first height H1, and the second side 402 of the oil inlet element may have a second height H2.

[0045] like Figure 3 and Figure 4 As shown, the housing mounting pin 316 can be coupled to the bottom 312 of the oil shield element 214. The housing mounting pin 316 can be used to couple the integrated oil shield and pump oil pickup 212 to the drive unit assembly housing to prevent the integrated oil shield and pump oil pickup 212 from moving (e.g., shifting, rotating, etc.) relative to the drive unit assembly housing. In this way, the integrated oil shield and pump oil pickup 212 can not interfere with the drive unit assembly and can continue to shield the assembly even if the assembly moves suddenly or violently. The housing mounting pin 316 can be coupled to a hole in the drive unit assembly housing. In some examples, one or more additional pins / slide plates may be included that can be triggered on a flat surface on the drive unit assembly housing to support the integrated oil shield and pump oil pickup 212 in an axial direction (e.g., relative to the y-axis), which can reduce the number of required drilling holes, thereby simplifying manufacturing. Although Figure 3-5 , it should be understood that additional housing mounting pins (e.g., 1-2 additional housing mounting pins) and slide plates may be included on the shroud member and / or the oil inlet member. The housing mounting pin 316 alone or in conjunction with additional housing mounting pins may allow the integrated oil shroud and pump oil pickup 212 to be positioned between the two halves of the clamshell housing cover without the use of any additional fasteners.

[0046] like Figure 4 As shown, the bottom 312 of the oil shield element 214 may have at least one drain hole, such as a first drain hole 406 and a second drain hole 408. Each drain hole may allow excess oil to drain from the oil shield element 214 and enter the bottom of the drive unit assembly housing. In some examples, the first drain hole 406 may be positioned at the lowest point of the first curved portion 320, and the second drain hole 408 may be positioned at the lowest point of the second curved portion 322. The second drain hole 408 may be positioned on the bottom 312 of the second curved portion 322 in front of the oil inlet element 216 (e.g., between the front side 314 of the oil shield element 214 and the front portion 302 of the oil inlet element 216). In other examples, more or fewer drain holes may be included on the bottom 312 of the oil shield element 214.

[0047] like Figure 3-6 As shown, the oil shield element 214 may have a front side 314 with an inner surface and an outer surface. Figure 5 As shown, the oil shield element 214 may have a rear side 502 with an inner surface and an outer surface. The texture of the inner surface of the front side 314 and the rear side 502 may be smooth, which may allow excess oil to slide along the inner surface toward the first drain hole 406 and / or the second drain hole 408. The outer surface of the front side 314 and the rear side 502 may include a ribbed pattern, which may provide structural support.

[0048] like Figure 5 and Figure 6 As shown, the oil shield element 214 may include internal ribs 504 that are connected to the rear side 502, the front side 314, and the bottom 312 of the oil shield element 214 at the intersection area 324 of the shield element. The internal ribs 504 can be of a suitable shape and can have a variable height, wherein the highest point is less than the height of the rear side 502 at the location of the internal ribs 504 (e.g., the height is 60% of the height of the rear side 502). The height of the internal ribs 504 can be highest at points proximate to the rear side 502 and the front side 314, and can be shortest at a central section of the internal ribs 504 (e.g., in the middle of the rear side 502 and the front side 314 relative to the z-axis). The internal ribs 504 can help prevent excess oil that has collected in the oil shield element 214 from splashing back onto the gear assembly. The internal ribs 504 also provide structural support for the integrated oil shield and pump oil pickup 212.

[0049] Return to reference Figure 2 It will be appreciated that the oil inlet element 216 is integrated with the oil shield element 214 at the second bend 322 so as to fit within the existing space within the drive unit assembly 200 and is sized and shaped to fit within the existing space within the drive unit assembly 200. For example, the housing 202 may more closely track the shape of the first rotating gear 206 than the second rotating gear 208, resulting in a smaller amount of free space in the drive unit assembly 200 below the first rotating gear 206 than below the second rotating gear 208. In addition, the housing 202 may extend past the second rotating gear 208 to accommodate additional components of the drive unit assembly (e.g., the third rotating gear 210), thereby creating additional free space to the side of the second rotating gear 208. The oil inlet element 216 may be sized such that the bottom of the oil inlet element 216 (and specifically the oil pick-up 218) is within at least a first distance (e.g., gap C1) of the bottom inner surface 203 of the housing 202 to facilitate oil pick-up, and is also sized such that the oil outlet 222 is conveniently positioned to be fluidly coupled to a pump external to the housing. The oil pick-up 218, magnet 220, and oil outlet 222 may all be aligned along / relative to a common longitudinal axis directly below the oil shield element 214, and may not be laterally offset from each other by more than a threshold amount (e.g., no more than 1 cm in lateral offset), which enables the oil inlet element 216 to occupy a lateral width that is less than, or at least no greater than, the lateral width of the oil shield element 214. In some examples, the oil inlet element 216 may be wider (e.g., larger with respect to the z-axis) than the oil shield element 214.

[0050] Thus, the integrated oil shield and pump oil pickup 212 described herein includes an entry element and a shield element combined to form one continuous component. In some examples, the entry element may include an oil pickup, a magnet, and an oil outlet, the oil outlet creating at least one passage through which excess oil can be pumped out of the housing of the drive unit assembly. In some examples, the shield element may include internal ribs, sides, and exhaust holes to reduce oil churning losses of at least the first rotating gear of the gear assembly. The integrated oil shield and pump oil pickup can be produced by plastic injection molding, additive manufacturing, or other suitable construction methods, which will result in a seamless connection of the entry element and the shield element.

[0051] Thus, the integrated oil shield and pump oil pickup described herein can provide the utility of both an oil shield and a pump oil pickup while reducing the expense and / or complexity of manufacturing by reducing two components to one. The integrated oil shield and pump oil pickup can also reduce the required vertical packaging space if there is a separate component for the gear assembly shield alongside a remote pickup tube or a separate oil filter.

[0052] In some examples, the oil shield element and the oil inlet element are not fully integrated as described herein, but can be manufactured as separate components and coupled together to form a combined oil shield and oil pickup. For example, the oil inlet element can be glued, welded, or otherwise secured to the oil shield element along a common middle portion. In still other examples, the oil shield element and the oil inlet element can be manufactured as separate components and each independently coupled to the housing and / or other component(s) of the drive unit assembly.

[0053] Figure 2-6An example configuration with relative positioning of various components is shown. If shown as directly contacting or directly connected to each other, such elements can be referred to as directly contacting or directly connected, respectively, at least in one example. Similarly, at least in one example, elements shown as continuous or adjacent to each other can be respectively continuous or adjacent to each other. As an example, components placed as face-shared contact with each other can be referred to as face-shared contact. As another example, in at least one example, elements positioned to be spaced apart from each other with only a spacing space between them and no other components can be referred to as such. As another example, elements shown as above / below each other, on opposite sides of each other, or on the left / right of each other can be referred to as such relative to each other. In addition, as shown in the accompanying drawings, in at least one example, the topmost element or the point position of the element can be referred to as the "top" of the component, and the bottommost element or the point position of the element can be referred to as the "bottom" of the component. As used herein, top / bottom, upper / lower, above / below can be relative to the vertical axis of the accompanying drawings and used to describe the positioning of the elements of the accompanying drawings relative to each other. Therefore, in one example, the element shown as above other elements is vertically positioned above the other elements. As yet another example, the shapes of elements depicted in the accompanying drawings may be referred to as having such shapes (e.g., such as rounded, straight, planar, curved, rounded, chamfered, angled, etc.). Additionally, in at least one example, elements shown as intersecting each other may be referred to as intersecting elements or intersecting each other. Further, in one example, an element shown as being within another element or outside another element may be referred to as such.

[0054] The present disclosure also provides support for an assembly, including: an oil shield element configured to surround a lower portion of at least one rotating gear of a gearbox, and an oil inlet element having an oil filter and an oil outlet, the oil outlet configured to be connected to a pump of an oil recirculation circuit, wherein the oil inlet element is in common contact with the oil shield element surface. In a first example of the system, the oil inlet element includes a front, a rear, a first side, a second side, a bottom, and a top to surround an internal volume, wherein the oil outlet is located on the front of the oil inlet element adjacent to the first side. In a second example of the system, which optionally includes the first example, the top of the oil inlet element includes a first top surface, a second top surface, and a common middle portion positioned between the first top surface and the second top surface, wherein the common middle portion forms a portion of the inner surface of the bottom of the oil shield element. In a third example of the system, which optionally includes one or both of the first and second examples, the bottom of the oil inlet element includes an oil pick-up, the oil pick-up includes at least one orifice and is positioned adjacent to the second side, and wherein the oil filter is positioned at the oil pick-up. In a fourth example of the system, which optionally includes one or more or each of the first to third examples, a first side of the oil inlet element is positioned beyond a first termination edge of the oil shield element, and a second side of the oil inlet element is positioned directly below a midpoint of the oil shield element, and wherein the oil inlet element has a first width that is less than a second width of the oil shield element. In a fifth example of the system, which optionally includes one or more or each of the first to fourth examples, a bottom of the oil inlet element includes a magnet facing the interior volume. In a sixth example of the system, which optionally includes one or more or each of the first to fifth examples, the oil shield element includes at least one drain hole. In a seventh example of the system, which optionally includes one or more or each of the first to sixth examples, the oil inlet element is coupled to the oil shield element without any seams or joints.

[0055] The present disclosure also provides support for a system including: a gearbox including a housing surrounding at least one rotating gear; a combined oil shield and oil pick-up contained within the housing, the combined oil shield and oil pick-up including an oil shield element shaped and sized to surround a lower portion of the at least one rotating gear; and an oil inlet element including an oil outlet configured to be coupled to an inlet of a pump and an oil pick-up including at least one orifice, the combined oil shield and oil pick-up having a common middle portion that forms a portion of a top of the oil inlet element and a portion of a bottom of the oil shield element. In a first example of the system, the oil pick-up element includes a bottom surface that faces the bottom inner surface of the housing and extends in a plane parallel to the plane of the bottom inner surface, and wherein the bottom surface of the oil pick-up element is positioned at least a first distance above the bottom inner surface of the housing. In a second example of the system, which optionally includes the first example, at least one rotating gear includes a first rotating gear and a second rotating gear, and wherein the oil shield element includes a first curved portion, a second curved portion, and an intersection area, the first curved portion is sized and shaped to surround the lower portion of the first rotating gear, the second curved portion is sized and shaped to surround the lower portion of the second rotating gear, and the intersection area is positioned between the first curved portion and the second curved portion. In a third example of the system, which optionally includes one or both of the first and second examples, the top of the oil inlet element includes a first top surface, a second top surface, and a common middle portion positioned between the first top surface and the second top surface, wherein the common middle portion forms a portion of the bottom of the second curved portion of the oil shield element. In a fourth example of the system, which optionally includes one or more or each of the first to third examples, and wherein the oil pick-up is cantilevered from the bottom of the second curved portion and terminates at a position vertically below the intersection area. In a fifth example of the system, which optionally includes one or more or each of the first to fourth examples, the combined oil shield and oil pick-up further includes a reinforcing plate connected between the second top surface and the oil shield element at the second curved portion and the intersection area. In a sixth example of the system, which optionally includes one or more or each of the first to fifth examples, the oil inlet element extends longitudinally beyond the terminal edge of the second curved portion on the first side, and the oil outlet is positioned on the front of the oil inlet element at the first side. In a seventh example of the system, which optionally includes one or more or each of the first to sixth examples, the oil shield element includes a bottom, a front, and a rear, each of the front of the oil shield element and the rear of the oil shield element is connected to the bottom of the oil shield element, the bottom of the oil shield element has a first width from the front of the oil shield element to the rear of the oil shield element, and wherein the oil inlet element has a second width from the front of the oil inlet element to the rear of the oil inlet element, the second width being less than the first width of the bottom of the oil shield element.In an eighth example of the system, which optionally includes one or more or each of the first to seventh examples, the oil shield element includes a first drain hole on the first curved portion and a second drain hole on the second curved portion.

[0056] The present disclosure also provides support for a system including: a gearbox including a housing surrounding at least a first rotating gear and a second rotating gear, the first rotating gear having teeth that mesh with teeth of the second rotating gear, and an oil shield and pickup housed in the housing, the oil shield and pickup including: an oil shield element, the oil shield element including a first curved portion sized and shaped to surround a lower portion of the first rotating gear, a second curved portion sized and shaped to surround a lower portion of the second rotating gear, and an intersection region positioned between the first curved portion and the second curved portion, wherein each of the first curved portion, the second curved portion, and the intersection region are aligned along a common longitudinal axis and have a common first width; and an oil inlet element, the oil inlet element being coupled to the oil shield element directly below the second curved portion and including an oil outlet configured to couple to an inlet of a pump and an oil pickup including at least one orifice, and wherein the oil outlet and the oil pickup are aligned relative to the common longitudinal axis so that the oil inlet element has a second width that is less than the first width. In a first example of the system, the oil shield element includes a first drain hole on the first bend and a second drain hole on the second bend, the second drain hole being positioned in front of the oil inlet element. In a second example of the system, which optionally includes the first example, the oil pick-up is cantilevered from the bottom of the second bend and terminates at a position vertically below the intersection area, and wherein the oil shield and the oil pick-up further include a reinforcement plate coupled between a top surface of the oil inlet element and a bottom surface of the oil shield element at the second bend and the intersection area.

[0057] It should be noted that the example control and estimation routines included herein can be used with various engine and / or vehicle system configurations. The control methods and routines disclosed herein can be stored as executable instructions in a non-transitory memory and can be executed by a control system including a controller combined with various sensors, actuators and other engine hardware. The specific routines described herein can represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, etc. In this way, the various actions, operations and / or functions shown can be performed in the order shown, in parallel, or omitted in some cases. Similarly, the processing order for implementing the features and advantages of the example embodiments described herein is not necessary, but is provided for ease of illustration and description. Depending on the specific strategy used, one or more of the actions, operations and / or functions shown can be repeatedly performed. In addition, the described actions, operations and / or functions can graphically represent the code in the non-transitory memory of a computer-readable storage medium to be programmed into the engine control system, wherein the described actions are performed by executing instructions in a system including various engine hardware components and combined with an electronic controller.

[0058] It is understood that the configurations and routines disclosed herein are exemplary in nature, and these specific embodiments should not be considered restrictive, as a variety of changes may be made. For example, the above techniques may be applied to V-6, I-4, I-6, V-12, opposed 4, and other engine types. In addition, unless expressly stated to the contrary, the terms "first," "second," "third," and the like are not intended to represent any order, position, quantity, or importance, but are merely used as labels to distinguish one element from another. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations and other features, functions, and / or characteristics disclosed herein.

[0059] As used herein, unless otherwise indicated, the term "about" is to be interpreted as meaning plus or minus five percent of the range.

[0060] The appended claims particularly point out certain combinations and subcombinations believed to be novel and non-obvious. These claims may refer to "an" element or a "first" element or the equivalent thereof. Such claims should be understood to include combinations of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or characteristics may be claimed in this or a related application by amendment of the present claims or by presentation of new claims. Such claims, whether broader, narrower, equal, or different in scope to the original claims, are deemed to be included in the subject matter of the present disclosure.

Claims

1. A drive unit assembly, characterized in that: include: an oil shield element (214) configured to surround a lower portion of at least one rotating gear (206, 208) of the gearbox; as well as An oil inlet element (216) having an oil filter and an oil outlet (222) is configured to be coupled to a pump (122) of an oil recirculation circuit, wherein the oil inlet element (216) is in common contact with the oil shield element (214).

2. The drive unit assembly according to claim 1, characterized in that: The oil inlet element (216) includes a front portion, a rear portion, a first side, a second side, a bottom portion and a top portion to enclose an internal volume, wherein the oil outlet (222) is located on the front portion of the oil inlet element (216) adjacent to the first side.

3. The drive unit assembly according to claim 2, characterized in that: The top of the oil inlet element (216) includes a first top surface, a second top surface, and a common middle portion positioned between the first top surface and the second top surface, wherein the common middle portion forms a portion of the inner surface of the bottom of the oil shield element (214).

4. The drive unit assembly according to claim 2, characterized in that: The bottom of the oil inlet element (216) includes an oil pick-up (218) including at least one aperture and positioned adjacent to the second side, and wherein the oil filter is positioned at the oil pick-up (218).

5. The drive unit assembly according to claim 4, characterized in that: The first side of the oil inlet element (216) is positioned beyond a first terminal edge of the oil shield element (214), while the second side of the oil inlet element (216) is positioned directly below a midpoint of the oil shield element (214), and wherein the oil inlet element (216) has a first width that is smaller than a second width of the oil shield element (214).

6. The drive unit assembly according to claim 2, characterized in that: The bottom portion of the oil inlet element (216) includes a magnet (220) facing the inner volume.

7. The drive unit assembly according to claim 1, characterized in that: The oil shield element (214) includes at least one drain hole (406, 408).

8. The drive unit assembly according to claim 1, characterized in that: The oil inlet element (216) is coupled to the oil shield element (214) without any seams or joints.

9. A transmission system, characterized in that: include: A gearbox comprising a housing (202) surrounding at least one rotating gear (206, 208); A combined oil shroud and oil pick-up is housed within the housing, the combined oil shroud and oil pick-up comprising an oil shroud element (214) and an oil inlet element (216), the oil shroud element being shaped and sized to surround a lower portion of the at least one rotating gear (206, 208), the oil inlet element comprising an oil outlet (222) configured to be coupled to an inlet of a pump (122) and an oil pick-up (218) comprising at least one orifice, the combined oil shroud and oil pick-up having a common middle portion forming a portion of a top portion of the oil inlet element and a portion of a bottom portion of the oil shroud element (214).

10. The transmission system according to claim 9, characterized in that The oil inlet element (216) includes a bottom surface, which faces the bottom inner surface of the housing (202) and extends in a plane parallel to the plane of the bottom inner surface, and wherein the bottom surface of the oil inlet element (216) is positioned at least a first distance above the bottom inner surface of the housing (202).

11. The powertrain according to claim 9, characterized in that: The at least one rotating gear (206, 208) includes a first rotating gear (206) and a second rotating gear (208), and wherein the oil shield element (214) includes a first curved portion, the first curved portion is sized and shaped to surround a lower portion of the first rotating gear (206); a second curved portion, the second curved portion is sized and shaped to surround a lower portion of the second rotating gear (208); and an intersection area, the intersection area is positioned between the first curved portion and the second curved portion, wherein the top of the oil inlet element (216) includes a first top surface, a second top surface, and a common middle portion positioned between the first top surface and the second top surface, wherein the common middle portion forms a portion of the bottom of the second curved portion of the oil shield element (214), and wherein the oil pick-up (218) is cantilevered from the bottom of the second curved portion and terminates at a position vertically below the intersection area.

12. The transmission system according to claim 11, characterized in that The combined oil shield and oil pick-up also includes a reinforcement plate (310) coupled between the second top surface and the oil shield element (214) at the second bend and the intersection area.

13. The transmission system according to claim 12, characterized in that The oil inlet element (216) extends longitudinally beyond a terminal edge of the second curved portion on a first side, and the oil outlet (222) is positioned on a front portion of the oil inlet element (216) at the first side.

14. The powertrain according to claim 12, characterized in that: The oil shield element (214) includes a bottom, a front portion, and a rear portion, each of the front portion of the oil shield element (214) and the rear portion of the oil shield element (214) being connected to the bottom portion of the oil shield element (214), the bottom portion of the oil shield element (214) having a first width from the front portion of the oil shield element (214) to the rear portion of the oil shield element (214), and wherein the oil inlet element (216) has a second width from the front portion of the oil inlet element (216) to the rear portion of the oil inlet element (216), the second width being smaller than the first width of the bottom portion of the oil shield element (214).

15. The powertrain according to claim 12, characterized in that The oil shield element (214) includes a first drain hole (408) on the first curved portion and a second drain hole (406) on the second curved portion.

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