Axle Assembly Dynamic Oil Level Control for Churning Loss Reduction
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Solution Overview
Problem
Existing axle assemblies in heavy vehicles suffer from reduced efficiency due to excess oil circulation under less arduous conditions, leading to 'churning' losses, and existing solutions are not suitable for retrofitting to vehicles already in use, requiring significant redesign and remanufacture.
Innovation Solution
An axle assembly with a housing, crown wheel, pinion, first and second reservoirs, a sensor, and a control system that adjusts fluid levels based on operating conditions, allowing for easy retrofitting without interfacing with the vehicle's existing control system, using a solenoid valve and scoop mechanism to transfer oil between reservoirs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a predetermined amount of oil is permanently circulated around the crown wheel pinion and differential assembly, then the assembly is adequately lubricated and cooled under all conditions, but excess oil causes churning losses and reduced efficiency under less arduous conditions
Solution Approach 1:
The patent implements a dynamic oil level control system that adjusts the oil level in the first reservoir based on operating conditions. A sensor monitors parameters such as vehicle speed, acceleration, or load, and a control system actuates a valve to transfer oil between the first reservoir (around crown wheel) and second reservoir (remote from crown wheel), thereby optimizing lubrication while minimizing churning losses under less arduous conditions
Solution Approach 2:
The system changes the physical parameter of oil level in the first reservoir based on operating conditions. By transferring oil to and from the second reservoir, the oil level parameter is dynamically adjusted to match actual lubrication and cooling requirements, reducing churning losses when less oil is needed while maintaining adequate lubrication when required
2Loss of energy
If the oil level around the crown wheel is raised under arduous conditions and lowered under less arduous conditions, then efficiency is improved by reducing churning losses, but prior art systems require significant redesign and remanufacture of the entire axle assembly
Solution Approach 1:
The patent segments the axle assembly into modular components, specifically identifying the differential carrier cover as a separate removable unit. The oil level control system (second reservoir, valve, sensor, and control system) is integrated onto this cover rather than requiring modification of the entire axle housing. This segmentation allows the cover to be removed, reworked independently, and reinstalled, enabling retrofitting without significant redesign of the complete axle assembly
Solution Approach 2:
The patent extracts the oil level control system from the main axle housing structure and relocates it to the differential carrier cover. By taking out the control system components and mounting them on the removable cover, the invention enables easy retrofitting to existing vehicles. The cover can be removed from the axle assembly, modified to include the control system, and reinstalled without requiring remanufacture of the entire axle
3Productivity
If prior art systems for dynamic oil level control are fitted to existing vehicles, then churning losses can be reduced, but the systems require significant redesign and remanufacture of the axle assembly
Solution Approach 1:
The patent segments the axle assembly into modular components, specifically identifying the differential carrier cover as a separate removable unit. The oil level control system (second reservoir, valve, sensor, and control system) is integrated onto this cover rather than requiring modification of the entire axle housing. This segmentation allows the cover to be removed, reworked independently, and reinstalled, enabling retrofitting without significant redesign of the complete axle assembly
Solution Approach 2:
The patent extracts the oil level control system from the main axle housing structure and relocates it to the differential carrier cover. By taking out the control system components and mounting them on the removable cover, the invention enables easy retrofitting to existing vehicles. The cover can be removed from the axle assembly, modified to include the control system, and reinstalled without requiring remanufacture of the entire axle
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces oil churning losses by dynamically adjusting oil levels based on operating conditions, improving efficiency without the need for extensive redesign, and can be easily applied to existing vehicles by replacing the differential carrier cover components.
Implementation Method 1
The second system includes a solenoid valve which forms part of the system for transferring fluid from the second reservoir to the first reservoir
Implementation Method 2
using a solenoid valve and scoop mechanism to transfer oil between reservoirs
Implementation Method 3
a sensor for generating a signal representative of an axle assembly characteristic, the axle assembly further including a control system for receiving said signal and operating said first system to transfer fluid from the first reservoir in response to said signal or operating said second system to transfer fluid to the first reservoir in response to said signal
Data Source
Figure 1
Figure 2~3
AI summary
An axle assembly (10) including a housing (11) having a first axle tube (16) and a second axle tube (18), a crown wheel (32) mounted in the housing, a pinion (30) in meshing engagement with the crown wheel, a first reservoir for retaining fluid in contact with the crown wheel for lubricating the crown wheel, a second reservoir (36) for retaining fluid remote from the crown wheel, a first system for transferring fluid in the first reservoir to the second reservoir, a second system for transferring fluid in the second reservoir to the first reservoir, a sensor (38) for generating a signal representative of an axle assembly characteristic, the axle assembly further including a control system (40) for receiving said signal and operating said first system and or said second system to transfer fluid to or from the first reservoir in response to said signal.