Differential Lubrication Ring Layout for Limited Oil Supply
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Solution Overview
Problem
Existing gearbox and differential lubrication systems often face insufficient lubrication due to limited oil supply, particularly in applications like E-axles, where complex pumps or mechanisms are not feasible.
Innovation Solution
A gear assembly with a rotatable housing and a lubricant deflector ring having radially outwardly directed vanes that overlap with a lubricant collection ring, enhancing lubricant flow by splashing and directing it towards lubrication in-flow openings within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gears are partially submerged in oil for lubrication, then the structure is simple, but insufficient lubrication occurs under certain driving conditions
Solution Approach 1:
The lubrication system uses the rotational motion of the gears themselves to drive the lubrication process. The gear teeth act as impellers that splashes and circulate the lubricant throughout the differential housing, eliminating the need for external pumps or complex circulation mechanisms while ensuring adequate lubrication delivery.
Solution Approach 2:
The lubrication system transitions from a static partial submersion arrangement to a dynamic circulation system. The lubricant is actively splashed and distributed throughout the housing by the rotating gears, adapting the lubrication delivery to the operating conditions and ensuring consistent lubrication regardless of gear position or speed.
2Quantity of substance
If a limited oil supply is shared between gearbox and differential, then the system is compact, but lubrication flow to the differential is insufficient
Solution Approach 1:
The differential gears themselves serve as the lubrication delivery mechanism, using their rotational energy to splash and circulate the limited oil supply throughout the housing and onto all necessary gear surfaces, maximizing the effectiveness of the shared lubricant supply without requiring additional housing volume or lubricant reservoirs.
Solution Approach 2:
The system uses the kinetic energy of the rotating gears to create a hydraulic splashing action that distributes the lubricant throughout the housing. The gear teeth act as implicit impellers, generating fluid motion and pressure that delivers adequate lubricant flow to all gear contacts despite the limited total oil supply.
3Reliability
If splash lubrication is used without deflector rings, then the structure is simple, but lubricant distribution is insufficient
Solution Approach 1:
The deflector rings serve as intermediary components that capture the lubricant splashed by the rotating gears and redirect it onto the gear surfaces. These rings act as intermediate elements between the lubricant source and the gear contacts, ensuring that the lubricant is properly directed and distributed to all necessary areas.
Solution Approach 2:
The deflector rings extend the lubrication process into a new spatial dimension by creating a lubricant circulation path that goes from the gear teeth, onto the deflector rings, and then back onto the gear surfaces. This multi-dimensional circulation pattern ensures more comprehensive lubricant distribution compared to simple direct splashing.
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 arrangement ensures improved lubricant flow and distribution to gear sets, effectively addressing the issue of insufficient lubrication without the need for complex pumps or mechanisms, thereby enhancing the performance and reliability of gearbox and differential systems.
Implementation Method 1
the vanes of the lubricant deflector ring are configured to fling lubricant radially outwardly against the radially outwardly located lubricant collection ring
Data Source
AI summary
A gear assembly having a rotatable housing with an axial end face and a lubrication in-flow opening and a gear set located therein. A lubricant collection ring having an axially extending outer wall is connected to the axial end face. A radially inwardly extending sidewall extends from the axially extending outer wall in a position spaced apart from the axial end face. A lubricant deflector ring is connected to the rotatable housing radially inwardly from the lubricant collection ring. The lubricant deflector ring has a plurality of radially outwardly directed vanes that overlap with the lubricant collection ring. The vanes are configured to fling lubricant against the radially outwardly located lubricant collection ring which directs the lubricant to the at least one lubrication in-flow opening to provide lubricant to the at least one lubricant in-flow opening in the rotatable housing in order to lubricate the gear set located therein.