Dual-Clutch Transmission Chamber Layout for Off-Road Lubrication
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Solution Overview
Problem
Dual-clutch transmissions (DCTs) have not been widely adopted in off-road vehicles due to high manufacturing costs and packaging issues, and maintaining efficient lubrication of their components is challenging in vehicles with limited space.
Innovation Solution
A dual-clutch transmission system with an internal dividing wall and a transmission fluid distribution system that includes a primary pump, fluid channels, fluid spraying devices, and a heat exchanger to ensure balanced pressure and efficient lubrication, while incorporating a rotary vane pump and suction pumps to manage fluid flow and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dual-clutch transmission is implemented in an off-road vehicle, then shifting performance and efficiency are improved, but manufacturing costs and packaging complexity increase
Solution Approach 1:
The transmission housing is divided into multiple chambers (first chamber, second chamber, third chamber) separated by internal dividing walls. This segmentation allows independent lubrication zones for different clutch assemblies and gear trains, enabling compact packaging while maintaining the complex dual-clutch functionality required for improved shifting performance.
2Productivity
If a dual-clutch transmission is implemented in an off-road vehicle, then shifting performance and efficiency are improved, but manufacturing costs increase
Solution Approach 1:
The transmission housing serves multiple functions simultaneously: it provides structural support, defines lubrication chambers, contains seals and gaskets, and facilitates fluid distribution through integrated passages. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while maintaining the complex dual-clutch transmission design for improved shifting performance.
3Volume of moving object
If the size of the DCT is limited by available space, then packaging is improved, but efficient lubrication of components becomes difficult to implement
Solution Approach 1:
A dedicated lubrication system with transmission fluid distributed through controlled passages and channels acts as an intermediary to deliver lubrication precisely to clutch plates, gears, and bearings. This systematic approach ensures adequate lubrication in the compact transmission design, maintaining reliability despite the reduced size and limited space for traditional lubrication methods.
Solution Approach 2:
The lubrication system uses hydraulic principles with transmission fluid pumped through controlled passages and channels to deliver pressurized lubrication to critical components. This hydraulic lubrication approach ensures efficient oil delivery to all moving parts within the compact transmission housing, maintaining component reliability despite the limited space available.
4Reliability
If transmission fluid is distributed throughout the transmission, then lubrication is improved, but device complexity increases
Solution Approach 1:
The lubrication system merges multiple functions into integrated components: the transmission housing itself contains lubrication passages, the pump is integrated into the housing structure, and fluid distribution channels are built into the dividing walls. This consolidation reduces the number of separate lubrication components while ensuring comprehensive lubrication coverage, improving reliability without proportionally increasing overall device complexity.
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
The system effectively addresses packaging and cost issues, providing efficient lubrication and cooling for DCT components, enhancing performance and reliability in off-road vehicles.
Implementation Method 1
a primary pump fluidly connected to the fluid tank and to the first and second chambers, the primary pump being configured to pump transmission fluid to the first and second chambers
Implementation Method 2
a heat exchanger fluidly connected to the primary pump and configured to absorb heat from transmission fluid received from the primary pump
Implementation Method 3
an air separator disposed in the separator compartment and configured to separate air from transmission fluid
Implementation Method 4
the internal dividing wall defines at least one air hole disposed in an upper portion of the internal dividing wall for balancing a pressure within the first chamber with a pressure within the second chamber
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A transmission for a vehicle (20) includes: an input shaft (122) for connection to an internal combustion engine (52) of the vehicle (20); a gear (605) shaft (122, 199, 400A, 400B) selectively operatively connected to the input shaft (122); a clutch selectively actuatable to transmit motion between the input shaft (122) and the gear (605) shaft (122, 199, 400A, 400B) for selectively operating the transmission in one of a plurality of transmission gears (600); an output shaft (740) operatively connected to the gear (605) shaft (122, 199, 400A, 400B) at least in part by the transmission gears (600); and a transmission housing (102) at least partly enclosing the input shaft (122), the transmission gears (600), the clutch and the output shaft (740). An internal dividing wall (506, 510) defines first and second chambers (350A, 502), the internal dividing wall (506, 510) being configured to limit flow of transmission fluid between the first and second chambers (350A, 502). The input shaft (122) and the clutch are disposed within the first chamber (350A, 350B, 508). The transmission gears (600) and the output shaft (740) are disposed within the second chamber (350A, 350B, 508).