Integrated Gear Clutch Assembly for Compact Shift Lubrication
Solution Overview
Problem
Previous transmission clutch designs are space inefficient, leading to compatibility issues in vehicles with constrained gearboxes, as they require a larger clutch envelope and compromise shifting performance.
Innovation Solution
A transmission system with friction clutches where discs are splined to the interior of gears, incorporating a hydraulic passage through the shaft for lubrication, and a bearing with a shield to enhance lubrication pressure, allowing for a more compact and efficient clutch arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional hydraulic clutch mechanisms with external clutch enclosures are used, then shifting performance can be maintained, but the clutch envelope becomes large and space inefficient
Solution Approach 1:
The clutch mechanism is merged with the gear structure itself. The gear body serves as the clutch housing, and the clutch discs are integrated within the gear's internal cavity. This merging eliminates the need for separate external clutch enclosures, significantly reducing the overall clutch envelope volume while maintaining all necessary clutch functions for reliable shifting.
Solution Approach 2:
The clutch components are nested within the gear's internal cavity. The clutch discs, pistons, and hydraulic components are arranged concentrically within the gear body, similar to nested dolls. This nesting approach maximizes space utilization and minimizes the external dimensions of the clutch assembly.
2Volume of moving object
If clutch discs are positioned centrally on the shaft, then the clutch can be compact, but lubrication delivery becomes complex
Solution Approach 1:
The clutch system serves its own lubrication needs through integrated lubrication ports directly on the clutch discs. These ports automatically receive lubricant through the gear's internal lubrication passages, eliminating the need for separate external lubrication delivery systems and reducing overall system complexity.
Solution Approach 2:
The gear structure serves multiple functions simultaneously: it acts as the transmission gear, the clutch housing, and the lubrication delivery system. The internal passages of the gear are used both for gear lubrication and for delivering lubricant to the clutch discs, consolidating multiple functions into a single component.
3Reliability
If the clutch is designed with a larger envelope for better lubrication access, then lubrication effectiveness improves, but the space efficiency decreases
Solution Approach 1:
The lubrication system transitions from external radial delivery to internal axial delivery through the gear thickness. Lubricant is delivered through passages that traverse the gear's internal volume, allowing effective lubrication of centrally positioned clutch discs without increasing the external envelope area of the clutch assembly.
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 solution enables rapid and smooth shifting between gears with a compact clutch design, reducing space constraints and improving shifting performance while maintaining effective lubrication.
Implementation Method 1
a hydraulic passage that extends through the shaft and includes an outlet in the shaft that directly supplies a lubricant to the first and second sets of discs during transmission system operation
Implementation Method 2
Positioning the bearing next to the friction clutch and with this shield arrangement allows the lubricant pressure to build up around the clutch to facilitate effective bearing and clutch lubrication
Data Source
AI summary
A transmission system and a method for operation of said transmission is provided. The transmission system includes a first friction clutch with a first set of discs splined to a shaft and a second set of discs splined to an inner circumference of a first gear. The system further includes a first hydraulic passage extending through the shaft and including an outlet in the shaft that directly supplies a lubricant to the first and second sets of discs during transmission system operation, where the first gear includes outer teeth that are positioned circumferentially around the first gear outward from the first and second sets of discs and is designed to mesh with a second gear in the transmission system.