Lubrication Catchment Feature for Power Train Components
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Solution Overview
Problem
Existing lubrication systems for power transmission components in vehicles face issues with excessive parasitic losses due to high oil levels and inadequate lubrication resulting from varying oil levels in the lubrication sump, leading to inefficient lubrication and potential component damage.
Innovation Solution
A lubrication apparatus with a catchment feature and lubrication passages that capture and redirect lubrication fluid to components, including annular gaps and drainage passages to ensure consistent lubrication and air venting, thereby managing oil distribution and preventing trapped air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the oil level in the lubrication sump is increased to ensure adequate lubrication of components, then lubrication reliability is improved, but parasitic losses increase due to windage losses of components rotating through the oil
Solution Approach 1:
The lubrication system is segmented into distinct zones: a lubrication sump for oil storage, a catchment feature for collecting excess oil, and a component cavity for housing rotating components. This segmentation allows the oil level in the sump to be maintained at an optimal level for lubrication while preventing excessive oil from contacting rotating components, thereby reducing windage losses while ensuring adequate lubrication.
Solution Approach 2:
The catchment feature acts as an intermediary element between the lubrication sump and the component cavity. It captures excess lubrication fluid from the sump and redirects it through lubrication passages to the components, preventing direct contact between high levels of oil and rotating components. This mediator role resolves the contradiction by enabling adequate lubrication delivery while minimizing parasitic losses from windage.
2Loss of energy
If the oil level in the lubrication sump is decreased to reduce parasitic losses, then energy efficiency is improved, but lubrication adequacy deteriorates leading to potential component damage
Solution Approach 1:
The catchment feature and lubrication passages serve as an intermediary delivery system that decouples the oil level in the sump from the actual lubrication of components. Even when the sump oil level is kept low to reduce windage losses, the catchment feature captures the necessary amount of oil and delivers it through passages to the components, ensuring adequate lubrication without requiring high oil levels in the sump.
Solution Approach 2:
The system enables self-service lubrication where the catchment feature automatically captures excess oil from the sump and the lubrication passages automatically deliver it to the components. This self-regulating mechanism ensures that components receive adequate lubrication without requiring manual intervention to maintain high oil levels, thus reducing parasitic losses while maintaining lubrication adequacy.
3Device complexity
If a traditional direct lubrication system is used where components rotate directly through the oil sump, then device complexity is minimized, but lubrication consistency deteriorates due to varying oil levels
Solution Approach 1:
The lubrication passages serve as intermediary channels that deliver oil from the catchment feature to the components in a controlled manner. This intermediary delivery system ensures that components receive consistent lubrication regardless of variations in the sump oil level, as the passages provide a direct and controlled oil supply path that is not affected by the overall oil level fluctuations in the sump.
Solution Approach 2:
The system applies local quality by providing dedicated lubrication passages that deliver oil directly to specific components needing lubrication. Instead of relying on general oil level in the sump, each component receives targeted lubrication through its own passage or annular gap, ensuring consistent lubrication quality at the local component level regardless of the global oil level in the sump.
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 captures and redistributes splashed lubrication fluid, ensuring consistent lubrication of components, reducing windage losses, and preventing air entrapment, which enhances the longevity and efficiency of power transmission components.
Implementation Method 1
Lubrication fluid may flow through the first annular flow path between the component cavity and the first bearing to lubricate the second component
Implementation Method 2
Lubrication fluid may flow through the second annular flow path between the component cavity and the second bearing to lubricate the second component
Data Source
AI summary
A lubrication apparatus for lubrication of one or more components is described. The apparatus may include a housing with an internal housing cavity containing lubrication fluid. A catchment feature may be located on an internal portion of the housing, the catchment feature having a lip and a reservoir, with the lip extending into the internal housing cavity above, at least in part, a lubrication fluid sump level of the internal housing cavity. A first lubrication passage may extend from the catchment feature into the housing. The lip and the reservoir of the catchment feature may catch lubrication fluid splashed above the lubrication fluid sump level. The first lubrication passage may direct lubrication fluid from the catchment feature to the one or more components.