Splitter Gear Lubrication Control for Lower Transmission Power Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In heavy-duty vehicles with stepped transmissions, the continuous lubrication and cooling of gear teeth in inactive gear sets result in energy wastage and increased load-independent power losses, particularly in the direct gear mode where no propulsive power is transferred, leading to inefficient fuel consumption and energy loss.
Innovation Solution
A lubrication control system that adjusts lubrication based on the positions of gear shift mechanisms, reducing or interrupting lubrication to inactive splitter gear sets when they are not transmitting power, using sliding closing devices connected to the gear shift mechanisms to control lubricant supply through openings or nozzles, ensuring lubrication is only provided when power is being transmitted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous lubrication is provided to all gear sets, then reliable lubrication and cooling is ensured, but energy wastage increases and fuel consumption deteriorates
Solution Approach 1:
The lubrication system transitions from a static continuous supply to a dynamic controlled supply. The control system activates lubrication only when gear sets are engaged and require it, and deactivates when they are inactive, making the lubrication supply adaptive to operational conditions.
Solution Approach 2:
The lubrication system uses information from the gear shift mechanisms about their own operational state to automatically control lubrication supply. The system self-regulates based on whether gear sets are actively transmitting power or idle, eliminating the need for external continuous lubrication.
2Reliability
If lubrication is continuously supplied to inactive gear sets, then cooling and lubrication is maintained, but load-independent power losses increase
Solution Approach 1:
The lubrication supply is made dynamic by linking it to the operational state of gear sets. When gear sets are inactive (not transmitting power), the lubrication supply is automatically reduced or interrupted, preventing unnecessary power consumption from oil pumping and windage.
Solution Approach 2:
The system changes the lubrication parameter (supply rate) based on operational conditions. When gear sets are inactive, the lubrication parameter is reduced to minimal or zero supply, thereby reducing power losses while maintaining reliability when needed.
3Loss of energy
If gear shift mechanisms control lubrication supply, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The gear shift mechanisms perform a dual function: they control gear engagement and simultaneously control lubrication supply. This multi-functionality eliminates the need for separate control systems, reducing overall device complexity while achieving energy efficiency.
Solution Approach 2:
The control functions for gear shifting and lubrication supply are merged into a single integrated system. The gear shift mechanisms directly control both mechanical engagement and lubrication flow, combining multiple control functions into one system.
Data Source
AI summary
The invention relates to a lubricating device for controlling lubrication in a stepped transmission comprising a splitter section (10, 20) with an input shaft (I) and a main gear section (30, 40, 50, 60) with an output shaft (O) and a countershaft (C); where the splitter section (10, 20) comprises a first splitter gear set (10) connectable to the input shaft (I) by a first gear shift mechanism (23); and a second splitter gear set (20) connectable to the input shaft (I) by the first gear shift mechanism (23); and connectable to the output shaft (O) by a second gear shift mechanism (33). A lubrication arrangement for the second splitter gear set (20) is arranged to be controlled by the current positions of the first and the second gear shift mechanisms (23, 33); wherein the lubrication arrangement is controlled to at least reduce lubrication when the first and the second gear shift mechanisms (23, 33) are simultaneously connected to or disconnected from the second splitter gear set (20).