Transfer Case Baffle Lubricant Distribution
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Solution Overview
Problem
Optimally providing lubricant flow to rotating and translating components in a vehicle driveline, particularly in all-wheel-drive systems, is challenging due to tilted installations where the input shaft elevation differs from the output shaft, affecting the distribution of lubricant to bearings and seal assemblies.
Innovation Solution
A transfer case design with a baffle and dam system that directs lubricant flow from the case's inlet to the bearing and seal assembly, ensuring adequate lubrication even when the vehicle is tilted, using a cup-shaped extension and planetary gear set to maintain lubricant circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the transfer case is installed at an angle (tilted installation), then the vehicle can accommodate different driveline configurations, but lubricant flow to the bearing and seal assembly becomes inadequate
Solution Approach 1:
The transfer case housing is segmented into multiple chambers separated by baffles. The first baffle creates a first chamber between the input shaft and the second baffle, while the second baffle creates a second chamber between it and the output shaft. This segmentation allows lubricant to be directed through specific passages to ensure proper flow to the bearing and seal assembly regardless of installation angle.
Solution Approach 2:
The patent introduces vertical lubricant passages that extend through the baffles in the vertical dimension. These passages provide a dedicated lubricant flow path from the upper chamber to the lower chamber, ensuring lubrication reaches the bearing and seal assembly even when the transfer case is installed at an angle, thus adding a vertical flow dimension to overcome gravitational effects.
2Ease of manufacture
If a simple housing design is used, then manufacturing is easier, but lubricant distribution to internal components becomes insufficient
Solution Approach 1:
The housing incorporates integrated baffles and lubricant passages as segmented features during manufacturing. The first and second baffles are positioned to divide the housing interior into functional chambers, with lubricant passages providing direct flow paths. This segmentation approach maintains manufacturing simplicity while ensuring reliable lubricant distribution to all internal components.
Solution Approach 2:
The baffles and lubricant passages act as intermediary structures within the housing. These intermediaries redirect and channel lubricant flow from the oil reservoir to specific components that would otherwise be difficult to reach, particularly the bearing and seal assembly on the input shaft, without requiring complex external lubrication systems.
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
Ensures effective lubrication of components in all-wheel-drive systems, maintaining performance and reducing wear even when the driveline is installed at an angle, enhancing the reliability and longevity of the drivetrain.
Implementation Method 1
A baffle may extend over the inlet on the second side and radially outside the bearing
Data Source
AI summary
A product may include a case, and a shaft that rotates may extend into the case. A bearing may support the shaft at the case. A seal may be positioned around the shaft outboard from the bearing. The bearing may have a first side facing the seal and a second side facing away from the seal. The case may define an inlet to an area between the bearing and the seal. A baffle may extend over the inlet on the second side and radially outside the bearing.