Transfer Case Pump Clutch for Parasitic Loss Reduction
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Solution Overview
Problem
Current transfer case lubrication systems lack control over lubricant flow rates to specific components, resulting in inefficient lubrication and parasitic losses due to continuous operation of the pumping elements.
Innovation Solution
A lubrication system with a pump clutch assembly that includes a first and second clutch rotor, where the second clutch rotor is axially movable to engage or disengage from the first rotor, and an electromagnetic coil or actuator to control the engagement, allowing the pump to be disconnected from the shaft when not in use, reducing parasitic losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pump is continuously mounted on the shaft to deliver lubricant, then lubrication is provided to components, but parasitic losses increase and energy consumption rises
Solution Approach 1:
The pump mounting is changed from a static continuous connection to a dynamic selectively engageable connection. The pump is mounted on the shaft through an engageable mounting structure that allows it to be selectively connected or disconnected, enabling the system to switch between lubrication mode and energy-saving mode based on operational requirements.
Solution Approach 2:
The pump operation is changed from continuous to periodic or selective action. The engageable mounting structure allows the pump to operate only when lubrication is required, rather than continuously running, thereby reducing parasitic losses during periods when lubrication is not needed while maintaining reliable lubrication when required.
2Reliability
If the pump operates continuously to ensure lubrication, then components are adequately lubricated, but energy consumption increases
Solution Approach 1:
The pump mounting structure provides dynamic control over pump operation. By being selectively engageable, it allows the system to adapt pump operation to actual lubrication needs, reducing energy consumption during normal operation while maintaining reliable lubrication when required through selective engagement.
3Loss of energy
If the pump is disengagable from the shaft, then parasitic losses are reduced, but control mechanisms are required
Solution Approach 1:
The engageable mounting structure serves multiple functions: it provides mechanical support for the pump, enables selective engagement/disengagement, and acts as a clutch mechanism. This multi-functionality reduces the need for separate dedicated clutch components, thereby managing device complexity while achieving the disengagable pump functionality.
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
This solution provides controlled lubricant flow and reduces energy consumption by disengaging the pump from the shaft during non-operation, enhancing efficiency and reducing parasitic losses.
Implementation Method 1
An electromagnetic coil is operable to produce a magnetic field when energized to cause the pump clutch assembly to move between the engaged position and the disengaged position
Implementation Method 2
at least part of the second clutch rotor is formed from a ferromagnetic material
Data Source
AI summary
A lubrication system (300) for a transfer case (200) includes a shaft (302) having a lubricant inlet port (306) and a hollow bore (304) for transporting lubricant within the shaft (302), a pump (310) having a pump housing (312) and one or more pumping elements (318) that are disposed in the pump housing (312), and a clutch assembly (330). The clutch assembly 330 has an engaged position in which rotational force from the shaft (302) is transferred to the one or more pumping elements (318) to cause operation of the pump (310), and a disengaged position in which rotational force from the shaft (302) is not transferred to the one or more pumping elements (318). An actuator (370, 410) is operable to cause the clutch assembly (330) to move between the engaged position and the disengaged position.