Transfer Case Pump with Multiple Flow Paths
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Solution Overview
Problem
Current lubrication systems for transfer cases lack control over lubricant delivery to components like the clutch, which have varying lubrication needs based on vehicle operation modes, leading to inefficiencies and increased fuel consumption.
Innovation Solution
A lubrication system with a pump and valves that allow for controlled fluid flow to transfer case components, using a fluid guide insert to direct lubricant flow and valve controls to adjust flow based on operating conditions, reducing parasitic and spin losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pump delivers lubricant through an axial bore in the input shaft and output shafts with supply ports, then lubrication is provided to transfer case components, but control over lubricant delivery to components with variable lubrication needs is limited
Solution Approach 1:
The lubrication system is segmented into multiple independent flow paths. The pump outlet connects to a first flow path leading to the clutch and a second flow path leading to other transfer case components. This segmentation allows independent control of lubricant delivery to different components, enabling adaptability to variable lubrication needs without requiring complete system redesign.
Solution Approach 2:
The system incorporates controllable valves in each flow path that can dynamically adjust or restrict lubricant flow based on operating conditions. The valves enable the system to transition between different lubrication modes (full flow, restricted flow, or shut-off) for the clutch specifically, while maintaining flow to other components, thus providing dynamic adaptability.
2Reliability
If full lubricant flow is delivered to all components continuously, then all components receive adequate lubrication, but fuel consumption increases due to parasitic and spin losses
Solution Approach 1:
The system uses controllable valves to periodically adjust lubricant flow to the clutch based on engagement status. When the clutch is disengaged, the valve restricts or shuts off lubricant flow to that component, eliminating unnecessary spin losses. When engaged, full flow is restored. This periodic adjustment of flow based on operational need reduces overall energy consumption while maintaining component reliability.
Solution Approach 2:
The system changes the flow parameter (lubricant delivery rate) to different components based on their instantaneous needs. The pump maintains adequate pressure, but valves modulate the actual flow quantity delivered to each component. For example, during clutch disengagement, flow to the clutch is reduced to minimal levels while flow to other components remains adequate, optimizing the balance between reliability and energy efficiency.
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 optimizes lubricant distribution according to vehicle mode, reducing lubricant consumption and minimizing spin losses when the clutch is disengaged, thereby enhancing fuel efficiency and component performance.
Implementation Method 1
The pump is operable to supply a lubricant along at least two fluid flow paths extending from a lubricant source to one or more transfer case components
Implementation Method 2
The first valve is operable between a first state in which fluid flows through the first valve outlet and is not restricted and a second state in which fluid flows through the first valve alternative outlet and is restricted
Implementation Method 3
The fluid guide insert is disposed within the power transfer assembly and is configured to direct the flow of fluid from the first inlet port to the first outlet ports and from the second inlet port to the second outlet ports
Implementation Method 4
The system optimizes lubricant distribution according to vehicle mode, reducing lubricant consumption and minimizing spin losses when the clutch is disengaged
Data Source
AI summary
A lubrication system for a transfer case includes a pump in fluid communication with a lubricant source and a power transfer assembly, as well as one or more valves positioned along fluid flow paths between the lubricant source and the power transfer assembly. The valves may allow full fluid flow or may restrict fluid flow to various components of the transfer case as conditions warrant. A fluid guide insert may be used to help direct lubricant flow to the components.