Transmission Hydraulic Pump Segmentation for Energy Loss Reduction
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Solution Overview
Problem
Existing transmission devices with hydraulic systems face challenges in efficiently supplying hydraulic fluid across various operating modes, particularly during coasting or switched-off states of the drive unit, leading to inadequate lubrication and delayed functionality, which increases energy losses and installation costs.
Innovation Solution
A transmission device with a pump system comprising a first pump unit connected to the transmission input shaft and a second pump unit connected to the transmission output shaft, allowing for hydraulic fluid supply to both primary and additional pressure circuits, with non-return valves and throttle devices ensuring fluid distribution across different operational states, reducing power losses and installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single pump device is used to supply all hydraulic consumers, then installation space and production costs are reduced, but power consumption increases and energy efficiency deteriorates
Solution Approach 1:
The hydraulic system is divided into two separate pump units: a first pump unit supplying the primary pressure circuit and a second pump unit supplying the additional pressure circuit. This segmentation allows each pump to be optimized for its specific circuit requirements, enabling the second pump to operate at lower pressures and thus reducing overall power consumption while maintaining compact installation space.
2Loss of energy
If the drive unit is switched off during coasting mode, then energy losses are reduced, but hydraulic supply to the transmission system stops causing downtime and functionality loss
Solution Approach 1:
The second pump unit is driven by the output shaft, which continues to rotate even when the drive unit is switched off during coasting mode. This preliminary action ensures that hydraulic fluid is continuously supplied to the additional pressure circuit, maintaining lubrication and readiness for immediate operation upon restart without causing downtime.
Solution Approach 2:
The output shaft acts as an intermediary power source that transfers rotational energy to the second pump unit independently of the drive unit's operational state. This intermediary mechanism ensures continuous hydraulic supply during coasting mode when the primary drive is switched off, eliminating downtime while maintaining energy efficiency.
3Loss of energy
If hydraulic consumers operate at much lower pressure levels, then energy requirements are reduced, but a single pump cannot efficiently serve both high and low pressure consumers simultaneously
Solution Approach 1:
The hydraulic system is segmented into two independent pressure circuits with separate pump units. The first pump unit handles high-pressure consumers (clutches, shift actuators) while the second pump unit handles low-pressure consumers (wheel set lubrication, bearing devices). This segmentation allows each pump to be optimized for its pressure range, improving overall energy efficiency while maintaining full hydraulic supply capability across all consumers.
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 solution enables continuous hydraulic fluid supply to transmission components, maintaining lubrication and reducing downtime, while minimizing energy losses and installation space, allowing for efficient operation during normal driving and coasting modes without the need for additional electric pumps.
Implementation Method 1
a first pump unit (4) of the pump device (3) connected to and drivable by the transmission input shaft (1.1), and a second pump unit (5) of the pump device (3) connected to and drivable by a transmission output shaft (1.2)
Implementation Method 2
with non-return valves and throttle devices ensuring fluid distribution across different operational states
Implementation Method 3
maintaining lubrication and reducing downtime, while minimizing energy losses
Data Source
AI summary
A transmission device with a hydraulic system includes a pump device, a primary pressure circuit, and at least one additional pressure circuit supplied with hydraulic fluid by the pump device. The pump device is coupled to and driven by a transmission input shaft. A first pump unit of the pump device is connected to and driven by the transmission input shaft. A second pump unit of the pump device is connected to and driven by a transmission output shaft. A pressure side of the first pump unit is connected to the primary pressure circuit, and is connectable to the additional pressure circuit, while a pressure side of the second pump unit is connected to the additional pressure circuit, and is able to be coupled with the primary pressure circuit.