The present disclosure relates to lubricant distribution for traction components of a vehicle transmission.
Transmissions, such as vehicle transmissions, have one or more gear meshes that selectively transfer torque from an input shaft to an output shaft of the transmission. The gear meshes commonly require lubrication during transmission operation. The gear meshes and lubricant may be contained within a transmission case or housing, and a sump may be provided to collect the fluid and act as a reservoir.
Lubrication systems are used to circulate lubricant and provide sufficient a quantity of filtered lubricant to all the moving parts of a transmission. Several types of lubrication systems are known. For example, a system referred to as a splash system utilizes a splasher or dipper affixed to one or more of the moving traction parts within an internal cavity of the transmission case. The moving parts are cycled through lubricant within the sump during the movement of parts and lubricant is splashed about the internal cavity of the case. The splash may be diverted using internal features of the transmission such as veins or funnels that direct the flow of lubricant as it drains. Splash systems include a high volume of lubricant and may allow lubricant to slosh within the internal cavity. One problem with splash lubrication is that it is speed dependent. There can be centrifugal effects, hydrodynamic effects, and effects from the gears working as pumps that may reduce efficiency of the transmission.
Dry lubrication systems distribute lubricant differently compared to splash systems. In dry systems, a significantly smaller volume of lubricant is contained in a sump within the transmission. The lubricant is drawn out of the sump and diverted to the traction components as required. A complex series of tubes may be assembled in a dry system where each tube has particular shapes for diverting lubricant to specific locations within the transmission. The complex tubes may be steel tubes that are formed and joined to separate nozzles. Several different tubes may be assembled to a larger central tube, or may be joined to each other by a larger over-molded body. Assembly of a large number of customized parts is often expensive and may require complex tooling.
This disclosure is directed to solving the above problem and other problems as summarized below.
A manifold for distributing lubricant in a transmission includes an inlet supply nozzle, a first body portion and a second body portion. The inlet supply nozzle receives transmission lubricant. The first body portion is in fluid communication with the supply nozzle and defines a first channel having a first open side along the first channel. The second body portion is in fluid communication with the supply nozzle and defines a second channel having a second open side along the second channel. The first and second body portions connect to form an assembled body in an assembled position such that the first and second channels collectively define a main tubular passage. A male extension portion can be formed on one of the first and second body portions. A female receiving portion can be formed on the other of the first and second body portions. The male extension portion can be received by the female receiving portion in the assembled position. A plurality of outlet ports can extend from the assembled body for dispersing lubricant from the main tubular passage across traction components of the transmission.
According to other features, the inlet supply nozzle can comprise a completely formed annular end of one of the first and second body portions. The outlet port can comprise a first, a second and a third outlet port. The first outlet port can be arranged to direct lubricant onto a first gear mesh of the transmission. The second outlet port can be arranged to direct lubricant onto an auxiliary drive of the transmission. The third outlet port can be arranged at a terminal end of the manifold and arranged to direct lubricant onto an auxiliary reduction gear mesh of the transmission.
In other features, the outlet ports can further comprise a fourth outlet port and a fifth outlet port. The fourth outlet port can be configured to be fluidly connected to an upper reverse idler tube. The fifth outlet port can be configured to be fluidly connected to the lower idler tube. The fourth and fifth outlet ports can be defined in the inlet supply nozzle. The first body portion can include a first pair of outwardly extending flanges. The second body portion can include a second pair of outwardly extending flanges that oppose and engage the first pair of outwardly extending flanges in the assembled position.
According to further features, the male extension portion can be formed on a flange of the first pair of outwardly extending flanges and the female receiving portion can be formed on an opposing flange of the pair of outwardly extending flanges. The male extension portion can comprise at least two distinct male extension portions. A first male extension portion can extend from a flange of the first pair of outwardly extending flanges. A second male extension portion can extend from a flange of the second pair of outwardly extending flanges. The female receiving portion can comprise at least two distinct female receiving portions. A first female receiving portion can be formed on a flange of the first pair of outwardly extending flanges. A second female extension portion can extend from a flange of the second pair of outwardly extending flanges.
According to still other features, at least one clip can be disposed around opposing flanges of the first and second pairs of outwardly extending flanges. The clips can have opposite distal ends that are nestingly received into complementary grooves formed in the opposing flanges of the first and second pairs of outwardly extending flanges. The inlet supply nozzle can be formed on the second body portion. The first body portion can comprise an upwardly extending support bracket having an inert-molded torque limiter and pin that facilitate mounting of the upwardly extending support bracket to internal structure of the transmission.
A manifold for distributing lubricant in a transmission and constructed in accordance to another example of the present disclosure includes an inlet supply nozzle, a first body portion and a second body portion. The inlet supply nozzle receives transmission lubricant. The first body portion is in fluid communication with the supply nozzle and defines a first channel having a first open side along the first channel. The second body portion is in fluid communication with the supply nozzle and defines a second channel having a second open side along the second channel. The first and second body portions connect to form an assembled body in an assembled position such that the first and second channels collectively define a main tubular passage. A plurality of outlet ports can extend from the assembled body for dispersing lubricant from the main tubular passage across traction components of the transmission. The inlet supply nozzle can comprise a completely formed annular end of one of the first and second body portions.
According to other features, the manifold includes a male extension portion formed on one of the first and second body portions. A female receiving portion can be formed on the other of the first and second body portions. The male extension portion can be received by the female receiving portion in the assembled position.
In other features, the outlet ports can further comprise a fourth outlet port and a fifth outlet port. The fourth outlet port can be configured to be fluidly connected to an upper reverse idler tube. The fifth outlet port can be configured to be fluidly connected to the lower idler tube. The fourth and fifth outlet ports can be defined in the inlet supply nozzle. The first body portion can include a first pair of outwardly extending flanges. The second body portion can include a second pair of outwardly extending flanges that oppose and engage the first pair of outwardly extending flanges in the assembled position. The inlet supply nozzle can be formed on the second body portion. The first body portion can comprise an upwardly extending support bracket having an insert-molded torque limited and pin thereon. The insert-molded torque limiter and pin can facilitate mounting of the upwardly extending support bracket to internal structure of the transmission.
The above aspects of the disclosure and other aspects will be apparent to one of ordinary skill in the art in view of the attached drawings and the following detailed description of the illustrated examples.
The illustrated examples are disclosed with reference to the drawings. However, it is to be understood that the disclosed examples are intended to be merely examples that may be embodied in various and alternative forms. The FIGS. are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.
According to an aspect of the present disclosure, a dry sump lubrication system is used to efficiently distribute transmission lubricant through the transmission 10. The dry sump configuration reduces drag losses caused by lubricant splash associated with a higher lubricant volume splash lubrication system. The internal cavity 14 defines a first section 20 and a second section 22, divided by a mid-wall 24. The first section 20 defines a sump 26, or reservoir, at a low point for collecting the lubricant. The maximum fill line 28 of the lubricant is lower than a maximum fill line of a splash type system because the moving components of the transmission 10 do not need to be substantially immersed in fluid. For example, in a dry lubrication system according to the present disclosure about twelve quarts of lubricant may be collected in the sump beneath the gear train traction components.
The lubrication system within the transmission case 12 is used to distribute the fluid lubricant from the sump 26. More efficient operation of the transmission is achieved by directing fluid lubricant to transmission traction components, generally housed in the region indicated by reference numeral 32. Active distribution of the fluid reduces the overall volume required to attain sufficient lubrication. The lubrication system is pressure driven and includes a strainer 30 and a pump 34. The pump 34 creates pressure and draws lubricant from the sump 26. A filter may be positioned near the intake of the pump 34 to restrict foreign particles from being cycled through the lubrication system. The lubrication system also may include a pressure regulator near an exhaust port of the pump 34 that opens when pressure in the system attains a predetermined value, for example, in the case of the filter clogging. Lubricant is forced through a supply tube 36 by the pump 34. The supply tube 36 is in fluid flow communication with a first manifold 38 that is arranged to distribute lubricant to the various transmission traction components 32.
Referring to
Referring to
Referring to the schematic of
The first manifold 38 may be formed as an injection molded plastic manifold that integrates several geometric features into a single component. However, forming complex bends and formations requires an expensive injection molding tool having multiple components and articulating slides to create features that are not aligned with the main direction of die movement. The main body 44 of the manifold 38 may be formed with a channel that has an open side along the length to reduce tooling costs and complexity. Including an open sided channel allows the main body 44 of the manifold 38 to be an open body having features integrally formed in the main direction of die movement.
Referring to
The main body 44 also defines a groove 60 along each of an opposing pair of edges on either side of the internal channel 46. The groove 60 defines a continuous path around the perimeter of the open side of the internal channel 46. The groove 60 receives a corresponding rib 62 disposed on the cover 58. The rib 62 nests in the corresponding shape of groove 60 to provide contact with multiple surfaces along a continuous path around the perimeter of the internal channel 46. The rib 62 creates a fluid seal when inserted into the groove 60. The cover 58 may be affixed to the main body 44 by adhesion, laser welding, or vibration friction welding to create a sealed seam joint between the cover 58 and the main body 44. In a preferred example, the cover 58 is joined by vibration friction welding. In alternative configurations, a recessed shoulder may be provided on each opposing side of the internal channel for receiving the cover. Mounting features 64 may be integrally molded into at least one of the main body 44 or the cover 58. The manifold 38 may be attached to corresponding features on an inner portion of the case 12 of the transmission.
Under extreme conditions, operating temperatures of the lubricant within the transmission may exceed 100 degrees Celsius. The manifold must be configured to maintain stiffness and dimensional stability at high operating temperatures. The manifold may injection molded from a resilient elastomer such as Polyamide 46. The elastomer preferably includes a predetermined volume of embedded glass fibers. In one example, the manifold 38 may have a wall thickness of about 2.5 mm.
Referring back to
A second manifold 66 may be used in conjunction with the first manifold 38 to provide a comprehensive transmission lubrication system. In at least one example, a first manifold and a second manifold are in series fluid flow communication to separately lubricate traction components within the first section 20 and the second section 22, respectively. The first and second manifolds 38, 66 may be fluidly connected to each other at the mid-wall 24 to distribute lubricant from one to the other. It may be desirable to arrange the first manifold 38 and the second manifold 66 in different orientations depending on the layout of the internal components within the transmission 10. The first manifold 38 may be elongate and oriented in a generally horizontal direction. The second manifold 66 may be elongate and oriented in a generally vertical direction.
Referring to
The second manifold 66 may also be constructed as a main body 80 joined to a cover 82. Similar to the first manifold discussed above, the cover 82 provides a fluid seal and encloses an internal channel to contain lubricant as it flows through the second manifold 66. The main body 80 is formed by injection molding to facilitate including various stiffening ribs 82 and gussets 84 that enhance the overall rigidity of the manifold.
The two manifolds cooperate to provide lubricant recirculation through the transmission. The exhaust nozzle 74 of the first manifold expels lubricant cycled through the manifold that is not dispersed from one of the outlet ports 48. The exhaust nozzle 74 is in fluid flow communication with a supply nozzle 76 of the second manifold 66 at a pass-through portion of the mid-wall 24. The second manifold 66 also includes a corresponding exhaust nozzle 78 that expels lubricant not dispersed by the ports 68. However, in the case of the second manifold 66, the lubricant is expelled to return back to the sump 26 for circulation. The exhaust nozzle 78 is directs lubricant through a pass-through portion of the mid-wall 24 to the first section 20 to drain back to the sump 26. In alternative configurations, the second manifold 66 may exhaust to a lubricant cooling system external to the transmission 10 prior to being directed back to the sump 26. Lubricant may be directed through the cooling system before dispersion across the traction components of the transmission 10 to aid in preventing excessive heat build-up.
With reference now to
As will be described in greater detail herein, the manifold 104 receives and distributes lubricant in addition to having outlet ports configured as spray orifices on it. Specifically, the manifold 104 has an inlet supply nozzle 120 that defines an opening 122 that receives lubricant from the pump 108 by way of a connecting tube 126. The manifold 104 has a plurality of outlet ports comprising a first outlet port 130, a second outlet port 132 and a third outlet port 134. Lubricant is sprayed out of the manifold 104 through each of the first, second and third outlet ports 130, 132 and 134.
With specific reference to
Additional features of the manifold 104 will now be described. The manifold 104 includes the inlet supply nozzle 120, a first body portion 202 and a second body portion 204. The inlet supply nozzle 120, first body portion 202 and second body portion 204 can be formed of injection molded plastic. As will be described, the manifold 104 comprises two distinct portions, the first body portion 202 and the second body portion 204 that are coupled together.
The first and second body portions 202 and 204 are in fluid communication with the inlet supply nozzle 120. In the particular example, the inlet supply nozzle 120 is integrally formed with the second body portion 204. The inlet supply nozzle 120 comprises a completely formed annular end of the second body portion 204. The first body portion 202 defines a first channel 212 having a first open side 216 along the first channel 212. The second body portion 204 defines a second channel 222 having a second open side 226 along the second channel 222. The first and second body portions 202 and 204 connect to form an assembled body 230 (
With particular reference now to
The first body portion 202 includes a first pair of outwardly extending flanges 270. The second body portion 204 includes a second pair of outwardly extending flanges 272 that oppose the first pair of flanges 270. In the example shown, the second male extension portion 244 and the first female receiving portion 250 are formed on the first pair of flanges 270. The first male extension portion 240 and the second female receiving portion 254 are formed on the second pair of flanges 272. The first body portion 202 can further include first grooves 280 formed on a flange of the first pair of flanges 270. The second body portion 204 can further include second grooves 282 formed on a flange of the pair of second flanges 272.
The first body portion 202 can further include an upwardly extending support bracket 286 having an insert-molded torque limiter 288 and pin 290 thereon. A support flange 292 can connect between the support bracket 286 and the second outlet port 132. The torque limiter 288 and pin 290 can be used to mount the manifold 104 to the case 112. In one configuration the torque limiter 288 is engaged with an intermediate wall of the case 112. The pin 290 is used to limit rotational movement of the manifold 104 while tightening an associated fastener (not specifically shown) extending through the insert-molded torque limiter 288 thus maintaining desired oil stream targeting.
A series of clips 302 and 304 can be located around opposing flanges of the first and second pairs of flanges 270, 272. The clips 302 and 304 can further couple the first and second body portions 202 and 204 together. The clips 302 and 304 can be formed of sheet steel and be crimped around the flanges 270, 272. The clips 302 can have fingers 312 that locate into the grooves 280 of the first body portion 202. The clips 304 can have fingers 314 that locate into the grooves 282 of the second body portion 204. In some examples, the crimping will deform the clips 302, 304 around the flanges. In one configuration, the adhesive and/or sealant 260 sufficiently couples the first and second body portions 202, 204 such that the clips 302 and 304 are optional.
The examples described above are specific examples that do not describe all possible forms of the disclosure. The features of the illustrated examples may be combined to form further examples of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of the following claims is broader than the specifically disclosed examples and also includes modifications of the illustrated examples.
This application is a continuation-in-part of U.S. patent application Ser. No. 14/315,434, filed on Jun. 26, 2014, which claims the benefit of U.S. Provisional Application No. 61/839,888, filed on Jun. 27, 2013. The disclosures of the above applications are incorporated herein in their entirety by reference.
Number | Date | Country | |
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61839888 | Jun 2013 | US |
Number | Date | Country | |
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Parent | 14315434 | Jun 2014 | US |
Child | 14962027 | US |