DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(See sections 10 & rule 13)
1. TITLE OF THE INVENTION
A COMBINED NATURAL COOLING SYSTEM FOR HIGH PERFORMANCE POWERTRAIN WITH INTEGRATED BEVEL GEAR, BULL GEAR, WHEEL BEARING AND WET MULTIPLE DISC BRAKE
2. APPLICANT (S)
NAME NATIONALITY ADDRESS
BEML LIMITED IN BEML Soudha, No 23/1, 4th Main S.R. Nagar, Bengaluru- 560027, Karnataka, India.
3. PREAMBLE TO THE DESCRIPTION
COMPLETE SPECIFICATION

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION:
[001] The present invention relates to the field of cooling system for high performance powertrain. The present invention in particular relates to a combined natural cooling system for high performance powertrain with integrated bevel gear, bull gear, wheel bearing and wet multiple disc brake.
DESCRIPTION OF THE RELATED ART:
[002] Waste heat from automotive (heat) engines is an essential consequence of the thermodynamics of converting the chemical energy of the fuel into mechanical work. In fact, in a practical engine, the greater portion of the fuel heating value must be removed from the engine proper as a result of which the essential engine exhaust and cooling requirements arise. While this heat is practically unavailable directly for producing further work within the engine itself, it can be made available indirectly by various means for relatively high level uses both within the engine, as by compounding or turbocharging, and external to the engine, as by heating, refrigeration (air conditioning) or other auxiliary power applications. In the first use, the waste heat provides the power to alter engine input conditions or to add recovered power to the output, resulting in increased power and/or fuel economy. The latter case represents a saving in engine power by substituting a waste-heat-powered by-product function for one which would otherwise take some additional prime engine shaft power and fuel to produce it.
[003] Reference may be made to the following:
[004] Publication No. US2014262644 relates to an inlet, positioned to access the flow of air passing around and under a moving vehicle, may draw in air which is conveyed through a duct and discharged to cool a brake on a vehicle. The inlet has a closure. The closure is opened and closed on demand by a temperature-operated actuator incorporating an active or smart material under the direction of a controller. In embodiments, a sensor, suitably positioned to sense a temperature representative of the brake temperature, communicates the sensed brake temperature to the controller.
[005] Publication No. US2020277035 provides a gas-electric parallel-serial hybrid marine power train system with LNG cooling, including a gas engine, an electric generator, a motor, a natural gas storage supplier. The gas engine is connected to the shaft belt motor through a gearbox, the motor is connected to the gearbox through a clutch, propellers are connected to the motor, and an engine cooling system and a fuel cell cooling system are connected to an LNG vaporization heat exchange apparatus; the electrical energy sources are the fuel cell, the electric generator and a storage battery.
[006] Publication No. KR20030016842 provides a cooling system for a bus to improve cooling efficiency and reduce noise by maximizing the suction amount of air with arranging a radiator and a cooling fan vertically, and to reduce fuel consumption by shutting off power in not requiring cooling.
[007] Publication No. CN107543268 provides a method comprising three schemes for naturally cooling an automobile, a chamber, a warehouse and underground space healthily, in order to achieve the main purpose of solving the heating-up problem of storage boxes and compartments in the automobile, the chamber, the warehouse and the underground space.
[008] Publication No. CN209875804 discloses an automatic cooling structure of a train wheel-mounted brake disc. Including an outer brake disc, a plurality of connecting steel ingots are arranged on one side of the outer brake disc; the multiple connecting steel ingots are distributed on the outer side face of the outer brake disc at equal intervals.
[009] Publication No. CN107470583 provides a semi-solid rheological squeeze casting mold and a molding method for a G-series high-speed train brake disc. The semi-solid rheological squeeze casting mold for the G-series high-speed train brake disc mainly comprises an upper mold fixing plate, an upper mold, a pressing plate, an axle hole core, a lower mold, a lower mold fixing plate, an axle hole core fixing column, lower pressing heads, a lower pressing head fixing plate and a pressurizing column. A disc body of the brake disc is located inside the lower mold, and cooling ribs of the brake disc are located in the upper mold. The upper mold is fixed to the upper mold fixing plate through the pressing plate, and the lower mold is fixed to the lower mold fixing plate through the pressing plate.
[010] Patent No. US8678426 relates to an inlet positioned to access the flow of air passing around and under a moving vehicle, draws in air which is conveyed through a duct and discharged to cool a brake on a vehicle. The inlet has a closure so that access of cooling air may be denied when the brake temperature is less than a predetermined temperature and opened only when the brake temperature exceeds that predetermined temperature.
[011] Publication No. CN212567007 discloses a cooling device for petrochemical engineering, which belongs to the field of petrochemical engineering and comprises a leg frame, a cooling box, a heat exchange water tank and a cooling coil pipe, the cooling box, the heat exchange water tank and the cooling coil pipe are arranged on the leg frame and are adjacent left and right, and the bottoms of the cooling box and the heat exchange water tank are fixed on the ground through the leg frame.
[012] Publication No. DE112009000225 provides a power transmission device with a bevel gear for supporting a bevel gear or a shaft with the bevel gear through a bearing. The bearing solely has a structure in which its rolling elements support without play a thrust load in both directions of the bevel gear or the shaft with the bevel gear. A pitch circle of each of the rolling elements may be located on the outside of an inner end of a tooth of the bevel gear in the radial direction.
[013] Publication No. US2006196290 relates to a bevel gear transmission without shims, especially for a controllable wheel of a service vehicle such as a lift truck, with a one-piece housing for the acceptance of a bevel gearset, a plurality of bearing borings, for the support of a pinion gear shaft, a UniPack bearing and a sealing cover. The sealing cover is placed at a position at which the vertical borings for the bearings of the pinion gear shaft are to be placed, and the cover being provided with a circumferential protrusion which enables that an appropriately dimensioned tool can be vertically introduced into the one-piece housing for a precise construction of the housing which is designed to the closely tolerated dimensions of sections (A) and (B).
[014] Publication No. US2006189433 relates to a transaxle comprising a transmission a pair of coaxial axles a deceleration assembly for decreasing output rotational speed of the transmission, a differential assembly for transmitting power from the deceleration assembly to the pair of axles, and a common housing incorporating the transmission. The differential assembly includes a pair of gear train units disposed on the respective axles, and a bull gear for receiving output rotation of the deceleration assembly.
[015] Publication No. CN215720614 provides a special gear motor structure for a servo press, which comprises a machine body, a crankshaft, a bull gear, a bull gear box body, a gear shaft, a planetary gear box and a servo motor, the crankshaft is arranged in the machine body, one end of the crankshaft is connected with the bull gear arranged in the bull gear box body, and the other end of the crankshaft is connected with the planetary gear box.
[016] Publication No. EP3482080 relates to geared turbomachine having a gearbox a drive unit and a plurality of output units which are integrated into a machine train; wherein the gearbox comprises a central large gear with a large gear shaft and a plurality of pinions with pinion shafts meshing with the large gear wherein the drive unit is designed as a steam turbine in which a first process gas is expanded to provide mechanical drive power; wherein a first output unit is designed as an at least two-stage main compressor, in which a second process gas is compressed using the mechanical drive power provided by the drive unit wherein an intercooler is connected between each two stages of the main compressor in order to cool the second process gas; wherein a plurality of second output units are designed as gear compressors, in which the second process gas is further compressed using the mechanical drive power provided by the drive unit wherein an intercooler is arranged between the last stage of the main compressor and the first gear compressor and between each two gear compressors and an end cooler is arranged downstream of the last gear compressor in order to cool the second process gas.
[017] Publication No. US2004237683 relates to an electric power-generating device with a rotor turned by an external source of energy, such as wind or water currents. The rotor is coupled to a main shaft. A pair of bull gears is located on the main shaft. A number of intermediate gears are located around a perimeter of the bull gears. An intermediate gear is connected to an input shaft having a double helix pinion that engages the pair of bull gears.
[018] Publication No. CN215791721 relates to a film bubble thickness local adjusting structure of a cooling air ring of film blowing equipment comprises a cooling air ring body, the cooling air ring body is provided with an annular main air channel and an annular air outlet, and a plurality of air blocking brake blocks are further vertically and slidably installed on the channel wall of a radial air guiding channel.
[019] Publication No. GB2107453 provides a hot box detector system in which an infra-red scanner is arranged to scan the wheel bearings of railway rolling stock passing over a section of track and to generate signals which are processed to determine the temperature of the bearing, the nature of the bearing, and, for signals derived from bearings within a closed housing to determine if the scanned surface of the housing is an inner sidewall or an outer sidewall of the housing relative to the bogie to which the bearing belongs.
[020] Publication No. CN112943908 relates to a lubricating system of a gearbox of a vehicle driving system. The lubricating system comprises a lubricating oil distribution system and a gear oil scraper.
[021] Publication No. CN207246300 discloses a rice and wheat straw graphite alkene train brake shoe, including metal backboard and friction material, metal backboard is curved tile form, and metal backboard outside middle part is equipped with the braking connecting portion, and the metal backboard both ends are equipped with the wing extension, metal backboard's inboard fixed mounting friction material, friction material is rice and wheat straw graphite alkene friction disc.
[022] Publication No. CN114261378 relates to the urban rail train, the braking force management method and system and the EBCU, the difference value delta F is compared with a set threshold value to determine the mode in which braking force management is carried out, when the difference value is smaller than or equal to the set threshold value, the total braking force calculated by a TCMS is taken as the standard, at the moment, the influence of short braking delay and small difference value on the whole train can be ignored, and the braking force management can be carried out through the EBCU. Therefore, the braking response time is shortened, the performance of a train braking system is improved, and the braking safety level is guaranteed.
[023] Publication No. CN206309828 relates to a brake disc with wear -resisting hydroxyapatite coating. At present, the basic brake mode that high speed train mainly adopted is the disc braking, and the brake disc need have excellent wearability, fatigue resistance and crack resistance as the disc brake core component.
[024] Publication No. JP2019143666 relates to a dump truck in which the clogging of a filter provided on a cooling circuit cooling a wet multiple disc brake can be suppressed. A dump truck comprises: a cooling circuit cooling a wet multiple disc brake by circulating cooling oil; a filter circuit filtering the cooling oil; a first switching valve and a second switching valve switching the cooling circuit and the filter circuit and a controller controlling operations of the first switching valve and the second switching valve.
[025] Patent No. US4280609 relates to a multiple wet disc brake or clutch is disclosed which includes a disc pack located in a housing. The stator discs in the disc pack are retained in the inner peripheral surface of the housing by curved tabs extending radially outward about the peripheral surface of each stator disc and engaging respective curved groove areas between margins in the inner peripheral surface of the housing. The stator disc tabs contact one margin of the respective grooves when the hub is rotated in a first direction to form a horn-shaped chamber between the converging outer surfaces of said respective tabs and grooves.
[026] Publication No. US2003188936 relates to a vehicle driveline component temperature control assembly utilizes compressed air or another fluid to cause air flow across an external portion of the driveline component. The airflow facilitates heat transfer or heat dissipation from within the driveline component to assist in maintaining the temperature of the component within an acceptable range.
[027] Publication No. CN113859271 relates to a power system of a hybrid power motor train unit. The power system comprises a power battery system, a traction power system and an auxiliary power system. The power battery system comprises a power battery, a power battery control system and a power battery thermal management system.
[028] Publication No. CN101992679 relates to a double planetary row four-axis hybrid power transmission device, which comprises a double planetary row improved from a ravigneaux planetary gear transmission mechanism, an engine arranged on the left side of the double planetary row, a motor A mainly playing a role in generating power and a motor B mainly playing a role in driving on the right side of the double planetary row, and a main speed reducer driven by a gear. Moreover, the device is also provided with a first locking clutch capable of locking the engine and a second locking clutch capable of locking the motor A; the motor A is connected with a small sun gear of the double planetary row; and the motor B is connected with a large sun gear of the double planetary row.
[029] Publication No. CN117360184 relates to an integrated electric propulsion system of a vehicle includes a single electric machine, a mechanical gear train, a rechargeable energy storage device, an integrated cooling system, and a power electronics system. The single electric machine, the mechanical gear train, the integrated cooling system, the rechargeable energy storage device, and the power electronics system are arranged in a single housing.
[030] Publication No. CN109130839 relates to an electric wheel assembly, axle and vehicle suitable for twin-tire parallel loading wheels. The electric wheel assembly comprises wheels and a support shaft assembly, an inner rotor hub motor, a planetary gear reducer and a braking system. A planet carrier is connected with a wheel hub, the wheel hub connects a spoke and a wheel rim, a wheel support shaft passes through a rotor sleeve, and hub bearings are arranged on the wheel support shaft to support the wheel hub and the whole wheel.
[031] Publication No. CN113006691 relates to an emergency and power compensation system and method for a hydraulic energy storage vehicle-mounted drilling and repairing machine.
[032] Publication No. CN215720614 relates to a special gear motor structure for a servo press, which comprises a machine body, a crankshaft, a bull gear, a bull gear box body, a gear shaft, a planetary gear box and a servo motor, the crankshaft is arranged in the machine body, one end of the crankshaft is connected with the bull gear arranged in the bull gear box body, and the other end of the crankshaft is connected with the planetary gear box.
[033] Publication No. CN212775388 relates to a motor is connected with a speed reducing mechanism, the speed reducing mechanism comprises a speed reducing machine box, a middle gear shaft and an output shaft, the two ends of the middle gear shaft are rotatably connected to the speed reducing machine box through a middle shaft upper bearing and a middle shaft lower bearing respectively, and a high-speed large gear is arranged at the upper end of the middle gear shaft.
[034] Patent No. US4655326 discloses an axle outer end including a planetary reduction drive unit and a multiple disc friction brake. The friction brake includes a plurality of rotatable and non-rotatable discs for selectively interconnecting the ring and sun gears of the planetary drive unit.
[035] The article entitled “Integrated management of powertrain and engine cooling system for parallel hybrid electric vehicles” by Xuefang Li; Simos Evangelou; Roberto Lot; IEEE Vehicle Power and Propulsion Conference (VPPC); September 2018 talks about the supervisory control strategy is proposed for parallel hybrid electric vehicles (HEVs). The control strategy is based on the equivalent consumption minimization strategy (ECMS) but it also considers the power consumed by the engine cooling system to optimize the overall fuel economy of the vehicle. To verify its effectiveness, the proposed cooling-sensitive ECMS is implemented on a through-the-road (TTR) HEV, after the mathematical model of the TTR HEV is developed based on power flows, and engine thermal dynamics is also included. Simulations are performed with different drive cycles, and the results show that the cooling-sensitive ECMS is able to improve the fuel economy by 2.7% compared to the baseline ECMS. Furthermore, it is shown that cooling-sensitive ECMS operates in a charge-sustaining manner provided that the equivalence factors are optimally selected.
[036] The article entitled “Powertrain Cooling Simulation” by Gamma Technologies, LLC; 2025 talks about the predictive thermal modeling GT-SUITE powertrain cooling models can be used to predict heat rejection to coolant, oil, and ambient, before engine hardware is available for physical testing. These models utilize a built-in finite element cylinder structure for more accurate predictions of heat distribution through the engine structure. Powertrain cooling models integrated with other vehicle systems can also be used to analyze engine warm-up and fuel economy during transient drive cycles. Construction of GT-SUITE engine thermal models is enhanced by powerful 3D tools for converting CAD geometry into GT models. The flexible range of fidelity provides an ideal simulation environment for system design, component selection, and controls optimization. Application highlights Easy-to-use parametric finite element cylinder structure transfers heat from combustion gas to the coolant and oil circuits. Liquid circuits and thermal masses built semi-automatically from 3D CAD data. Flow solution is based on Navier-Stokes equations and is stable with zero flow to support thermostat valve modeling and advanced warm-up strategies. Always solves energy equation (thermo-hydraulics). Heat distribution model is easy to integrate with full vehicle models for transient drive cycle analysis. Advanced features accurately account for interactions between engine cooling system, thermal structure, and combustion chamber. Built-in FE solver predicts engine structure temperatures, steady state and transient. Predicts engine thermal balance by detailed modeling of conduction paths between all heat sources and sinks. Predicts heat rejection to coolant, oil and ambient. Study the potential fuel savings associated with concepts for more efficient warmup of engine fluids and structure. Parametric finite element cylinder available for easy model setup. Custom finite element meshes of the engine components can be used for more detailed analysis. No extra cost, included in every GT-SUITE license.
[037] The article entitled “Principle and Design of Cooling System on multi-function Wet Type Multi-disk Brakes” by Chuanwei Zhang, Wang Miao; Proceedings of the 2016 Joint International Information Technology Mechanical and Electronic Engineering; October 2016 talks about the wet brake, structure and principle of multi-function wet type multi-disk brake, focusing on its principle of cooling system and design of fully-closed multi-function multi-disk wet brake, as well as calculated and analyzed the cooling system of the vehicle brake on different kinds of cars.
[038] Traditional powertrain systems for heavy vehicles typically employ planetary gear sets for torque reduction. While effective in many applications, planetary gear systems can exhibit limitations in terms of torque capacity and inherent efficiency due to inherent internal losses. Furthermore, conventional braking systems, often relying on separate components and cooling circuits, may not provide the desired performance and reliability in demanding operating conditions such as off-road applications. These separate cooling systems for the powertrain and braking components can significantly increase the complexity and maintenance requirements of the overall vehicle system.
[039] In order to overcome above listed prior art, the present invention aims to provide a combined natural cooling system for high performance powertrain with integrated bevel gear, bull gear, wheel bearing and wet multiple disc brake. The proposed invention differs from traditional systems by combining integrated bevel and bull gear reduction with a common drive shaft, an integrated wet multiple disc brake arrangement, and a common internal cooling system. The advantages include enhanced torque transmission efficiency through bevel and bull gear reduction, improved braking performance with the wet multiple disc brake arrangement, and a simplified cooling system with a common internal cooling system, reducing complexity and maintenance.
[040] The proposed invention addresses these issues by providing a more robust and efficient torque transmission through bevel and bull gear reduction, integrating a wet multiple disc brake arrangement for improved braking performance, and utilizing a common internal cooling system to maintain optimal operating temperatures and enhance overall system maintenance. It also eliminates the isolation of all the systems from each other during operation, unlike conventional systems.
OBJECTS OF THE INVENTION:
[041] The principal object of the present invention is to provide a combined natural cooling system for high performance powertrain with integrated bevel gear, bull gear, wheel bearing and wet multiple disc brake.
[042] Another object of the present invention is to provide which a combined natural cooling system for high performance powertrain ensures robust and efficient torque transmission, superior braking performance, and optimal operating temperatures for both the powertrain and braking system, enhancing overall system reliability and efficiency.
[043] Yet another object of the present invention is to provide a robust and efficient torque transmission system, superior braking performance, and effective cooling for both the powertrain and brake components, all within a streamlined and integrated design.
SUMMARY OF THE INVENTION:
[044] The present invention relates to a combined natural cooling system for high performance powertrain with integrated bevel gear, bull gear, wheel bearing and wet multiple disc brake.
[045] The architecture integrates a common natural cooling system to enhance the overall efficiency, durability, and performance of heavy-duty vehicles. It utilizes a single chamber cooling system for all components. This system maintains optimal operating temperatures, reducing complexity and maintenance requirements. The common cooling system ensures that all components, including the bevel and bull gears, wet multiple disc, producing and supplying these cutting-edge drive axle systems to both original equipment manufacturers (OEMs) and aftermarket customers.
[046] The invention integrates spiral bevel gear reduction for enhanced torque transmission efficiency with bull gear reduction for robust torque handling. This combination is uniquely tailored to achieve higher torque output and operational reliability in heavy-duty applications, particularly for off-road and demanding environments. The system features an enclosed wet multiple disc braking arrangement directly integrated into the powertrain architecture. This provides superior braking performance and eliminates the need for separate braking systems, reducing complexity and improving reliability under high loads and harsh conditions.
[047] A novel cooling arrangement is introduced, utilizing a single internal cooling chamber shared by the powertrain, wheel bearing and braking components. This passive or natural cooling system enhances thermal management, ensures optimal operating temperatures, and eliminates the need for separate cooling circuits, thereby reducing system weight, complexity, and maintenance requirements. The integrated design improves power density by consolidating multiple systems into a compact architecture. This enhances the system's durability and reliability while reducing the number of components and interfaces, which are potential points of failure.
[048] The integration of the torque transmission system, braking system, and cooling mechanism into a single unit minimizes assembly complexity and maintenance requirements. This feature addresses a critical limitation of traditional heavy-duty powertrains, which rely on separate subsystems with higher maintenance demands. By replacing traditional planetary gear systems with spiral bevel and bull gear configurations, the invention overcomes the inherent inefficiencies and torque limitations associated with planetary setups. This innovative approach significantly improves system efficiency and load-handling capacity.
BREIF DESCRIPTION OF THE INVENTION
[049] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments.
[050] Figure 1 illustrates the schematics of a bevel differential, bull gear, and wet multiple-disc brake system integrated with a common cooling mechanism.
[051] Figure 2 describes the mixed floating drive axle architecture system and its components.
DETAILED DESCRIPTION OF THE INVENTION:
[052] The present invention provides an advanced powertrain architecture that integrates spiral bevel and bull gear reduction with an enclosed wet multiple disc brake arrangement and a common internal cooling system for powertrain and brake applications. This system enhances the overall efficiency, durability, and performance of heavy-duty vehicles, particularly in demanding operational environments such as off-road conditions. By combining these elements, the invention provides a robust and efficient torque transmission system, superior braking performance, and effective cooling for both the powertrain and brake components, all within a streamlined and integrated design. This approach not only improves the power density and reliability of the powertrain but also reduces the complexity and maintenance requirements, making it a highly effective solution for modern heavy-duty crane application.
[053] The present invention introduces an advanced powertrain architecture that integrates spiral bevel and bull gear reduction with an enclosed wet multiple disc brake arrangement and a primary natural combined cooling system. This innovative design emphasizes natural or passive cooling as the primary method for managing the thermal demands of both the powertrain and braking components. The cooling system leverages the shared internal volume of the integrated components to facilitate natural fluid circulation and effective heat dissipation, eliminating the need for active cooling mechanisms. This approach reduces energy consumption, system complexity, and maintenance requirements while ensuring optimal operating temperatures, even in extreme environments. The powertrain features a combination of spiral bevel and bull gear reductions, delivering high-efficiency torque transmission and robust torque capacity to meet the demands of heavy-duty and off-road applications. Additionally, the enclosed wet multiple disc brake system enhances braking performance by providing consistent, reliable operation under high loads while benefiting from the shared cooling system. By unifying the gear reduction, braking, and cooling systems into a compact and streamlined design, the invention achieves superior efficiency, reduced weight, and simplified maintenance. This architecture eliminates the reliance on active cooling systems, improves system robustness, and ensures reliable performance in harsh conditions, making it particularly suitable for applications such as hydraulic rough terrain cranes, forklifts, dump trucks, and other heavy-duty machinery.
[054] The invention introduces a combined powertrain system that combines bevel and bull gear reduction with an integrated wet multiple disc braking system and a common natural/passive internal cooling system for all components. The invention combines various powertrain elements with an integrated single chamber cooling system. These include bevel gear reduction, which enhances torque transmission efficiency, and bull gear reduction, which provides robust torque transmission. A common drive shaft transmits power from the differential to the wheels, while the wet multiple disc brake arrangement ensures superior braking performance. Additionally, a common natural internal cooling system, which utilizes the volume of the combined system, maintains optimal operating temperatures for all components in both the powertrain and braking system, enhancing overall system reliability and efficiency.
[055] The novel feature of the invention involves the combination of all powertrain elements, including bevel and bull gear reduction, along with a wet multiple disc brake system, and a common natural cooling system for all components together. This integrated approach ensures robust and efficient torque transmission, superior braking performance, and optimal operating temperatures for both the powertrain and braking system, enhancing overall system reliability and efficiency.
[056] This drive axle system possesses significant potential for integration into a diverse range of heavy-duty machinery and equipment such as hydraulic rough terrain cranes, forklifts, dump trucks, load haul dumpers, and heavy-duty tractors.
[057] Figure 1 illustrates the schematics of a bevel differential, bull gear, and wet multiple-disc brake system integrated with a common cooling mechanism. In this configuration:
• (1) represents the power input to the bevel transmission system.
• (2) denotes the differential unit, which is responsible for distributing power to the left and right bull gears.
• (3) and (4) identify the left and right bull gears, respectively.
• (5) represents the common oil/lubricant reservoir, which provides lubrication and cooling for the bull gears, differential, wet multiple-disc brakes, and wheel bearings.
[058] The system ensures efficient power distribution and a unified cooling and lubrication arrangement for enhanced performance and durability.
[059] Figure 2 describes the Innovative mixed floating drive axle architecture system and its components. The system comprises:
1. Spiral Bevel Pinion (1): Receives power from the engine and transmission, then transfers rotational power to the bevel gear/crown.
2. Bevel Gear/Crown (2): Accepts power from the pinion, splits it for the left and right axles, and transmits it to the spider gear within the differential case.
3. Drive Bull Gear (3): Gets power from the differential and passes it on to the driven bull gear, connecting with the left and right axles through the differential.
4. Driven Bull Gear (4): Receives power from the drive bull gear, then transmits it to the drive shaft, meshing with the drive bull gear and connected to the drive shaft.
5. Drive Shaft (5): Receives power from the driven bull gear, transmitting it to the wheel hub, and features unique attributes based on the innovation.
6. Wheel Hub (6): Holds the wheel bearings, connects to the drive shaft and wheel rim, allowing the wheel to rotate freely while supporting the vehicle's weight.
7. Wheel Rim (7): Supports the tire, provides a mounting surface for the wheel hub, and forms the outer structure of the wheel.
8. Inner Cylindrical Roller Bearing (8): Supports the drive shaft's rotation within the wheel hub, ensuring smooth rotation while handling radial loads.
9. Outer Cylindrical Roller Bearing (9): Offers extra support for the drive shaft within the fixed casing, reducing axial loads on the shaft.
10. Taper Roller Bearing (10): Facilitates the drive shaft's rotation within the fixed casing with high axial load capacity, arranged back-to-back for increased support.
11. Differential Case (11): Contains the differential gears, enabling independent rotation of the left and right wheels, housing the spider gear, drive bull gears, and related components.
12. Fixed Outer Casing (12): Acts as a common cooling chamber for the bevel gear, bull gear, wet multiple-disc brake, and wheel bearings.
13. Spacer (13) (Optional): Ensures optimal bearing performance by maintaining proper spacing between the cylindrical roller bearing and taper roller bearing.
14. Tire (14): Offers traction for the vehicle, transmitting power from the drive shaft to the road surface.
[060] All the bevel differential, bull gear, and wet multiple-disc brake and wheel bearings are equipped with a common cooling system.
[061] The invention introduces a novel combined powertrain system that integrates bevel and bull gear reduction with an integrated wet multiple-disc braking system, all within a common natural/passive internal cooling system.
[062] Bevel gear reduction enhances torque transmission efficiency. Bull gear reduction provides robust torque transmission. Drive shaft transmits power from the differential to the wheels, a crucial element in ensuring seamless power transfer. Wet multiple-disc brake arrangement ensures superior braking performance through its design. Common natural internal cooling system utilizes the volume of the combined system to maintain optimal operating temperatures for all components in both the powertrain and braking system.
[063] 1. Power Transmission Subsystem
[064] Spiral bevel pinion receives power from the engine and transmission, converting it into rotational power.
[065] Bevel gear/crown distributes rotational power from the pinion to the left and right axles through the differential system.
[066] Drive bull gear & driven bull gear ensures power transmission between the differential and drive shaft, facilitating the rotation of the wheels.
[067] 2. Drive Mechanism Subsystem
[068] Drive shaft receives power from the driven bull gear, transmitting it to the wheel hub.
[069] Wheel rub holds the wheel bearings, connects to the drive shaft and wheel rim, allowing the wheel to rotate freely while supporting the vehicle's weight.
[070] Wheel rim provides structural support for the tire and mounting surface for the wheel hub.
[071] Tire transmits power from the drive shaft to the road surface, ensuring traction.
[072] Inner Cylindrical Roller Bearing: Provides support for the drive shaft's rotation within the wheel hub, handling radial loads.
[073] Outer Cylindrical Roller Bearing: Offers additional support within the fixed casing, reducing axial loads on the drive shaft.
[074] Taper Roller Bearing: Ensures smooth rotation of the drive shaft within the fixed casing, designed to handle high axial loads.
[075] 4. Differential and Gear Subsystem
[076] Differential case houses the differential gears, allowing for the independent rotation of the left and right wheels, containing the spider gear and drive bull gears.
[077] Bevel gear & bull gear work in tandem to manage and distribute power across the drive system effectively.
[078] 5. Cooling and Housing Subsystem
[079] Fixed Outer Casing: Acts as a common cooling chamber for the bevel gear, bull gear, wet multiple-disc brake, and wheel bearings, maintaining proper alignment and cooling of components.
[080] Spacer (Optional) ensures optimal performance of the bearings by maintaining proper spacing between the cylindrical roller bearing and taper roller bearing.
[081] 6. Braking Subsystem
[082] Wet multiple-disc brake integrated within the fixed outer casing's cooling system, provides efficient braking by utilizing a multi-disc design immersed in cooling fluid.
[083] This architecture ensures an efficient, robust, and innovative combined cooling system that enhances overall system reliability and efficiency by maintaining optimal operating temperatures for all integrated components.
[084] The versatility of the invention makes it suitable for a wide range of heavy-duty machinery, including hydraulic rough terrain cranes, dump trucks, and other specialized vehicles. The design's robustness and adaptability to various operating conditions highlight its potential for widespread industrial use. The integrated system is specifically designed to handle the demanding requirements of off-road applications. The combination of efficient torque transmission, reliable braking, and effective cooling ensures consistent performance in rugged terrains and extreme environments.
[085] The invention provides comprehensive technical support and maintenance services to ensure optimal system performance and customer satisfaction. This offers tailored solutions to meet the requirements of individual customers, such as adapting the design for specific load capacities or operating conditions.
[086] By delivering a superior product that boasts enhanced performance, reliability, and efficiency, this invention has the potential to revolutionize the heavy-duty machinery industry, fostering new avenues for innovation and market growth brakes, and wheel bearings, are effectively cooled, enhancing overall system reliability and efficiency.
[087] The invention is a combined natural cooling system for a high-performance powertrain that integrates several key components into a single, streamlined design. This cooling system is designed specifically for heavy-duty vehicles operating in demanding environments, such as off-road conditions.
[088] Instead of using separate cooling systems for power transmission, braking, and cooling, this invention combines them into a single unified architecture. This includes, Power Transmission (Bevel and Bull gear) & Braking:
[089] Power transmission (bevel and bull gear) uses a combination of a spiral bevel gear and a bull gear for torque reduction. The spiral bevel pinion receives power from the engine and transmission, transferring it to the bevel gear, which splits the power to the left and right axles. The drive and driven bull gears receive from bevel gear and then transmit this power to the drive shaft, which powers the wheels. This configuration is intended to provide robust and efficient torque transmission, overcoming the limitations of traditional planetary gear systems.
[090] Braking is an enclosed wet multiple-disc brake which is directly integrated into the powertrain architecture. This design provides superior braking performance, especially under high loads and harsh conditions, and eliminates the need for a separate braking system. The multi-disc design is immersed in a cooling fluid within the system.
[091] A central feature is the common natural/passive cooling system includes single, shared internal cooling chamber, which is the fixed outer casing, contains and cools all the integrated components, including the bevel gear, bull gear, wet multiple-disc brake, and wheel bearings. This system uses the shared internal volume to facilitate fluid circulation and heat dissipation, which eliminates the need for an active cooling mechanism and reduces complexity, weight, and maintenance requirements.
[092] This integrated design aims to enhance overall efficiency, durability, and performance while simplifying maintenance by consolidating multiple systems into a compact unit.
[093] This is a unique combination and integration of multiple, previously separate subsystems into a single, unified architecture with a shared cooling system.
[094] Traditionally, heavy-duty vehicles use separate cooling system/subsystem for their powertrain and braking, each often requiring its own cooling circuit. The inventive step is the consolidation of the spiral bevel gear reduction, bull gear reduction, wet multiple-disc brake, and wheel bearings into one unit that utilizes a common, natural/passive internal cooling chamber. This integration is a novel approach that:
a) Simplifies the design by reducing the number of components and interfaces, which are potential points of failure.
b) Improves efficiency by overcoming the inherent losses and torque limitations of traditional planetary gear systems.
c) Enhances thermal management by using a single chamber for passive heat dissipation, which reduces complexity, energy consumption, and maintenance.
d) Boosts performance by providing a more robust and efficient torque transmission and superior braking capability in a single integrated system.
[095] The core of the invention is not a new component itself, but rather the architectural innovation of combining these specific elements to create a more efficient, reliable, and lower-maintenance system.
[096] The method involves a specific architectural design and component arrangement to achieve the integrated system.
[097] The process begins with the spiral bevel pinion receiving power from the vehicle's engine and transmission. This rotational power is then transferred to the bevel gear, which, located within the differential case, splits the power to the left and right axles.
[098] The power is then transmitted to the drive bull gear and subsequently to the driven bull gear. This bull gear reduction provides a robust final stage of torque handling before the power is sent to the wheels. The drive shaft receives power from the driven bull gear and transmits it to the wheel hub.
[099] An enclosed wet multiple-disc brake is integrated directly into the system. The wheel hub, which holds the wheel bearings, is connected to the drive shaft, allowing the wheel to rotate. All these components are housed within a single, fixed outer casing.
[100] The fixed outer casing acts as a common cooling chamber for all the integrated components. This chamber is filled with a common oil or lubricant that serves two purposes: lubrication and cooling. The system leverages the shared internal volume to facilitate the natural circulation of this fluid, which dissipates heat from the bevel gear, bull gears, wet multiple-disc brake, and wheel bearings. This passive or natural cooling method maintains optimal operating temperatures without the need for additional fans, pumps, or other active cooling mechanisms, thus reducing energy consumption and complexity.
[101] Numerous modifications and adaptations of the system of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the true spirit and scope of this invention.
,CLAIMS:WE CLAIM:
1. A combined natural cooling system for high performance powertrain with integrated bevel gear, bull gear, wheel bearing and wet multiple disc brake comprises:
a) Spiral bevel pinion (1) wherein pinion receives power from the engine and transfers rotational power to the bevel gear/crown (2) which splits it for the left and right axles, and transmits it to the spider gear within the differential case.
b) Drive bull gear (3) receives power from the differential and passes it on to the driven bull gear, connecting with the left and right axles through the differential and driven bull gear (4) receives power from the drive bull gear, then transmits it to the drive shaft, meshing with the drive bull gear and connected to the drive shaft (5) characterized in that the the driven bull gear supplies power to shaft (5) which transmits it to the wheel hub (6), which holds the wheel bearings, connects to the drive shaft and wheel rim, allowing the wheel to rotate freely while supporting the vehicle's weight.
c) Wheel rim (7) provides a mounting surface for the wheel hub, and forms the outer structure of the wheel.
d) Inner cylindrical roller bearing (8) supports the drive shaft's rotation within the wheel hub,
e) Outer cylindrical roller bearing (9) provides extra support for the drive shaft within the fixed casing,
f) Taper Roller Bearing (10) rotates drive shaft within the fixed casing with high axial load capacity, arranged back-to-back for increased support.
g) Differential case (11) contains the differential gears, enabling independent rotation of the left and right wheels, housing the spider gear, drive bull gears, and related components.
h) Fixed outer casing (12) is a common cooling chamber for the bevel gear, bull gear, wet multiple-disc brake, and wheel bearings.
i) Spacer (13) between the cylindrical roller bearing and taper roller bearing ensuring proper spacing and hence optimal bearing performance.
j) Tire (14) providing traction for the vehicle, transmitting power from the drive shaft to the road surface.
2. The combined natural cooling system, as claimed in claim 1, wherein the system uses a spiral bevel pinion and bevel gear/crown to transmit and distribute power from the engine and transmission which power is then transferred to a drive bull gear and a driven bull gear for robust torque handling, which then powers the drive shaft, an integrated wet multiple-disc brake provides superior braking performance using a multi-disc design immersed in cooling fluid.
3. The combined natural cooling system, as claimed in claim 2, wherein the assembly is housed within a fixed outer casing, which serves as a common cooling chamber.
4. The combined natural cooling system, as claimed in claim 3, wherein the common chamber uses a shared oil/lubricant reservoir to cool all components, including the gears, brake, and wheel bearings, through a natural and passive process, which enhances efficiency and reliability while reducing complexity and maintenance.
5. The combined natural cooling system, as claimed in claim 1, wherein the drive shaft receives power from the driven bull gear, transmitting it to the wheel hub which holds the wheel bearings, connects to the drive shaft and wheel rim, allowing the wheel to rotate freely and providing structural support for the tire and mounting surface for the wheel hub.
6. The combined natural cooling system, as claimed in claim 1, wherein the bevel gear & bull gear work in tandem to manage and distribute power across the drive system effectively.
7. The combined natural cooling system, as claimed in claim 1, wherein the wet multiple-disc brake integrated within the fixed outer casing's cooling system, provides efficient braking by utilizing a multi-disc design immersed in cooling fluid.