Power transmission

Abstract: A power transmission has a housing comprised of a bell housing (14), an end support (10), an outer casing (12), and an end cover (16); an input shaft (46); an output shaft (48); and a pair of countershafts (42). The input shaft and the countershafts are supported in the end support on bearings (30,34). A dowel and seal sleeve (164) also supports the countershafts in the bell housing and locates the end support. Each countershaft has a central clutch feed passage (102) and an annular lube passage (98) with connecting radial passages (106,108).

Description: This invention relates to power transmissions and more particularly to power transmissions having multiple countershafts. Specifically, this invention relates to a dowel and seal sleeve structure which provides for alignment of the countershafts, an end support plate and a bell housing or engine mount and oil passages for lubrication and clutch feed. Power transmissions with multiple countershafts generally have a housing assembly formed with at least two members that are aligned by dowel pins. These members generally include a casing and an end cover or bell housing. The bell housing generally encloses a torque converter or friction clutch. The countershafts are supported in the casing at one end and in the end cover at the other end. The input shaft is generally supported in the end cover and the output shaft is supported in the casing. The alignment and parallelism of the shafts is determined by the doweling between the casing and cover and the bearing bores in each of the casing and end cover. The machining of the required dowel and bearing bores is subject to manufacturing tolerances which must be held within close limits for quiet, efficient and durable operation of the power transmission. As is well known, close tolerance machining adds to the overall cost of the product. A further disadvantage of the prior art is the need for an inspection opening which permits visual inspection during assembly. This opening usually is provided in the bottom of the casing and is covered by a pan which is secured to the casing by fasteners during final assembly. A gasket must be installed between the casing and the pan to ensure against fluid leakage from the assembly. More than one inspection port has been provided in the prior art, and each of these ports must be closed with a gasket, cover and fasteners which, of course, add to the overall cost. An example of the prior art is shown in US Patent Re No. 25,458. A power transmission in accordance with the present invention is characterised by the features specified in the characterising portion of Claim 1. The present invention seeks to overcome many of the disadvantages known in multiple countershaft prior art power transmissions. In the preferred embodiment, the present invention has an input shaft, two countershafts and an output shaft. Each countershaft has pressfit thereon a pair of tapered roller bearings. Two end extensions, one formed on each countershaft for the purpose of engaging a dowel and seal sleeve which provides dowel alignment at assembly, machining datums and passages for lubrication fluid during transmission operation. The dowel and seal sleeve is pressed into prepared openings in the transmission bell housing. An end support is aligned on the dowel and seal sleeves. Each countershaft and supporting bearings are aligned with bearing recesses in the end support, and the end extensions are aligned in respective ones of the dowel and seal sleeves. This will permit the distribution of clutch engagement fluid through a central clutch feed passage in the countershaft and lube and cooling fluid through an annular lube passage formed by a bore in the countershaft and a tube member positioned therein. The centre of the tube is subjected to high pressure fluid whenever clutch engagement is desired and the annular lube passage between the tube and the countershaft is supplied with lube fluid which is conducted to the bearings and cooling fluid which is supplied to the clutch assemblies during engagement. The supporting structure of the countershaft and the end cover or end support also includes a bushing, which provides for the dowel and seal sleeve structure between the countershaft, the end support and the bell housing or transmission housing. This combined dowel and seal sleeve ensures dowel pin alignment between the components and provides fluid passages to supply the various fluids to the longitudinal passages in the countershaft. The seal arrangement and passages are disposed to direct any leakage from the clutch feed circuit to the lube circuit. This contributes to an increase in the overall efficiency of the unit and a reduction in the size requirement of the supply pump. The end support in which the input shaft is rotatably supported also has bearing locations for the countershafts. The end support, after securement to the bell housing, will permit the assembly of the countershafts, the input shaft and the output shaft, in a vertical orientation, prior to the outer casing being installed on the power transmission. Thus, as the power transmission progresses along the assembly line, visual or automated inspection of the various components on the shafts and their relationship with other portions of the power transmission is always possible. It is an object of this invention to provide an improved power transmission having a pair of spaced parallel countershafts, and an input shaft, wherein an end support has bearing locations to rotatably support one end of each countershaft and the input shaft, and wherein each countershaft end is rotatably disposed in a dowel and seal sleeve which is operable to align the end support with the bell housing, such that alignment between the transmission casing components is controlled to the countershafts. This invention preferably provides an improved multiple countershaft transmission assembly having improved manufacturability wherein bearing supports for the countershafts and input shaft are located relative to the bell housing by dowel and seal sleeves and wherein a substantially cylindrical outer casing having shaft bearing supports therein is located on the bell housing by dowel pins. This invention preferably provides an improved power transmission having an input shaft, a longitudinally aligned output shaft and a pair of parallel spaced countershafts which rotatably support a plurality of gear members meshing with gear members on the input and output shaft, respectively, and wherein an end support is provided for rotatably supporting the countershaft and the input shaft such that during the assembly process, the gearing members and clutch assemblies are visible in the assembled state prior to the installation of the outer casing about the gearing assembly, allowing quality and automated inspection. The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a block diagram showing the interconnection of Figures 2a through 2d; Figures 2a through 2d are cross-sectional elevational views of various components within the power transmission, which when assembled as shown in Figure 1, will provide a cross-sectional representation of the preferred embodiment of the power transmission; Figure 3 is an end view of the power transmission taken with the end cover removed to show the positioning of the input shaft and the countershafts and some of the gearing within the outer casing; Figure 4 is block diagram showing the positioning of Figures 5a and 5b; Figures 5a and 5b, when combined, depict the one typical countershaft assembly with the gearing and clutch members assembled thereto; Figure 6 is an end view taken along line 6--6 of Figure 2d; and Figure 7 is a plan view taken along line 7--7 of Figure 6. Figures 2a through 2d, when combined as shown in Figure 1, depict a cross-sectional elevational view of a multiple countershaft power transmission having a multiple piece housing comprised of an end support 10, an outer casing 12, a bell housing or engine mounting member 14 (which with end support 10 defines a first end cover), and a second end cover 16. The end support 10 defines an assembly support plate and is a substantially annular disc member having bearing support recesses 18 and 20 for countershaft members and recess 22 for input shaft support. The outer casing 12 is located on the bell housing 14 by dowel pins, not shown, and the second end cover 16 is located on the outer casing 12 by dowel pins, not shown. The outer casing 12 is a substantially cylindrical member with an annular semi-closed end portion having recesses 24 and 26 formed therein for countershaft bearing support and a recess or opening 28 formed therein for output shaft bearing support. Preferably the bearings 30 through 40 which are disposed in the recesses or openings 18 through 28, respectively, are identical and therefore selection of any particular bearing to be placed in a specific recess or opening is eliminated. The bearings 30-40, however, can be of different sizes if the conditions and assembly warrant. The bearings 30 and 36 support a countershaft 42 while the bearings 32 and 38 support a countershaft 44. The bearing 34 rotatably supports and input shaft 46 and the bearing 40 rotatably supports an output shaft 48. The output shaft 48 is also rotatably supported by a needle bearing 50 and a thrust bearing assembly 52 which cooperate with the input shaft 46. In particular, the neddle bearing 50 and thrust bearing assembly 52 cooperate with a (first) head gear 54, which is formed integral with or otherwise secured to the input shaft 46. The head gear 54 meshes with a (second) head gear 56 splined to countershaft 42 and a third head gear 58 splined to countershaft 44. The countershafts 42 and 44 are dimensionally identical from end-to-end, however, their assembly structure is considerably different as seen in Figures 2a through 2d. The assembly of countershaft 42 is shown in Figures 5a and 5b. In Figure 5a, it can be seen that the countershaft 42 has reduced diameter ends 60 and 62 and a pair of bearing surfaces 64 and 66 adjacent the reduced diameter ends 60 and 62, respectively. Looking along the countershaft 42 from reduced diameter end 60 toward reduced diameter end 62, the outer surface of countershaft 42 has a spline portion 68, a constant diameter portion 70, a slightly larger diameter portion 72, a piston mounting surface or diameter 74, a central clutch housing support surface 76, a piston mounting surface 78, a pair of constant diameter surfaces 80 and 82, and a reduced diameter surface 84 adjacent the bearing surface 66. The countershaft 44 has an identical structure and the corresponding surfaces are given the same numerical designation with an "a" suffix. The countershaft 42 has a pair of longitudinal passages 86 and 88 that extend inwardly from the reduced diameter ends 60 and 62, respectively, and terminate at 90 and 92, respectively, aligned with the central clutch housing support surface 76. Each passage 86 and 88 has disposed therein tubes 94 and 96, respectively, which cooperate with the respective passages 86 and 88 to form a pair of annular lube or lubrication passages 98 and 100, and have formed therein a respective clutch feed passage 102 and 104. The annular lube passage 98 has a pair of radially extending fluid passages 106 and 108 which communicate with the larger diameter portion 72 and piston mounting surface 74, respectively. A radial passage 110 communicates fluid from the clutch feed passage 102 to a position on piston mounting surface 74 adjacent central clutch housing support surface 76. The annular lube passage 100 has communicating therewith three passages 112, 114 and 116 which are effective to communicate fluid with the piston mounting surface 78 and constant diameter surfaces 80 and 82, respectively. A radial passage 118 provides fluid communication from clutch feed passage 104 to the piston mounting surface 78 adjacent the central clutch housing support surface 76. As will become more apparent in the following description, the passages 106, 108, 112, 114 and 116 provide cooling and/or lubrication fluid for various gear members and clutch assemblies which are disposed on the countershaft 42 while the radial passages 110 and 118 are effective to distribute clutch engagement pressure to clutch assemblies disposed on the countershaft 42. The countershaft 44 has identical passages and tube assemblies secured thereto. These corresponding components have been given the same numerical designation with an "a" suffix. The head gear 56 is splined to the spline portion 68 in abutment with the bearing 30 which is positioned on the countershaft 42 by a locking ring 120. Adjacent head gear 56 is a spacer sleeve 122 which is disposed in abutment with the head gear 56 and a thrust bearing assembly 124. The thrust bearing assembly 124 is in abutment with a ratio gear member 125 which is rotatably supported on the countershaft 42 by needle bearings 126. The ratio gear member 125 is in abutment with a thrust bearing 128 which is positioned by a shoulder 130 formed adjacent the large diameter portion 72. A clutch assembly 132 (friction clutch means) is disposed on the countershaft 42 and includes an annular housing 134 which is welded or otherwise secured to the countershaft 42, an annular piston 136 which is slidably disposed in the annular housing 134 and on the countershaft 42, a plurality of friction plates 138 and 140 which are alternately splined to the annular housing 134 and an output hub 142, respectively. The output hub 142 is welded or otherwise secured to the ratio gear member 125. A return spring assembly 144 is effective to urge the annular piston 136 rightward as viewed in Figure 5a to a disengaged position. When fluid pressure is supplied to clutch feed passage 102 and radial passage 110, the annular piston 136 will move leftward to cause frictional engagement between the alternately spaced friction plates 138 and 140, whereby the ratio gear member 125 will be drivingly connected to the countershaft 42. A second clutch assembly 132a is secured to the countershaft 42 adjacent the clutch assembly 132 and is a mirror image thereof. The corresponding components of clutch assembly 132a are given the same numerical designation as the components in clutch assembly 132 with an "a" suffix. The output hub 142a is secured to a gear assembly 145 which includes a reverse gear 146, a sleeve 148 and a ratio gear member 150 (first ratio gear). The gear assembly 145 is positioned on the countershaft 42 by a pair of thrust bearings 152 and 154 and is rotatably supported on the countershaft 42 by needle bearings 156 and 158. The thrust bearing 154 is disposed in abutment with the bearing 36 which is positioned on the countershaft 42 by a locking ring 160. The reduced diameter ends 60 and 62 have formed therein seal grooves 162 which cooperate with a dowel and seal sleeve 164 at reduced diameter end 60 and on a sleeve 164a at reduced diameter end 62. The reduced diameter end 60 has a feed passage 166 which is in communication with the annular lube passage 98 and the reduced diameter end 62 has a fluid passage 166a which is in communication with the annular lube passage 100. The dowel and seal sleeve 164 is pressfit in the bell housing 14 and has a dowel fit with the end support 10 thereby providing for alignment between the end support 10 and the bell housing 14. The sleeve 164a is pressfit in the second end cover 16. The bearing support recesses 18 and 20 are held in close tolerance with the bores in the end support for the dowel and seal sleeve 164 and another dowel and seal sleeve 164b. Thus, the bearing locations for the input end of the countershafts 42 and 44 and input shaft 46 are closely controlled to the bell housing 14. The countershaft 44 has assembled thereon the bearing 32 and head gear 58. A spacer sleeve 168 is disposed between the head gear 58 and a thrust bearing 170 which cooperates with a thrust bearing 172 to position a ratio gear 174 which is rotatably supported on the countershaft 44 by needle bearings 176. The ratio gear 174 is selectively connectible with the countershaft 44 through controlled operation of a clutch assembly 132b which is identical in structure with clutch assembly 132 and has an output hub 142b secured to the ratio gear 174. The remaining components of clutch assembly 132b are identical with the components of the clutch assembly 132 and have therefore been given the same numerical designation with a "b" suffix. Adjacent the clutch assembly 132b is a clutch assembly 132c which is a mirror image of clutch assembly 132b and is comprised of components identical with clutch assembly 132 such that the same numerical designates with a "c" suffix are utilized. The output hub 142c is secured to a sleeve 180 which is positioned on the countershaft 44 by a pair of thrust bearings 182 and 184, and rotatably supported by needle bearings 186. The sleeve 180 is splined to a conventional synchronizer assembly 187 (synchronizer clutch means) which is selectively operable to connect a ratio gear 188 (second ratio gear) or a reverse gear 190 with the output hub 142c of clutch assembly 132c. Therefore, selective positioning of the synchronizer assembly 187 and actuation of the clutch assembly 132c will establish a drive relationship between countershaft 44 and either ratio gear 188 or reverse gear 190. Reverse gear 190 is a member of the reverse gear train and is disposed in meshing relation with the gear assembly 146 which is rotatably supported on countershaft 42. The ratio gear 188 is supported on a needle bearing 192 and is positioned longitudinally by the thrust bearing 184, a thrust bearing 194, a sleeve 196 and the bearing 38. As previously mentioned, the assembly of countershaft 44 has components identical with the countershaft 42 and these components have been given an "a" suffix. In particular, the tubes 94a and 96a are effective to establish the cooling and lubrication passages and the clutch apply passages for fluid which is to be delivered through the dowel and seal sleeve 164b and a sleeve 164c in a manner similar to that described above for dowel and seal sleeve 164 and the sleeve 164a, respectively. The head gear 54 has secured thereto a hub member 142d which is a component in a clutch assembly 132d which is identical with the clutch assembly 132. In the alternative, the clutch assembly 132d can be constructed with fewer friction plates 138d and 140d, and the annular housing 134d can be axially shortened. This has the benefit of reducing the axial length of the power transmission. This axial shortening of the clutch assembly 132d results in less torque capacity which is permitted because the engine torque is not increased by the head gear set 54-56 or 54-58 prior to delivery to the clutch assembly 132d. While this clutch assembly would then have to be treated differently in production, the overall material savings and axial length savings may overshadow this drawback. The remaining gear ratios 1, 2, 3, 5 and reverse all have the engine torque increased, as a result of the respective head gear sets, prior to delivery to the respective clutch assemblies which establish these ratios. The remaining components of clutch assembly 132d have been given the same numerical designation as the corresponding components of clutch assembly 132. The annular housing 134d of clutch assembly 132d is secured to the output shaft 48 such that selective engagement of the clutch assembly 132d, by fluid pressure in a passage 200, will enforce a direct drive connection between the input shaft 46 and the output shaft 48. The output shaft 48 has splined thereto a plurality of ratio output gear members 202, 204, 206 and 208 which are in constant mesh with respective ratio gears 174 on countershaft 44, and ratio gear member 150 on countershaft 42. The ratio gear member 150 and 208 will provide a low forward gear ratio between the input shaft 46 and the output shaft 48 upon selective engagement of the clutch assembly 132a. Second gear operation is provided by ratio gear 174 and ratio output gear member 202 upon selective engagement of clutch assembly 132b. A third forward gear ratio is provided by rightward selection of the synchronizer assembly 187 and selective engagement of the clutch assembly 132c. A fourth forward gear ratio is provided by selective engagement of clutch assembly 132d as described above. This is a direct drive ratio. A fifth and overdrive forward gear ratio is provided by selective engagement of the clutch assembly 132. Quite obviously, only one clutch assembly 132 through 132d can be engaged at any one time. The selective engagement of these clutch assemblies and their interchange can be controlled by many of the currently available and well known hydraulic control circuits. To establish a reverse drive ratio in the transmission, the synchronizer assembly 187 is established in its leftward position and the clutch assembly 132c is selectively engaged. With this power flow path engaged, power flow is from the input shaft 46 through head gears 54, 58, countershaft 44, reverse gears 190 and 146, and ratio gear members 150 and 208 and head gear set 54-58 to the output shaft 48. The reverse gears 146 and 190 provide for reversing of the rotational direction during a reverse ratio and provide first and second members respectively of reverse gear means. The meshing ratio gear members 150, 208 and head gear set 54-58 establish the speed ratio of the reverse gear ratio which is identical with the low forward gear ratio. Since the gear reversing or reverse idling function is provided by reverse gears 146 and 190, a separate idler gear axis is not required with the present invention. A park gear 210 is secured to the reverse gear 146 and therefore is connectible with the output shaft 48 through the low forward ratio of ratio gear members 150 and 208. A conventional parking pawl mechanism can be utilized to engage the park gear 210 such that a mechanical advantage is gained between the park gear 210 and the output shaft 48. This advantage is equal to the ratio of the low forward ratio gear members 150, 208 without benefit of the head gear set 54-56. During assembly of the power transmission, the positioning of the countershafts 42 and 44 and the output shaft 48 is controlled by cam shim pack assemblies 212, 214 and 216, respectively. These cam shim pack assemblies 212-216 are identical in structure and include an inner cam ring 218, an outer cam ring 220 and a locking ring 222. The locking ring 222 prevents rearward axial displacement of the outer cam ring 220 relative to the outer casing 12. The inner cam ring 218 is nonrotatably supported in the outer casing 12 by a plurality of radially extending tabs 224. The inner cam ring 218 is disposed in abutment with bearings 36, 40, and 38, respectively, for each of the cam shim pack assemblies. During assembly, the outer cam ring 220 is rotated relative to the inner cam ring 218 thereby causing relative axial movement between the outer casing 12 and the inner cam ring 218 to enforce longitudinal positioning of the countershafts 42 and 44 and the output shaft 48 through the respective bearing assemblies which support the shafts in the outer casing 12. A tabbed washer 225 is connected at the outer diameter with the outer casing 12, and the inner diameter of the tabbed washer 225 is displaceable into an opening 227 in the outer cam ring 220 to prevent movement between the inner and outer cam rings 218, 220 after assembly. The adjustment mechanisms can be constructed in accordance with the bearing adjustment mechanism shown in US Patent No. 3,901,568. The countershafts 42, 44, input shaft 46 and output shaft 48 and their respective components, can be assembled onto the end support 10 as the end support is vertically positioned on an assembly line or bell housing 14. This assembly can be competed with the outer casing 12 having been installed over the gear assemblies. Thus, as the power transmission assembly progresses along the assembly line, continuous visual inspection is available to ensure that proper gear positioning and gear meshing is occurring. The outer casing 12 can then be installed over the power transmission assembly and secured to the bell housing 14 or in the alternative, to the end support 10. When this assembly is completed, the adjustment mechanisms provided by cam shim pack assemblies 212, 214 and 216 are manipulated to ensure proper placement of the shaft assemblies and then the second end cover 16 can be positioned and secured to the outer casing 12. It should be noted that the end support 10 and bell housing 14 are both aligned with the countershafts 42 and 44 through the dowel and seal sleeve components 164 and 164b. This eliminates the need for additional dowel locations being machined through the various components which would have to rely on some dimensional location on the end support 10 and outer casing 12 for proper alignment. The commonalty of the countershafts 42 and 44 greatly reduce the inventory and machining requirements for these components. Further, material savings are established through the use of the common clutch assemblies. The savings are occasioned not only by the reduction in the number of different components to be utilized, but also in the fact that the likelihood of misassembly of the clutch assemblies is greatly reduced. Each annular piston 136 through 136d has an inner skirt portion 226 which is slidably disposed on the respective portions of the countershafts 42, 44 and output shaft 48. The inner skirt portion 226 partially or completely covers the respective lube and cooling passage, such as 108, for clutch assembly 132 when the clutch is disengaged. During movement of the annular piston 136 to engage the clutch, an opening 228 in the inner skirt portion 226 will be placed in fluid communication with the respective lube passage thereby permitting unrestricted fluid flow from the annular lube passage 98 to the alternately spaced friction plates 138 and 140. This permits controlled cooling flow during clutch engagement when it is desirable to have such flow but limits or eliminates fluid flow in this circuit when the clutch assemblies are disengaged. With the reduced cooling flow requirements, the system flow requirements are also reduced which makes more fluid available for lubrication circuits and reduces the volume of the control pump required to supply the fluid to the control system. It should be noted that the arrangement of the seals, clutch feed passages and lube passages minimize oil leakage and, the oil leakage that may occur from the clutch feed is directed to the lube circuit. This feature contributes to a reduction in the required volume of the supply pump. Also, as pointed out previously, the extended skirts on the annular pistons also contribute to a reduced pump requirement by reducing the amount of continuous oil flow to the system. A further savings in material and inventories is also provided through the use of commonalty between various thrust bearings and needle bearings which are components within the power transmission assembly. It should further be appreciated that wide latitude is permitted in the selection of the various gear ratios and that the changing of the gear ratios after assembly can be accomplished without significant changes in the other components of the transmission. One other advantage of the present invention is the provision for identical low and reverse drive ratios. Attention is drawn to related patent application nos. 91200386.0 (MJD/3461) and 91200388.6 (MJD/3463), filed the same day as the present application.

Claims: A power transmission comprising a housing including a bell housing (14), an outer casing (12), and an end cover (16); an input shaft (46) rotatably supported on a first bearing (34); and a pair of countershafts (42,44) rotatably supported on second (30) and third (32) bearings; characterised by an assembly support plate (10) having bearing locations (18,20,22) for supporting the first, second and third bearings; in that each of the countershafts has a centrally disposed clutch feed passage (102) and an annular lubrication passage (98); by a dowel and seal sleeve member (164) secured in the bell housing for each countershaft, said dowel and seal member including a surface for locating the assembly support plate for positioning of the assembly support plate during securement with the bell housing; by a radial passage (106,108) for communicating fluid with the annular lubrication passage; and by an axial end opening for communicating fluid pressure with the clutch feed passage. A power transmission as claimed in Claim 1, in which each of the countershafts (42,44) is rotatably supported in bearings (36,38) secured in the outer casing (12) and has a second central clutch feed passage (104) and a second annular lubrication passage (100); wherein a sleeve (164a) is disposed in the end cover (16) and surrounds one end of the countershaft; wherein a radial passage (112,114,116,166a) is present for directing fluid flow to the second annular lubrication passage; and wherein an axial passage is present for communication with the second clutch feed passage.

Inventors: LATSHAW HARRY EARL, ORDO JAMES PATRICK, LATSHAW, HARRY EARL, ORDO, JAMES PATRICK
Applicants: GEN MOTORS CORP, GENERAL MOTORS CORPORATION
Application year: 1991
Main classification: F16H3
IPC codes: F16H3, F16D25