Customer Objective
An innovative transmission design and manufacturing company began development of a new, high-power, infinitely variable transmission (IVT) product. Targeted at heavy-duty commercial and military off-highway vehicles, the transmission design required both a hydraulic boost pump and a scavenge pump. The pumps would have to address the following design challenges:
- Integrate tightly with the overall transmission design
- Simplify the transmission hydraulic system design
- Minimize weight
- Reduce part count
Cascon Solution
When the customer contacted Cascon, their engineering department had already begun work on a design for the required pump. The customer recognized that engaging our expertise in the design and manufacture of pumps would free their engineering team to focus on the new transmission product’s key features, and on the core characteristics that differentiate their company’s product line.
Cascon engineering reviewed the pump designs started by the customer’s team. While conceptually sound, the designs needed refinement to optimize performance and reliability. Cascon incorporated the necessary revisions to the pump’s internal components, which included adding load carrying capacity to the pump bearings and improvements to the gerotor pumping element profile. Working closely with the customer’s team, Cascon engineers completed the necessary system and pump envelope design iterations to arrive at an optimum mounting and interface solution, which included a through drive arrangement for powering other subassemblies in the transmission. Check and relief valves were integrated into the design to reduce the overall transmission part count and simplify the transmission fluid system design.
Cascon produced, tested and delivered prototypes for customer validation testing. While putting the transmission through its paces, the customer uncovered a need for additional output flow from the pump under certain operating conditions. The pump design was again revised to incorporate the additional displacement needed and the design was readied for serial production.
The new transmission was introduced by the customer and is being incorporated into a variety of large construction and military vehicle applications.
Pump Features
- Cast aluminum housing: Durable, lightweight construction.
- Integrated pressure relief, check, and bypass valves: Streamlined, space-efficient design for easy system integration.
- Hardened powdered-metal gerotor pumping element: Proven gerotor technology ensures reliability.
- Through drive with hardened male and female spline connections: Designed to power multiple subassemblies and deliver long life under continuous use.
