Demonstrator 4x4 vehicle Transfer Case
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Customer: BRACE internal
Market: -
BRACE execution: Powertrain domain cluster
Location: BRACE office
This demonstrator was intended to show the competence of BRACE automotive in development of shafts, bearings, gears setups and in the development of housings. A small transfer case was chosen as all the elements can be included. The transfer case is designed with two gears (high and low) and with an electronic shifting actuator in mind.
Major steps included in the project:
- Requirement folder setup - performance, packaging constraints, reliability en endurance, etc.
- Gear train design concept
- Initial Gear geometry
- Initial Shaft design
- Initial Bearing calculations
- KISSsys and KISSsoft simulations and calculations
- Update designs on Gears and Shafts, update requirements to the Bearing selection
- Lifetime expectation
- Gear teeth design updates
- Weight reduction, manufacturability and lubrication improvements
- Housing requirement folder
- Housing geometry concept by assesment of critical dimensions
- Concept housing by three bodies method
- Flank between left and right housing & mounting point on the housing
- Improved bearing supports
- Improvements required for casting process
- Weight reduction of housing
- Machining optimization
- Tolerance studies on the housing
- Preliminary manufacturing drawings and assembly drawings
For more information see the blog's that were published about the project:
https://brace-automotive.com/en/blog/concept-realization-of-an-4x4-vehicles-transfer-ca/
https://brace-automotive.com/en/blog/part-2-of-concept-realization-of-an-4x4-vehicles-t/
https://brace-automotive.com/en/blog/part-3-of-concept-realization-of-an-4x4-vehicles-t/
https://brace-automotive.com/en/blog/part-4-of-concept-realization-of-an-4x4-vehicles-t/
other references
about BRACE automotive
BRACE automotive engineers are “passionate about technology”. We develop and engineer automotive systems and components for OEM vehicle manufacturers, 1st and 2nd Tier suppliers and other niche organizations. Our main disciplines are organized in vehicle systems, embedded controls and software, mechanical design and development, and specific competence clusters.
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