reference

Demonstrator 4x4 vehicle Transfer Case

Be ingenious

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.