LUBRICATION SYSTEM DESIGN

Brendan Higgins

Spring 2014

LUBRICATION SYSTEM SCHEMATIC

2013 DESIGN

Stock internal high pressure pump not shown

2014 DESIGN 1ST ITERATION

2014 DESIGN 2ND ITERATION

2014 2.0 2013

2014 DESIGN IMPROVEMENTS

• Utilized half of stock internal pump to save weight and space• New custom gear teeth and rotary lobe designs to improve durability and flow rate• Block plates used to divide scavenge stages and ease producibility on CNC• New cylinders between pan and scavenge stages designed to simplify assembly issues• Took advantage of pre-existing internal engine oil lines to reduce the number of external

lines• Saves weight• Reduces assembly time and complexity• Frees up space in engine bay• Reduces number of leakage points and AN fittings required• Provides shorter & easier path for oil travel

• Quick disconnect fittings drastically improves assembly time• Custom block fitting design used to eliminate relief valve line• Optimized oil pan design

• Fewer channels – simplifies manufacturing process• Not as thick as previous years – reduces weight & allows lower engine placement

All design changes carefully considered for weight savings, performance, producibility, & assembly purposes

2014 DESIGN 2ND ITERATION

2014 DESIGN 1ST 2ND ITERATION

2014 DESIGN 2ND ITERATION

2014 DESIGN 2ND ITERATION

Gear stage drives idler shaft

Rotary lobe scavenge stages collect oil from pan and turbo and return to oil reservoir

Oil flows out to reservoir

Engine case

Stock internal half of pump

Custom half of high pressure pump

Gerotor not shown for clarity

With the exception of the stock internal half of pump (and gerotor), the engine case, and AN fittings, every component was designed in house. Most parts were entirely or at least pre and post-machined in house on CNC or standard mills & lathes. The drive shafts were pre-machined out of house for precision, but heat treated and grinded in house. Some of the housings were EDM’ed out of house, but pre-machined and post-machined in house.

Oil flow direction

CONTACT INFORMATION

• Please feel free to contact me by any of the following methods to discuss this design in further detail:• Email: bah87@cornell.edu• Cell: (845) – 283 – 5894