An automatic shift stroke self-adapting adjusting device and an automatic transmission

Abstract

The application discloses an automatic gear shifting stroke self-adaptive adjusting device and an automatic transmission, and relates to the technical field of vehicle automatic transmission. The device comprises a power modulation component and a motion execution component, and the motion execution component is arranged on one side of the outer wall of the power modulation component. The power modulation component comprises a brushless direct current motor, a sun gear, three planetary gears, a planet carrier and a ring gear. The brushless direct current motor is used for providing constant basic torque required for driving the synchronizer to engage and separate. The sun gear, the three planetary gears, the planet carrier and the ring gear form a complete planetary differential assembly. Through the cooperative linkage of the power modulation component and the motion execution component, the core defects of the traditional automatic gear shifting adjusting device, such as discontinuous grading control, power regulation function coupling, poor anti-vibration stability, complicated assembly and maintenance, and weak working condition adaptability, are accurately solved, and the core requirements of high-precision stepless regulation, high smoothness and low impact, strong working condition adaptability and long service life and low operation and maintenance in the field of vehicle automatic transmission are fully met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle automatic transmission, in particular to an automatic shift stroke adaptive adjustment device and an automatic transmission. BACKGROUND

[0002] The automatic shift stroke adaptive adjustment device is the core execution and control unit of the vehicle automatic transmission, and bears the functions of power conversion between the transmission control unit instruction and the synchronizer shift action, and stroke precision regulation. The adjustment precision, response speed and operation reliability of the device directly determine the shift smoothness, power transmission efficiency of the automatic transmission, and the comfort and safety of the vehicle driving.

[0003] The current automatic transmission field has rigid requirements for the shift process, such as stepless adaptive adjustment, low impact and high smoothness, strong working condition adaptability, and long service life and low operation and maintenance. The fundamental conflict between the above requirements and the traditional shift adjustment device, which has stepwise regulation, coupled power regulation function, insufficient anti-vibration and environmental adaptability, is increasingly prominent. The traditional scheme relies on single power source driving, discrete stroke control and extensive structure integration, which is difficult to adapt to the flexible adaptation requirements of complex driving conditions of vehicles and different vehicle transmissions, resulting in two core defects in the existing technology. First, the precision and smoothness of shift regulation are insufficient, which can easily cause operation failure. Among them, the traditional automatic shift adjustment device, such as the shift fork shaft, the electromagnet driving mechanism and the single motor gear type shift component, adopts a stepwise stroke regulation logic, relies on fixed gear ratio or step motor discrete rotation to achieve shift stroke adjustment, and cannot be steplessly adjusted according to the synchronizer engagement resistance, vehicle speed and power demand. At the same time, the shift power output and stroke speed adjustment are completed by the same power source, and the function coupling leads to shift impact when the power is excessive and synchronizer jamming when the power is insufficient. The single contact type stroke feedback structure is easily disturbed by vibration, and the offset of the shift fork and the synchronizer interface is further aggravated, which further aggravates the micro-motion wear of the contact surface, and long-term operation can cause shift abnormal noise, synchronizer ablation and even transmission gear failure, forming a vicious cycle of performance degradation. Second, the structure integration and working condition adaptability are insufficient, which leads to difficult assembly and maintenance. The traditional device is integrated with the transmission body, and the structure coupling degree is high. Once a fault occurs, the transmission core gear set needs to be disassembled for maintenance, which is high in operation and maintenance cost and low in efficiency. The anti-vibration protection relies on simple rubber pads, and the insulation protection relies on ordinary plastic shells. Under the conditions of high and low temperature, jolt and vibration of the vehicle, and erosion of the transmission oil, the shell is easily aged and failed, and the fixed structure is easily displaced, which cannot guarantee long-term stable operation.

[0004] Therefore, we propose an automatic shift stroke adaptive adjustment device and an automatic transmission to solve the problems mentioned above. SUMMARY

[0005] The application aims to provide an automatic shift stroke adaptive adjusting device and an automatic transmission, which accurately solves the core defects of traditional automatic shift adjusting devices, such as discontinuous grading control, coupled power regulation function, poor anti-vibration stability, complicated assembly and maintenance, and weak working condition adaptability, and fully meets the core needs of high-precision stepless regulation, high-smoothness low-impact, strong working condition adaptability, and long service life and low operation and maintenance in the field of vehicle automatic transmission.

[0006] To achieve the above-mentioned purpose, the application provides the following technical scheme: an automatic shift stroke adaptive adjusting device, comprising a power modulation assembly and a motion execution assembly, wherein the motion execution assembly is arranged on one side of the outer wall of the power modulation assembly;

[0007] The power modulation assembly comprises a brushless DC motor, a sun gear, three planetary gears, a planet carrier, and a ring gear, wherein the brushless DC motor is used to provide a constant basic torque required for driving the synchronizer to engage and separate, the sun gear, the three planetary gears, the planet carrier, and the ring gear form a complete planetary differential assembly, and the planetary differential assembly is used to realize stepless continuous regulation of the output rotating speed of the planet carrier by using the double-power input of the sun gear and the ring gear.

[0008] The motion execution assembly comprises a lead screw, a nut, a retainer, a set of balls, and a shift fork, wherein the lead screw, the nut, the retainer, and the set of balls form a complete ball screw pair, and the ball screw pair is used to convert the rotating motion output by the planet carrier in the planetary differential assembly into linear motion, and the shift fork is used to engage and separate the synchronizer by clamping the annular groove of the synchronizer sleeve in the U-shaped fork and receiving the linear power of the nut.

[0009] Preferably, the power modulation assembly further comprises a modulation cavity shell, the outer wall of the modulation cavity shell is sealingly connected with a first end cover and a second end cover at both ends, respectively, the first end cover is connected with the opposite side of the brushless DC motor by bolts, the first encoder is integrated in the interior of the brushless DC motor, the L-shaped bracket is connected with the outer wall of the second end cover by bolts, the modulation servo motor is connected with the outer wall of the L-shaped bracket by screws, the second encoder is integrated in the interior of the modulation servo motor, the modulation servo motor is used to realize stepless speed regulation, the first motor output shaft is rotatably connected with the shaft end of the brushless DC motor, the torque sensing ring is sleeved on the outer surface of the first motor output shaft, and the torque sensing ring is used to monitor the torque change of the main first motor output shaft in real time and indirectly perceive the resistance during the synchronizer engagement process.

[0010] Preferably, the outer surface of the first motor output shaft is sleeved with a first radial bearing and a second radial bearing respectively, the outer surface of the first radial bearing is connected with the inner surface of the first end cover, and the outer surface of the second radial bearing is connected with the inner surface of the planet carrier.

[0011] Preferably, the outer surface of the sun gear is connected with the outer surfaces of three planetary gears in mesh, the outer surfaces of the three planetary gears are connected with the inner surface of the ring gear in mesh, the inner surfaces of the three planetary gears are inserted with planet shafts, the outer surfaces of the three planet shafts are inserted into the shaft holes of the planet carrier, and the outer wall of the planet carrier is connected with a planet carrier output shaft on one side.

[0012] Preferably, the outer surface of the ring gear is symmetrically sleeved with a third radial bearing, the outer surfaces of the two third radial bearings are connected with the inner surface of the modulation cavity shell, the outer surface of the ring gear is provided with a group of external teeth, and the group of external teeth is arranged between the outer walls of the two third radial bearings.

[0013] Preferably, a groove is arranged in the wall thickness of the modulation cavity shell, the shaft end of the modulation servo motor is rotatably connected with a second motor output shaft, the second motor output shaft is symmetrically sleeved with a fourth radial bearing, the outer surface of one of the fourth radial bearings is connected with the inner surface of the first end cover, and the outer surface of the other fourth radial bearing is connected with the inner surface of the groove.

[0014] Preferably, the outer surface of the second motor output shaft is sleeved with a micro gear, the outer surface of the micro gear is connected with a transition gear in mesh, the inner surface of the transition gear is connected with a micro bearing, the inner surface of the micro bearing is inserted with a rotating rod, the outer surface of the rotating rod is symmetrically connected with metal plates, each metal plate is bolted to one side of the outer wall of a corresponding third radial bearing, and the bottom of the transition gear is connected with the top of the group of external teeth in mesh.

[0015] Preferably, the motion execution assembly further comprises a dust cover and a position sensor, one end of the outer wall of the dust cover is fixedly connected with a sealing support end cover, the other end of the outer wall of the dust cover is fixedly connected with one side of the outer wall of the second end cover, one side of the outer wall of the sealing support end cover is fixedly connected with a connecting flange, the inner surface of the sealing support end cover is embedded with a fifth radial bearing, the inner surface of the fifth radial bearing is rotatably connected with the outer surface of a lead screw, and one end of the outer wall of the lead screw is rotatably connected with the opposite end of the planet carrier output shaft.

[0016] Preferably, the outer surface of the screw rod and the inner surface of the nut are connected in a sleeved manner, the inner surface of the nut and the outer surface of the retainer are connected, a group of the balls are arranged between the retainer and the screw rod, the bottom of the nut is fixedly connected with the axial slider, the bottom of the axial slider is connected with the top of the shift fork, the outer wall of the sealing support end cover and the connecting flange is penetrated by the mounting hole, the inner surface of the mounting hole is slidably connected with the lubricating grease nozzle, the position sensor is opposite to one side of the outer wall of the shift fork, and the position sensor and one side of the outer wall of the second end cover are bolted, and the position sensor is used for monitoring the linear displacement and movement speed of the shift fork in real time.

[0017] The application further provides an automatic transmission comprising the automatic shift stroke adaptive adjustment device.

[0018] Compared with the prior art, the automatic shift stroke adaptive adjustment device has the following beneficial effects:

[0019] In the application, through the cooperative linkage of the power modulation assembly and the motion execution assembly, the core defects of the traditional automatic shift adjustment device, such as discontinuous grading control, coupled power regulation function, poor anti-vibration stability, complicated assembly and maintenance, and weak working condition adaptability, are accurately solved, and the core needs in the field of vehicle automatic transmission, such as high-precision stepless regulation, high smoothness and low impact, strong working condition adaptability, and long service life and low operation and maintenance, are fully met; the power modulation assembly is decoupled by a double-power source design of a brushless DC motor and a modulation servo motor, cooperates with a rotation speed synthesis mechanism of a planetary differential assembly, realizes independent control of shift power and stroke regulation, can realize stepless adaptive regulation of the shift stroke according to the synchronizer resistance and the vehicle speed condition, and completely solves the shift impact or jamming problem caused by the traditional single-power source; the integrated first encoder and the integrated layout of the torque sensing ring can realize real-time monitoring of the power input state and the shift resistance without additional expansion of the installation space, cooperates with a TCU to form a closed-loop regulation, avoids regulation lag and loss of control, and adapts to complex driving conditions; secondly, the motion execution assembly is accurately matched by the ball screw pair and the shift fork, efficiently converts the rotary motion of the planetary carrier into a linear shift stroke, cooperates with the close fit of the rectangular clamping groove above the shift fork, the nut and the axial slider, limits the rotation of the nut while ensuring smooth power transmission, and avoids shift looseness and abnormal noise; the composite structure of the fifth radial bearing of the screw rod and the sealing support end cover can compensate the vibration and thermal expansion gap, limit the radial displacement of the screw rod, ensure the transmission accuracy and stability, and cooperate with the design of the dust cover to block the erosion of transmission oil and the invasion of impurities, and improve the running stability in harsh conditions; the integrated layout of the position sensor can collect the shift stroke signal in real time and feed it back to the TCU, and accurately correct the regulation error. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is a front structure perspective view of the automatic shift stroke adaptive adjustment device.

[0021] Figure 2 isometric view of a cross-sectional structure of an automatic shift stroke adaptive adjustment device of the present application;

[0022] Figure 3 isometric view of an installation position structure of a power modulation assembly in an automatic shift stroke adaptive adjustment device of the present application;

[0023] Figure 4 isometric view of an installation position structure of an L-shaped bracket, a modulation servo motor, and a second motor output shaft in an automatic shift stroke adaptive adjustment device of the present application;

[0024] Figure 5 isometric view of an installation position structure of a planetary carrier output shaft, a gear ring, and a third radial bearing in an automatic shift stroke adaptive adjustment device of the present application;

[0025] Figure 6 isometric view of an installation position structure of a planetary shaft, a planetary carrier, and a planetary carrier output shaft in an automatic shift stroke adaptive adjustment device of the present application;

[0026] Figure 7 isometric view of an installation position structure of a motion execution assembly in an automatic shift stroke adaptive adjustment device of the present application; Figure 5

[0027] isometric view of an installation position structure of a sealing support end cover, a connecting flange, and a fifth radial bearing in an automatic shift stroke adaptive adjustment device of the present application; Figure 8 Figure 6 isometric view of an installation position structure of a lubricating grease nipple and a position sensor in an automatic shift stroke adaptive adjustment device of the present application;

[0028] Figure 9 isometric view of an installation position structure of a ball and an axial slider in an automatic shift stroke adaptive adjustment device of the present application;

[0029] Figure 10 isometric view of an installation position structure of a sealing support end cover, a connecting flange, and a fifth radial bearing in an automatic shift stroke adaptive adjustment device of the present application;

[0030] Figure 11 isometric view of an installation position structure of a lubricating grease nipple and a position sensor in an automatic shift stroke adaptive adjustment device of the present application;

[0031] Figure 12 isometric view of an installation position structure of a ball and an axial slider in an automatic shift stroke adaptive adjustment device of the present application;

[0032] Figure 13 Figure 12 isometric view of an installation position structure of a sealing support end cover, a connecting flange, and a fifth radial bearing in an automatic shift stroke adaptive adjustment device of the present application;

[0033] ​​In the figure: 100, power modulation assembly; 101, modulation cavity shell; 102, first end cover; 103, second end cover; 104, brushless DC motor; 105, first radial bearing; 106, first motor output shaft; 107, torque sensing ring; 108, sun gear; 109, second radial bearing; 110, planetary gear; 111, planet shaft; 112, planet carrier; 113, planet carrier output shaft; 114, ring gear; 115, third radial bearing; 116, external teeth; 117, L-shaped bracket; 118, modulation servo motor; 119, second motor output shaft; 120, fourth radial bearing; 121, micro gear; 122, metal plate; 123, transition gear; 124, grooving; 200, motion execution assembly; 201, dust cover; 202, sealing support end cover; 203, connecting flange; 204, fifth radial bearing; 205, lead screw; 206, nut; 207, retainer; 208, ball; 209, axial slider; 210, yoke; 211, mounting hole; 212, grease nipple; 213, position sensor. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all the other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0035] As shown in the figure, the present embodiment discloses an automatic shift stroke adaptive adjustment device, comprising a power modulation assembly 100 and a motion execution assembly 200, the motion execution assembly 200 is arranged on one side of the outer wall of the power modulation assembly 100. Figures 1-2 The power modulation assembly 100 is used for decoupling the shift power output and the stroke speed adjustment function and realizing stepless adaptive control of the shift power.

[0036] The motion execution assembly 200 is used for realizing high-precision conversion of rotary motion to linear motion and pushing the synchronizer to complete the shift action.

[0037]

[0038] Figures 5-6 ​​As shown, the power modulation assembly 100 includes a brushless DC motor 104, a sun gear 108, three planet gears 110, a planet carrier 112, and a ring gear 114. The brushless DC motor 104 is used to provide the constant base torque required for the engagement and disengagement of the drive synchronizer. The sun gear 108, the three planet gears 110, the planet carrier 112, and the ring gear 114 form a complete planetary differential assembly. The planetary differential assembly is used to achieve stepless continuous adjustment of the output speed of the planet carrier 112 by utilizing the dual power inputs of the sun gear 108 and the ring gear 114.

[0039] like Figure 11 As shown, the motion execution assembly 200 includes a lead screw 205, a nut 206, a cage 207, a set of balls 208, and a shift fork 210. The lead screw 205, nut 206, cage 207, and set of balls 208 form a complete ball screw pair. The ball screw pair is used to convert the rotational motion output by the planet carrier 112 in the planetary differential assembly into linear motion. The shift fork 210 is used to engage the annular groove of the synchronizer sleeve with the lower U-shaped fork and receive the linear power of the nut 206 to drive the synchronizer to complete the engagement and disengagement actions.

[0040] The embodiment mainly aims at the rigid demand for stepless adaptive adjustment, low impact and high smoothness, strong working condition adaptability, long service life and low operation and maintenance in the current automatic transmission field, and the increasing conflict with the fundamental conflict of the traditional shift regulation device, such as stepwise regulation, power regulation function coupling, anti-vibration and environmental adaptability. The traditional scheme relies on single power source driving, discrete stroke control and extensive structure integration, which is difficult to adapt to the flexible adaptation demand of complex driving conditions of vehicles and different vehicle transmissions, resulting in two core defects in the existing technology: first, the precision and smoothness of shift regulation are insufficient, which can easily cause operation failure. Among them, the traditional automatic shift regulation device, such as the shift fork shaft, the electromagnetic drive mechanism and the single motor gear type shift component, mostly uses stepwise stroke regulation logic, relies on fixed gear ratio or step motor discrete rotation to realize shift stroke regulation, and cannot realize stepless adaptive adjustment according to the synchronizer engagement resistance, vehicle speed and power demand. At the same time, the shift power output and stroke speed regulation are completed by the same power source, and the function coupling causes shift impact when the power is excessive, and causes synchronizer jamming when the power is insufficient. The single contact type stroke feedback structure is easily disturbed by vibration, and the shift fork 210 and the synchronizer are not in contact with the inclined interface, which further aggravates the micro-motion wear of the contact surface, and long-term operation can cause shift abnormal noise, synchronizer ablation and even transmission gear failure, forming a vicious cycle of performance degradation. Secondly, the structure integration and working condition adaptability are insufficient, which leads to difficult assembly and maintenance. The traditional device is mostly integrated and designed with the transmission body, and the structure coupling degree is very high. Once a fault occurs, the transmission core gear set needs to be disassembled for maintenance, which is high in operation and maintenance cost and low in efficiency. The anti-vibration protection relies on simple rubber pads, and the insulation protection relies on ordinary plastic shells. Under the conditions of high and low temperature, jolt and vibration of vehicles and erosion of transmission oil, the shell is easy to age and fail, the fixed structure is easy to displace, and long-term stable operation cannot be guaranteed.

[0041] The embodiment is completed to solve the problems of the prior art. Through the cooperative linkage of the power modulation assembly 100 and the motion execution assembly 200, the core defects of the traditional automatic gear shifting adjustment device, such as discontinuous grading control, coupled power regulation function, poor anti-vibration stability, complicated assembly and maintenance, and weak working condition adaptability, are accurately solved, and the core needs of high-precision stepless regulation, high-smoothness low-impact, strong working condition adaptability, and long service life low operation and maintenance in the field of vehicle automatic transmission are fully met. The power modulation assembly 100 is decoupled by the double power sources of the brushless direct current motor 104 and the modulation servo motor 118, cooperates with the rotation speed synthesis mechanism of the planetary differential assembly, realizes independent control of the shifting power and the stroke adjustment, can realize stepless adaptive regulation of the shifting stroke according to the synchronizer resistance and the vehicle speed working condition, and completely solves the shifting impact or jamming problem caused by the traditional single power source. The integrated layout of the integrated first encoder and the torque sensing ring 107 can realize real-time monitoring of the power input state and the shifting resistance without additional expansion installation space, cooperates with the TCU to form a closed-loop control, avoids regulation lag and loss of control, and adapts to complex driving conditions. Secondly, the motion execution assembly 200 is accurately designed by the precise matching design of the ball screw pair and the shift fork 210, efficiently converts the rotary motion output by the planetary carrier 112 into a linear shifting stroke, cooperates with the close fit of the rectangular clamping groove above the shift fork 210, the nut 206, and the axial slider 209, limits the rotation of the nut 206 while ensuring smooth power transmission, avoids shifting slack and abnormal noise, the composite structure of the fifth radial bearing 204 of the screw 205 and the sealed support end cover 202 can compensate the vibration and thermal expansion gap, limit the radial displacement of the screw 205, ensure the transmission accuracy and stability, cooperate with the design of the dust cover 201, block the erosion of transmission oil and the invasion of impurities, and improve the running stability in harsh conditions. The integrated layout of the position sensor 213 can collect the shifting stroke signal in real time and feed back to the TCU, and accurately correct the regulation error.

[0042] According to Figures 3-4 As shown in the figure, the power modulation assembly 100 further comprises a modulation cavity shell 101, the outer wall of the modulation cavity shell 101 is sealingly connected with a first end cover 102 and a second end cover 103 at both ends respectively, the opposite side of the brushless direct current motor 104 is bolted to the first end cover 102, and the first encoder is integrated in the inside of the brushless direct current motor 104, the outer wall of the second end cover 103 is bolted with an L-shaped frame 117 on one side, the outer wall of the L-shaped frame 117 is screwed with a modulation servo motor 118 on one side, and the second encoder is integrated in the inside of the modulation servo motor 118, the modulation servo motor 118 is used to realize stepless speed regulation, the shaft end of the brushless direct current motor 104 is rotatably connected with a first motor output shaft 106, according to Figure 7 As shown in the figure, the outer surface of the first motor output shaft 106 is sleeved with a torque sensing ring 107, and the torque sensing ring 107 is used to monitor the torque change of the main first motor output shaft 106 in real time and indirectly perceive the resistance size in the synchronizer engagement process.

[0043] In the embodiment of the present application, first, the cavity shell 101, the first end cover 102, the second end cover 103 and the L-shaped frame 117 are integrally forged by high-strength aluminum alloy, which can effectively reduce the overall weight of the power modulation assembly 100 and perfectly adapt to the lightweight design requirements of the vehicle, while ensuring the structural rigidity to resist the operation of the transmission; wherein the shell of the brushless DC motor 104 and the modulation servo motor 118 is made of die-cast aluminum alloy, and the internal coil is made of oxygen-free copper core to ensure stable power output; secondly, the first end cover 102 and the brushless DC motor 104, and the L-shaped frame 117 and the modulation servo motor 118 are connected by internal hexagonal bolts, the bolt material is 304 stainless steel, and the bolt is matched with a lock washer, which is convenient to disassemble and assemble and has high connection strength, and can avoid loosening caused by long-term vibration; the double motors are respectively integrated with the first encoder and the second encoder, the encoder is designed by magnetoelectric type, without additional independent sensor, which greatly simplifies the structure layout, realizes real-time and accurate collection of the rotation speed and angle of the brushless DC motor 104 and the modulation servo motor 118, and the first motor output shaft 106 is made of alloy steel and subjected to carburizing and quenching treatment, which has high strength and high wear resistance, the torque sensing ring 107 sleeved on the outer surface of the first motor output shaft 106 is made of magnetic elastomer alloy sheet material, which is arranged on the first motor output shaft 106 without occupying additional axial space, can capture the torque change amount in real time, and indirectly perceive the synchronizer engagement resistance, cooperate with the TCU to quickly adjust the motor output power, and solve the gear shifting impact or jamming problem caused by lack of resistance monitoring in the traditional device from the root.

[0044] According to Figure 4 and Figure 6 , the outer surface of the first motor output shaft 106 is sleeved with the first radial bearing 105 and the second radial bearing 109, respectively, the outer surface of the first radial bearing 105 is connected with the inner surface of the first end cover 102, and the outer surface of the second radial bearing 109 is connected with the inner surface of the planetary carrier 112, according to Figure 5 , the outer surface of the first motor output shaft 106 is rotationally connected with the inner surface of the sun gear 108.

[0045] In the embodiment of the present application, first, the first radial bearing 105 and the second radial bearing 109 are both made of high-carbon chromium bearing steel material, and are internally provided with lithium-based lubricating grease sealing structure, which can work stably for a long time in the transmission oil environment and can effectively reduce the rotating friction loss of the first motor output shaft 106; wherein the first radial bearing 105 is in interference fit with the inner surface of the first end cover 102, and the second radial bearing 109 is embedded in the inner surface of the planet carrier 112, and the double support structure ensures the stability of the first motor output shaft 106 and avoids radial movement during rotation; second, the sun gear 108 is made of alloy steel, the tooth surface is treated by nitriding, and the sun gear 108 is connected with the first motor output shaft 106 by spline, which not only ensures the stable transmission of power, but also adapts to the speed difference during the cooperative work of the double power sources, and solves the defects of insufficient transmission rigidity and easy wear of the tooth surface of the traditional single power source device.

[0046] According to Figure 6 As shown in the figure, the outer surface of the sun gear 108 and the outer surface of the three planetary gears 110 are meshed and connected, the outer surface of the three planetary gears 110 and the inner surface of the ring gear 114 are meshed and connected, the inner surface of the three planetary gears 110 is inserted with the planetary shaft 111, the outer surface of the three planetary shafts 111 is inserted into the shaft hole of the planet carrier 112, and the outer wall of the planet carrier 112 is connected with the planet carrier output shaft 113 on one side.

[0047] In the embodiment of the present application, first, the planetary gear 110 is made of alloy steel material which is homologous to the sun gear 108, and the tooth surface is also treated by nitriding, and the planetary shaft 111 is made of alloy structural steel, which can effectively withstand the alternating load during meshing transmission; second, the planet carrier 112 and the planet carrier output shaft 113 are formed by aluminum alloy integrated forging process, which is compact in structure and has no connection gap, which can effectively improve the anti-vibration performance and power transmission efficiency; and the ring gear 114 is made of alloy steel material, the inner tooth surface is hardened, and at the same time, the three planetary gears 110 are uniformly distributed between the sun gear 108 and the ring gear 114, the included angle is one hundred and twenty degrees, and the planetary shaft 111 and the planet carrier 112 are fixed, forming a stable differential transmission structure, which can not only receive the basic power transmitted by the sun gear 108, but also respond to the speed regulation of the ring gear 114, realize stepless continuous adjustment of the output speed of the planet carrier 112, and completely break through the limitations of the traditional device stepwise regulation, so that the shift stroke can accurately adapt to different vehicle speeds and power requirements.

[0048] According to Figures 5-6 As shown in the figure, the outer surface of the sun gear 108 and the outer surface of the three planetary gears 110 are meshed and connected, the outer surface of the three planetary gears 110 and the inner surface of the ring gear 114 are meshed and connected, the inner surface of the three planetary gears 110 is inserted with the planetary shaft 111, the outer surface of the three planetary shafts 111 is inserted into the shaft hole of the planet carrier 112, and the outer wall of the planet carrier 112 is connected with the planet carrier output shaft 113 on one side.

[0049] In the embodiment of the present application, first, the third radial bearing 115 also adopts high-carbon chromium bearing steel material, which is consistent with the material of the first radial bearing 105 and the second radial bearing 109, to ensure the wear resistance and lubrication compatibility of the overall transmission system; it is symmetrically sleeved on the outer surface of the gear ring 114 and is in transition fit with the inner surface of the modulation cavity shell 101, which can provide stable radial support for the gear ring 114 and reduce friction and deviation during rotation; the outer teeth 116 on the outer surface of the gear ring 114 are arranged between the two third radial bearings 115, which ensures that the stress point during meshing is within the support structure range, thereby improving the transmission stability; this design makes the gear ring 114 not easy to deform when bearing the meshing torque, and rotates more smoothly, thereby solving the problems of meshing deviation, vibration and noise caused by insufficient support in traditional gear transmission, and the gear ring 114 made of alloy steel can resist long-term wear.

[0050] According to Figure 4 As shown in FIG. 1, a groove 124 is arranged in the wall thickness of the modulation cavity shell 101, and the shaft end of the modulation servo motor 118 is rotatably connected to a second motor output shaft 119, the second motor output shaft 119 is symmetrically sleeved with a fourth radial bearing 120, and the outer surface of one of the fourth radial bearings 120 is connected to the inner surface of the first end cover 102, and the outer surface of the other fourth radial bearing 120 is connected to the inner surface of the groove 124.

[0051] In the embodiment of the present application, first, the groove 124 in the wall thickness of the modulation cavity shell 101 is an integrated molding structure, which is processed by CNC milling without additional processing and assembly, and provides installation space for the fourth radial bearing 120 without reducing the strength of the shell, thereby realizing compact design of the structure; the second motor output shaft 119 is made of 40Cr alloy steel, and the fourth radial bearing 120 is made of the same material as the first radial bearing 105, the second radial bearing 109 and the third radial bearing 115, thereby ensuring the wear resistance and consistency of the overall transmission system; and the two fourth radial bearings 120 are respectively supported in the first end cover 102 and the groove 124, thereby avoiding meshing deviation of the micro gear 121 caused by vibration, which not only saves installation space but also improves the accuracy of power transmission, thereby adapting to the working condition requirement of dense internal elements of the transmission.

[0052] According to Figure 6 and Figure 8 As shown in FIG. 1, the outer surface of the second motor output shaft 119 is sleeved with a micro gear 121, the outer surface of the micro gear 121 is meshingly connected to a transition gear 123, the inner surface of the transition gear 123 is connected to a micro bearing, the inner surface of the micro bearing is inserted with a rotating rod, the outer surface of the rotating rod is symmetrically connected to a metal plate 122, each metal plate 122 is bolted to one side of the outer wall of a corresponding third radial bearing 115, and the bottom of the transition gear 123 is meshingly connected to the top of a group of outer teeth 116.

[0053] In the embodiment of the present application, firstly, the micro gear 121 and the transition gear 123 are both made of alloy steel material, the surface is quenched and tempered by carburizing, the micro bearing is made of high-carbon chromium bearing steel material, secondly, the rotating rod is made of 304 stainless steel material, and the metal plate 122 is made of aluminum alloy material; wherein the transition gear 123 is connected with the rotating rod through the micro bearing, the metal plate 122 fixes the rotating rod on the outer wall of the third radial bearing 115, ensures the accurate installation position of the transition gear 123, and the meshing gaps of the micro gear 121, the outer tooth 116 of the gear ring 114 are uniform; the multi-stage gear transmission structure can accurately transmit the speed regulation power of the modulation servo motor 118, and the fixing mode of the metal plate 122 has strong anti-vibration performance, can mesh without loosening in different vibration environments, avoids the problems of loosening and wear caused by vibration in the traditional gear transmission, and ensures the stable realization of the stepless speed regulation function.

[0054] According to Figures 9-10 As shown in FIG. 8, the motion execution assembly 200 further comprises a dust cover 201 and a position sensor 213, one end of the outer wall of the dust cover 201 is fixedly connected with a sealing support end cover 202, the other end of the outer wall of the dust cover 201 is fixedly connected with one side of the outer wall of the second end cover 103, one side of the outer wall of the sealing support end cover 202 is fixedly connected with a connecting flange 203, the inner surface of the sealing support end cover 202 is embedded with a fifth radial bearing 204, the inner surface of the fifth radial bearing 204 is rotationally connected with the outer surface of a lead screw 205, and one end of the outer wall of the lead screw 205 is rotationally connected with the opposite end of the planetary carrier output shaft 113.

[0055] In the embodiment of the present application, firstly, the dust cover 201 is made of fluororubber and glass fiber reinforced engineering plastic composite material, has excellent oil resistance and flexibility, and has high mechanical strength, can effectively block the invasion of transmission oil and impurities into the internal components; wherein the sealing support end cover 202 and the connecting flange 203 are both made of aluminum alloy material, the fifth radial bearing 204 is made of high-carbon chromium bearing steel, and the lead screw 205 is made of alloy steel material with chrome plating treatment, which has rust resistance and wear resistance; secondly, the two ends of the dust cover 201 are respectively fixed with the second end cover 103 and the sealing support end cover 202 by buckling and sealing glue, forming an effective sealed space, cooperating with the radial positioning of the fifth radial bearing 204 to the lead screw 205, ensuring the stability of the coaxiality of the lead screw 205 during rotation; and the connecting flange 203 is provided with 8 bolt holes with a hole distance suitable for common transmission installation positions, so that the motion execution assembly 200 can be quickly fixed to the transmission housing by bolts, thereby adapting to the installation requirements of different specifications of displacement transmission, and solving the defects of poor installation compatibility and insufficient protection of the traditional device.

[0056] According to Figures 11-12As shown, the outer surface of the screw rod 205 and the inner surface of the nut 206 are connected in a sleeve manner, the inner surface of the nut 206 and the outer surface of the retainer 207 are connected, a set of balls 208 are arranged between the retainer 207 and the screw rod 205, the bottom of the nut 206 is fixedly connected with an axial sliding block 209, the bottom of the axial sliding block 209 is connected with the top of the shift fork 210, according to Figure 4 As shown, the outer wall of the sealing support end cover 202 and the connecting flange 203 is penetrated by a mounting hole 211, the inner surface of the mounting hole 211 is slidably connected with a lubricating grease nozzle 212, according to Figure 11 As shown, the position sensor 213 is opposite to the outer wall side of the shift fork 210, and the position sensor 213 is bolted to the outer wall side of the second end cover 103, the position sensor 213 is used for monitoring the linear displacement and movement speed of the shift fork 210 in real time.

[0057] In the embodiment of the present application, first, the nut 206 is made of alloy steel, the retainer 207 is made of glass fiber reinforced nylon engineering plastic, which has self-lubricating property and oil resistance, the ball 208 is made of high-carbon chromium bearing steel, the axial sliding block 209 is made of alloy steel and is integrally milled with the nut 206, the shift fork 210 is made of aluminum alloy and is forged, the lubricating grease nozzle 212 is made of brass and has strong corrosion resistance, and the position sensor 213 is a Hall sensor; wherein the ball screw pair replaces sliding friction with rolling friction of the ball 208, the retainer 207 can prevent the ball 208 from falling off and ensure stable transmission; the rectangular clamping groove of the axial sliding block 209 and the shift fork 210 adopts transition fit, thereby limiting the rotation of the nut 206 and efficiently converting rotary motion into linear motion; second, the lubricating grease nozzle 212 facilitates regular injection of lithium-based lubricating grease, prolonging the service life of the components; the position sensor 213 can monitor the displacement and speed of the shift fork 210 in real time and feed back signals to the TCU, thereby realizing closed-loop control and solving the problems of travel feedback lag and low gear shifting accuracy of the traditional device, and the aluminum alloy shift fork 210 and the dust cover 201 and the sensor shell made of composite material take into account light weight and weather resistance, ensuring long-term stable operation of the device under harsh working conditions such as high and low temperature and vibration.

[0058] In use, when the vehicle needs to shift during driving, the entire device operates in a logical order around the logic of command receiving, power modulation, motion conversion, shift execution, and closed-loop feedback. Through the coordinated linkage of the power modulation assembly 100 and the motion execution assembly 200, the precise cooperation of each component realizes high-precision, low-impact adaptive shifting. The specific process is as follows: First, during the command issuance and power startup phase, the transmission control unit TCU collects real-time driving data such as vehicle speed and engine load, generates a shift command in combination with the preset shift strategy, and simultaneously issues startup and parameter adjustment commands to the brushless DC motor 104 and the modulation servo motor 118 in the power modulation assembly 100. At this time, the brushless DC motor 104 installed on the outside of the first end cover 102 at one end of the modulation cavity housing 101 starts first, outputs the constant basic torque required for synchronizer engagement and disengagement, and its internally integrated first encoder collects real-time speed and angle signals. The torque is transmitted through the first motor output shaft 106 at the shaft end of the brushless DC motor 104, and the torque sensing ring 107 sleeved on the outer surface of the first motor output shaft 106 is started simultaneously to monitor the torque change of the first motor output shaft 106 to indirectly sense the synchronizer engagement resistance. At the same time, the modulation servo motor 118 fixed to the outside of the second end cover 103 starts according to the speed regulation command, and the internally integrated second encoder collects speed signals. The speed regulation power is transmitted to the micro gear 121 through the second motor output shaft 119. Then, it enters the power modulation and speed synthesis stage. First, the first motor output shaft 106 rotates smoothly under the double support of the first and second radial bearings 105 and 109, transmitting torque to the sun gear 108. The sun gear 108 is in mesh with three evenly distributed planet gears 110, driving the planet gears 110 to rotate around the planet shaft 111. At the same time, the power of the modulation servo motor 118 is transmitted through the second motor output shaft 119, the micro gear 121, and the multi-stage meshing of the transition gear 123 to the external teeth 116 on the outer surface of the ring gear 114, driving the ring gear 114 to rotate under the support of the two third radial bearings 115. Then, the basic power of the sun gear 108 and the speed regulation power of the ring gear 114 are synthesized in the planetary differential assembly. The three planet gears 110 rotate around the sun gear 108 while the planet carrier 112 rotates around the sun gear 108. The planet carrier output shaft 113 outputs continuously adjustable rotary power, and all sensor signals including torque, speed, and angle are fed back to the TCU in real time. In the motion conversion and shift execution stage, the planet carrier output shaft 113 transmits rotary power to the lead screw 205 of the motion execution assembly 200. The lead screw 205 rotates smoothly under the support of the fifth radial bearing 204 embedded in the sealed support end cover 202. Since the lead screw 205 and the nut 206 form rolling friction through a set of balls 208 in the retainer 207, rotary motion is efficiently converted into linear motion of the nut 206.The axial slider 209 fixed at the bottom of the nut 206 is tightly fitted with the rectangular clamping slot at the top of the fork 210, so as to limit the rotation of the nut 206 and ensure the transmission of power without looseness; secondly, the fork 210 moves along the preset trajectory under the action of linear driving force, and the U-shaped fork at the bottom accurately clamps the annular groove of the synchronizer sleeve, so as to push the synchronizer sleeve to complete the engagement and separation action, thereby realizing the switching of gears; in this process, the dust cover 201 blocks the invasion of transmission oil and impurities, the sealing support flange 203 outside the outer side of the second end cover 103 is fixed through the bolts in the mounting hole 211, and the lubricating grease nozzle 212 can be regularly filled with lubricating grease to ensure smooth transmission; then enters the closed-loop feedback and accurate adjustment stage, in the gear shifting execution process, the position sensor 213 fixed outside the second end cover 103 real-time monitors the linear displacement and movement speed of the fork 210, and feeds back the data to the TCU; wherein the TCU combines the resistance signal of the torque sensing ring 107, the rotation speed signal of the first encoder of the brushless DC motor 104 and the second encoder of the modulation servo motor 118, and dynamically judges the gear shifting state; if it is detected that the synchronizer engagement resistance is too large, the TCU adjusts the rotation speed of the modulation servo motor 118, adjusts the output rotation speed of the planetary carrier 112 through the gear ring 114, reduces the advancing speed of the fork 210 to avoid impact; if the position sensor 213 detects that the displacement deviation of the fork 210, the TCU will immediately fine-tune the output torque of the brushless DC motor 104, correct the gear shifting stroke, and ensure the accurate docking of the synchronizer; finally, it enters the gear shifting completion and standby stage, when the position sensor 213 feedbacks the gear shifting in-place signal, the TCU issues an instruction to stop the brushless DC motor 104 and the modulation servo motor 118, the planetary differential assembly stops power output, and the fork 210 remains at the current position to stabilize the gear; if it is necessary to switch other gears, the TCU repeats the above process; when the vehicle is running at a constant speed without gear shifting, the device enters a low-power standby state, the torque sensing ring 107 and the position sensor 213 continuously monitor the state to ensure that the gear shifting instruction can be responded at any time; in the whole process, the modulation cavity shell 101, the first end cover 102, the second end cover 103 and other structures provide stable installation and sealing protection, and each bearing ensures smooth operation of the components, thereby greatly prolonging the service life of the device.

[0059] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can modify the technical solutions described in the foregoing embodiments or make equivalent replacements to some of the technical features, as long as they are within the spirit and principles of the present application. Any modification, equivalent replacement, improvement, etc. made shall be included in the protection scope of the present application.

Claims

1. An automatic shift stroke adaptive adjustment device, characterized in that: It includes a power modulation component (100) and a motion execution component (200), wherein the motion execution component (200) is mounted on one side of the outer wall of the power modulation component (100); The power modulation assembly (100) includes a brushless DC motor (104), a sun gear (108), three planet gears (110), a planet carrier (112), and a ring gear (114). The brushless DC motor (104) is used to provide the constant base torque required for the engagement and disengagement of the drive synchronizer. The sun gear (108), the three planet gears (110), the planet carrier (112), and the ring gear (114) form a complete planetary differential assembly. The planetary differential assembly is used to achieve stepless continuous adjustment of the output speed of the planet carrier (112) by utilizing the dual power input of the sun gear (108) and the ring gear (114). The motion execution component (200) includes a lead screw (205), a nut (206), a cage (207), a set of balls (208), and a shift fork (210). The lead screw (205), nut (206), cage (207), and set of balls (208) form a complete ball screw pair. The ball screw pair is used to convert the rotational motion output by the planet carrier (112) in the planetary differential assembly into linear motion. The shift fork (210) is used to engage the annular groove of the synchronizer sleeve with the lower U-shaped fork and receive the linear power of the nut (206) to drive the synchronizer to complete the engagement and disengagement actions.

2. The automatic shift stroke adaptive adjustment device according to claim 1, characterized in that: The power modulation assembly (100) further includes a modulation cavity housing (101). A first end cover (102) and a second end cover (103) are respectively sealed and connected to both ends of the outer wall of the modulation cavity housing (101). The first end cover (102) is bolted to the opposite side of a brushless DC motor (104), and a first encoder is integrated inside the brushless DC motor (104). An L-shaped bracket (117) is bolted to one side of the outer wall of the second end cover (103), and screws are connected to one side of the outer wall of the L-shaped bracket (117). A modulated servo motor (118) is provided, and a second encoder is integrated inside the modulated servo motor (118). The modulated servo motor (118) is used to achieve stepless speed regulation. The shaft end of the brushless DC motor (104) is rotatably connected to a first motor output shaft (106). A torque sensing ring (107) is sleeved on the outer surface of the first motor output shaft (106). The torque sensing ring (107) is used to monitor the torque change of the main first motor output shaft (106) in real time and indirectly sense the resistance during the synchronizer engagement process.

3. The automatic shift stroke adaptive adjustment device according to claim 2, characterized in that: The outer surface of the first motor output shaft (106) is respectively fitted with a first radial bearing (105) and a second radial bearing (109). The outer surface of the first radial bearing (105) is connected to the inner surface of the first end cover (102), the outer surface of the second radial bearing (109) is connected to the inner surface of the planet carrier (112), and the outer surface of the first motor output shaft (106) is rotatably connected to the inner surface of the sun gear (108).

4. The automatic shift stroke adaptive adjustment device according to claim 3, characterized in that: The outer surface of the sun gear (108) meshes with the outer surfaces of the three planet gears (110), the outer surfaces of the three planet gears (110) mesh with the inner surface of the gear ring (114), the inner surfaces of the three planet gears (110) are all fitted with planet shafts (111), the outer surfaces of the three planet shafts (111) are fitted with the shaft holes of the planet carrier (112), and the outer wall of the planet carrier (112) is connected to a planet carrier output shaft (113).

5. The automatic shift stroke adaptive adjustment device according to claim 4, characterized in that: The outer surface of the gear ring (114) is symmetrically fitted with third radial bearings (115). The outer surfaces of the two third radial bearings (115) are connected to the inner surface of the modulation cavity housing (101). The outer surface of the gear ring (114) is provided with a set of external teeth (116), and the set of external teeth (116) is located between the outer walls of the two third radial bearings (115).

6. The automatic shift stroke adaptive adjustment device according to claim 5, characterized in that: The wall of the modulation cavity housing (101) has a groove (124). The shaft end of the modulation servo motor (118) is rotatably connected to the second motor output shaft (119). The second motor output shaft (119) is symmetrically fitted with a fourth radial bearing (120). The outer surface of one of the fourth radial bearings (120) is connected to the inner surface of the first end cover (102), and the outer surface of the other fourth radial bearing (120) is connected to the inner surface of the groove (124).

7. The automatic shift stroke adaptive adjustment device according to claim 6, characterized in that: The outer surface of the second motor output shaft (119) is fitted with a micro gear (121), the outer surface of the micro gear (121) is meshed with a transition gear (123), the inner surface of the transition gear (123) is connected with a micro bearing, the inner surface of the micro bearing is inserted with a rotating rod, the outer surface of the rotating rod is symmetrically connected with metal plates (122), each metal plate (122) is bolted to one side of the outer wall of a corresponding third radial bearing (115), the bottom of the transition gear (123) is meshed with the top of a set of external teeth (116).

8. The automatic shift stroke adaptive adjustment device according to claim 2, characterized in that: The motion execution component (200) also includes a dust cover (201) and a position sensor (213). One end of the outer wall of the dust cover (201) is fixedly connected to a sealing support end cap (202). The other end of the outer wall of the dust cover (201) is fixedly connected to one side of the outer wall of the second end cap (103). One side of the outer wall of the sealing support end cap (202) is fixedly connected to a connecting flange (203). A fifth radial bearing (204) is embedded in the inner surface of the sealing support end cap (202). The inner surface of the fifth radial bearing (204) is rotatably connected to the outer surface of the lead screw (205). One end of the outer wall of the lead screw (205) is rotatably connected to the opposite end of the planetary carrier output shaft (113).

9. The automatic shift stroke adaptive adjustment device according to claim 8, characterized in that: The outer surface of the lead screw (205) and the inner surface of the nut (206) are sleeved and connected. The inner surface of the nut (206) and the outer surface of the cage (207) are connected. A set of balls (208) are disposed between the cage (207) and the lead screw (205). An axial slider (209) is fixedly connected to the bottom of the nut (206). The bottom of the axial slider (209) is connected to the top of the shift fork (210). The outer walls of the sealing support end cap (202) and the connecting flange (203) have a mounting hole (211) through them. A grease nipple (212) is slidably connected to the inner surface of the mounting hole (211). The position sensor (213) is directly opposite to one side of the outer wall of the shift fork (210). The position sensor (213) is bolted to one side of the outer wall of the second end cap (103). The position sensor (213) is used to monitor the linear displacement and movement speed of the shift fork (210) in real time.

10. An automatic transmission, characterized in that, Includes the automatic shift travel adaptive adjustment device as described in any one of claims 1-9.

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