Off-road vehicle transfer case misoperation prevention device and control method
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TAIAN AEROSPACE SPECIAL VEHICLE CO LTD
- Filing Date
- 2023-08-23
- Publication Date
- 2026-07-14
Smart Images
Figure CN117108736B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of off-road vehicle transfer case technology, and in particular to an off-road vehicle transfer case anti-misoperation device and control method. Background Technology
[0002] Transfer cases are widely used in heavy-duty off-road vehicles. Their function is to distribute the power output from the transmission to each drive axle and drive the superstructure equipment through the power take-off. In order to further increase the output torque of the transmission, they play the role of speed reduction and torque increase. High-power transfer cases in heavy-duty off-road vehicles generally have high gear, low gear, neutral, power take-off and other working modes, thereby changing the dynamic performance of the vehicle, adapting to different working conditions, and improving the power and economy of the whole vehicle.
[0003] Current heavy-duty off-road vehicle transfer cases employ an electro-pneumatic, meshing sleeve shifting mechanism. High / low gear selectors, mounted in the driver's cab, directly control relevant solenoid valves to switch the transfer case's operating mode. This mechanism fails to assess whether the vehicle is stationary, whether the transfer case has input torque, or whether the auxiliary air pressure is too low, relying entirely on the driver's subjective experience. In reality, due to the lack of necessary safety protection measures, transfer case damage caused by improper or incorrect driver operation is frequent, posing a threat to the safety of transfer case use. Summary of the Invention
[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a transfer case anti-misoperation device and control method for off-road vehicles, so as to completely solve the problem of driver misoperation and improve the safety of using the transfer case in heavy off-road vehicles.
[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:
[0006] In a first aspect, a transfer case anti-misoperation device for an off-road vehicle includes:
[0007] The data acquisition unit is used to collect and transmit vehicle driving data;
[0008] The controller connects the data acquisition unit and the actuator. The actuator includes solenoid valves and indicator lights. The solenoid valves include high-speed solenoid valves, low-speed solenoid valves, neutral solenoid valves, and power take-off solenoid valves. The solenoid valves are used for electro-pneumatic operation to switch the transfer case's working mode. The indicator lights are used to display the current working mode of the transfer case and fault alarms.
[0009] Based on the vehicle driving data acquired by the data acquisition unit, the controller controls the transfer case to take power by energizing a solenoid valve. By combining the working modes of multiple solenoid valves, it controls the gear positions of various models of transfer cases, realizing automatic configuration of the transfer case, fault detection, and control of the actuator to enable the transfer case to switch working modes safely.
[0010] As a further implementation, a redundant circuit is also included, which connects the controller and the actuator to control the actuator via the redundant circuit in the event of a controller failure.
[0011] As a further implementation, a debugger is also included. The debugger is connected to the controller and has a communication interface for data communication with the controller. It is used for status display, transfer case configuration, and parameter modification, making it convenient for vehicle use.
[0012] As a further implementation, the actuator controls the transfer case to engage and disengage by energizing a two-position three-way solenoid valve, and controls the switching of various transfer cases by using multiple two-position three-way solenoid valves in working modes of individual energization, combined energization, and delayed de-energization.
[0013] As a further implementation, the actuator indicates the current working mode of the transfer case by keeping the indicator light constantly on; if there is a fault, the indicator light flashes, with the flashing indicator light taking priority.
[0014] As a further implementation, a gear control switch and a power take-off control switch are provided between the controller and the redundant circuit, and the gear control switch and the power take-off control switch are connected to a solenoid valve.
[0015] As a further implementation, the controller is connected to the transmission gear position sensor, the transmission clutch position sensor, the transmission output shaft speed sensor, the vehicle speed sensor, and the auxiliary air pressure sensor, and the controller is also connected to the vehicle bus.
[0016] Secondly, a method for preventing misoperation of a transfer case in an off-road vehicle is provided, characterized by employing a transfer case misoperation prevention device as described above, including automatic transfer case configuration, with the following specific steps:
[0017] The power-on system performs a self-test and determines the appropriate transfer case for the current controller by checking the indicator light status.
[0018] If the transfer case is mismatched, activate the transfer case configuration function of the controller via the gear position control switch;
[0019] After the indicator light flashes, operate the gear control switch. The controller will change the transfer case configuration according to the status of the gear control switch and the detection signal. The transfer case configuration can be confirmed by the status of the indicator light.
[0020] Exit transfer case configuration function.
[0021] As a further implementation method, transfer case gear control is also included, with the following specific steps:
[0022] Operate the transfer case gear control switch;
[0023] Determine if the vehicle is stationary, the transmission is in neutral, the transmission output shaft is stationary, and the auxiliary air pressure is sufficient;
[0024] If the conditions are met, the transfer case gear shifting operation will be executed;
[0025] If the condition is not met, maintain the current gear of the transfer case.
[0026] As a further implementation method, transfer case power take-off control is also included, with the following specific steps:
[0027] Operate the transfer case power take-off control switch;
[0028] Determine if the vehicle is stationary, the transmission is in neutral, the transmission output shaft is stationary, the transfer case is in neutral, and the auxiliary air pressure is sufficient.
[0029] If the conditions are met, the transfer case power take-off operation will be executed;
[0030] If the condition is not met, maintain the current state of the power take-off.
[0031] The beneficial effects of the present invention are as follows:
[0032] 1. This invention acquires vehicle driving data through a data acquisition unit, comprehensively analyzes and judges to derive a reasonable control strategy, realizes automatic transfer case configuration, fault detection, and control actuators to enable the transfer case to switch working modes in a safe manner, completely solves the problem of driver misoperation, and improves the safety of using transfer cases in heavy off-road vehicles.
[0033] 2. This invention achieves interlock between vehicle driving and transfer case operating status. Regardless of whether the vehicle is driving, whether the transfer case is currently operating, or whether the driver makes a mistake, it can ensure that the transfer case switches operating modes safely when the vehicle is stationary, the transfer case has no input torque, and the auxiliary air pressure is sufficient. This effectively improves the safety of using the transfer case in heavy-duty off-road vehicles and ensures the normal operation of the superstructure equipment. Attached Figure Description
[0034] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.
[0035] Figure 1 This is a system block diagram of the transfer case anti-misoperation device provided in an embodiment of the present invention.
[0036] Figure 2 This is a flowchart of the automatic configuration process for the transfer case provided in an embodiment of the present invention.
[0037] Figure 3 This is a flowchart of the transfer case gear control provided in an embodiment of the present invention.
[0038] Figure 4 This is a flowchart of the transfer case power take-off control provided in an embodiment of the present invention.
[0039] Figure 5 This is an application circuit diagram of the transfer case anti-misoperation device provided in an embodiment of the present invention.
[0040] The diagram exaggerates the spacing or dimensions between parts to show their positions; the diagram is for illustrative purposes only. Detailed Implementation
[0041] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.
[0042] Example 1
[0043] In a typical embodiment of the present invention, reference is made to Figures 1-5 As shown, a transfer case anti-misoperation device for off-road vehicles includes a data acquisition unit, a controller, an actuator, redundant circuits, and a debugging instrument.
[0044] The data acquisition unit is connected to the controller, the controller is connected to the actuator, the controller is also connected to the actuator through redundant circuits, the debugger is connected to the controller, and the controller is connected to the vehicle bus and the vehicle speed sensor.
[0045] The data acquisition unit is used to collect and transmit vehicle driving data.
[0046] Vehicle driving data includes transfer case gear position control switch, transfer case power take-off control switch, transmission neutral signal, transmission clutch signal, transmission output shaft speed signal, vehicle speed signal, auxiliary air pressure signal, bus communication data, transfer case gear position detection signal, and transfer case power take-off detection signal. Based on the preferred monitoring of transmission neutral and output shaft speed signals, the transmission clutch signal is monitored. The transfer case input torque determination conditions are optimized, and bus technology is adopted to adapt to the needs of heavy-duty off-road vehicles with various transmissions.
[0047] The controller is also connected to the transmission gear position sensor, transmission clutch position sensor, transmission output shaft speed sensor, and auxiliary air pressure sensor. Depending on the actual vehicle configuration, the vehicle driving data such as the transmission neutral signal, transmission clutch signal, transmission output shaft speed signal, vehicle speed signal, and auxiliary air pressure signal mentioned in this embodiment can be directly obtained from the corresponding sensors or originate from vehicle bus communication data.
[0048] The actuator includes a solenoid valve and an indicator light. The solenoid valve is used for electro-pneumatic operation to switch the transfer case's working mode, and the indicator light is used to display the current working mode of the transfer case and fault alarms. The indicator light is integrated into the instrument cluster.
[0049] The solenoid valves include a high-gear solenoid valve, a low-gear solenoid valve, a neutral solenoid valve, and a power take-off solenoid valve. The solenoid valves are connected to the controller through redundant switches inside the redundant circuit. A gear control switch and a power take-off control switch are also provided between the controller and the redundant circuit. The gear control switch and the power take-off control switch are integrated on the corresponding rocker switch.
[0050] In this embodiment, the controller is the core of the control. The controller analyzes and judges the vehicle driving data obtained by the data acquisition unit to obtain a reasonable control strategy. The power take-off of the transfer case is controlled by energizing a solenoid valve. The working modes of multiple solenoid valves are combined to control the gear positions of various models of transfer cases, so as to realize automatic configuration of the transfer case, fault detection, and control of the actuator to enable the transfer case to switch working modes in a safe manner.
[0051] The actuator controls the transfer case engagement via a 2-position 3-way solenoid valve. It controls the switching of various transfer case models through the operation modes of individually energizing, combining energizing, or delaying de-energizing two or three 2-position 3-way solenoid valves. Further details are provided below:
[0052] The first type of transfer case uses two solenoid valves to control the gear switching. When solenoid valve I is energized, the transfer case is in the high gear state; when solenoid valve II is energized, the transfer case is in the low gear state.
[0053] The second type of transfer case uses two solenoid valves to control the gear switching. When solenoid valve I is energized, the transfer case is in the high gear state; when solenoid valve II is energized, the transfer case is in the low gear state. When solenoid valves I and II are energized simultaneously, after the transfer case is in the neutral state, solenoid valves I and II are de-energized after a delay. This control circuit ensures that the air circuit has sufficient action time, effectively eliminating the possibility that the transfer case cannot be in the neutral state due to a fault in a solenoid valve or its control circuit. This ensures both the reliability and safety of the transfer case, which is conducive to ensuring the normal operation of the upper equipment.
[0054] The third type of transfer case uses three solenoid valves to control the gear switching. When solenoid valve I is energized, the transfer case is in the high gear state; when solenoid valve II is energized, the transfer case is in the low gear state; and when solenoid valve III is energized, the transfer case is in the neutral gear state.
[0055] The fourth type of transfer case uses three solenoid valves to control the gear switching. When solenoid valves I and II are energized at the same time, the transfer case is in the high gear state; when solenoid valve III is energized, the transfer case is in the low gear state; when solenoid valves I and III are energized at the same time, the transfer case is in the neutral gear state.
[0056] The actuator indicates the current operating mode of the transfer case by having a constantly lit indicator light; if there is a fault, the indicator light will flash, with the flashing indicator light taking priority.
[0057] The redundant circuit is used for redundant control of the transfer case control circuit for emergency use; when the controller fails, the driver can easily switch the transfer case anti-misoperation control circuit to the original vehicle transfer case control circuit to ensure that the superstructure equipment can still work normally.
[0058] The tester connects to the controller and has a communication interface for data communication with the controller. It is used for status display, transfer case configuration, and parameter modification, facilitating vehicle compatibility. The tester uses a 3.5-inch serial touchscreen and can also perform transfer case configuration and fault detection. Its status display includes data status, fault status, and controller I / O status.
[0059] Example 2
[0060] A method for preventing misoperation of a transfer case in an off-road vehicle, using the device described in Embodiment 1, includes automatic transfer case configuration and transfer case operating mode control.
[0061] Automatic transfer case configuration: The controller automatically identifies different models of transfer cases based on the acquired transfer case gear control switch and detection signal status. Within 3 seconds of power-on self-test, the indicator light status can determine the current transfer case applicable to the controller. If the transfer case is mismatched, the transfer case configuration can be automatically changed by operating the high and low gear control switches when the engine is not running, the transmission is in neutral, and the vehicle is stationary, thus meeting the needs of heavy-duty off-road vehicles for various transfer case models.
[0062] The specific steps for automatic transfer case configuration are as follows:
[0063] 1) The power-on system performs a self-test, and the indicator light status determines which transfer case is applicable to the current controller;
[0064] 2) If the transfer case is mismatched, activate the transfer case configuration function of the controller by quickly operating the high and low gear control switches;
[0065] 3) After the gear position indicator light flashes, operate the high and low gear control switch normally. The controller will change the transfer case configuration according to the gear position control switch and the detection signal status. The transfer case configuration can be confirmed by the indicator light status.
[0066] 4) Exit the transfer case configuration function.
[0067] Transfer case operating mode control: This includes transfer case gear and power take-off control. Based on the transfer case's operating characteristics and input signals, the controller determines the current vehicle status in each execution cycle. Through reasonable logical calculations, it ensures that the transfer case performs the corresponding operation under safe conditions; otherwise, it maintains the current operating mode of the transfer case, rejects unsafe operations by the driver, and protects the transfer case.
[0068] The specific steps for controlling the transfer case gear position are as follows:
[0069] 1) Operate the transfer case gear control switch;
[0070] 2) Determine that the vehicle is stationary, the transmission is in neutral, the transmission output shaft is stationary, and the auxiliary air pressure is sufficient;
[0071] 3) If step 2) is met, perform the transfer case gear shifting operation;
[0072] 4) If step 2) is not met, maintain the current gear of the transfer case.
[0073] The specific steps for transfer case power take-off control are as follows:
[0074] 1) Operate the transfer case power take-off control switch;
[0075] 2) Determine that the vehicle is stationary, the transmission is in neutral, the transmission output shaft is stationary, the transfer case is in neutral, and the auxiliary air pressure is sufficient;
[0076] 3) If step 2) is met, execute the transfer case power take-off operation;
[0077] 4) If step 2) is not met, maintain the current state of the power take-off.
[0078] Through the above-mentioned device and control method, the interlock between vehicle driving and transfer case operation is realized. Regardless of whether the vehicle is driving, whether the transfer case is currently working, or whether the driver makes a mistake, it can ensure that the transfer case switches working modes under safe conditions when the vehicle is stationary, the transfer case has no input torque, and the auxiliary air pressure is sufficient. This effectively improves the safety of using the transfer case in heavy-duty off-road vehicles and ensures the normal operation of the superstructure equipment.
[0079] In this embodiment, the controller automatically identifies different transfer cases based on the acquired transfer case gear control switch and detection signal status. Within 3 seconds of power-on self-test, the indicator light status can determine the applicable transfer case for the current controller; Table 1 shows the indicator light status during the power-on self-test. If the transfer case is mismatched, and the engine is not started, the transmission is in neutral, and the vehicle is stationary, such as... Figure 2 As shown, the transfer case configuration can be changed automatically by operating the high and low gear control switches.
[0080] Table 1 Power-on self-test indicator status
[0081] Indicator light status Adapter Transfer Case Chang Liang The program is applicable to type 1 transfer case. Flash twice The program is applicable to the second type of transfer case. Flash 3 times The program is applicable to the third type of transfer case. Flash 4 times The program is applicable to the fourth type of transfer case.
[0082] Based on the transfer case's operating characteristics and input signals, the controller performs appropriate logical operations to ensure safe switching between corresponding operating modes. For example... Figure 3 , 4 As shown, in each execution cycle, the program determines the current vehicle status and derives a reasonable control strategy to ensure that the transfer case is controlled to perform the corresponding operation under safe conditions; otherwise, it maintains the current working mode of the transfer case, rejects unsafe operations by the driver, and protects the transfer case.
[0083] The following example illustrates the transfer case gear control process using the low-gear driving mode. When the driver wants the vehicle to travel at a low speed, they operate the low-gear control switch. The controller first determines the vehicle's status. If the vehicle is stationary (no reverse-phase input torque at the transfer case output, i.e., no signal output from the vehicle speed sensor), the transmission is in neutral, and the transmission output shaft is stationary (no input torque at the transfer case input, i.e., the transmission neutral switch is closed, the transmission output shaft speed sensor has no signal output, or the transmission clutch switch has been closed for 8 seconds), and the auxiliary air pressure is higher than 6.5 bar, the program determines that low-gear operation is permitted. The low-gear solenoid valve is energized, the vehicle switches to low-gear driving mode, and the low-gear indicator light illuminates. Otherwise, the current operating mode of the transfer case is maintained, preventing unsafe operation by the driver and protecting the transfer case. If a fault occurs during transfer case gear operation, the controller enters a fault alarm mode, and the gear indicator light flashes at a certain frequency, displaying a fault code.
[0084] When the driver wishes to perform transfer case take-off (PTO) operation, they operate the PTO control switch. The controller first determines the vehicle's status. If the vehicle is stationary (no reverse input torque at the transfer case output, i.e., no signal output from the vehicle speed sensor), the transmission is in neutral and the transmission output shaft is stationary (no input torque at the transfer case input, i.e., the transmission neutral switch is closed, the transmission output shaft speed sensor has no signal output, or the transmission clutch switch has been closed for 8 seconds), the transfer case is in neutral (no output torque at the transfer case, i.e., both the high and low gear indicator switches are open), and the auxiliary air pressure is higher than 6.5 bar, the program determines that PTO operation is permitted. The transfer case PTO solenoid valve is energized, the vehicle enters PTO mode, and the PTO indicator light illuminates. Otherwise, the current transfer case operating mode is maintained, preventing unsafe operations by the driver and protecting the transfer case. If a fault occurs during PTO operation, the controller enters fault alarm mode, and the PTO indicator light flashes at a certain frequency, displaying the fault code.
[0085] To ensure the reliability of the transfer case control circuit, it is considered to add an anti-misoperation device while retaining the original transfer case control circuit, such as... Figure 5 The diagram shows a redundant circuit for redundant control of the transfer case control circuit in case of emergency. When the controller malfunctions, the driver can easily switch the transfer case anti-misoperation control circuit to the original vehicle transfer case control circuit, ensuring that the superstructure equipment can still work normally.
[0086] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. A method for preventing misoperation of a transfer case in an off-road vehicle, characterized in that, A transfer case anti-misoperation device for off-road vehicles is adopted, comprising: The data acquisition unit is used to collect and transmit vehicle driving data; The controller connects the data acquisition unit and the actuator. The actuator includes solenoid valves and indicator lights. The solenoid valves include high-speed solenoid valves, low-speed solenoid valves, neutral solenoid valves, and power take-off solenoid valves. The solenoid valves are used for electro-pneumatic operation to switch the transfer case's working mode. The indicator lights are used to display the current working mode of the transfer case and fault alarms. Based on the vehicle driving data acquired by the data acquisition unit, the controller controls the transfer case to take power by energizing a solenoid valve. It controls the gear positions of various models of transfer cases by combining the working modes of multiple solenoid valves, thereby realizing automatic configuration of the transfer case, fault detection, and control of the actuator to enable the transfer case to switch working modes in a safe manner. The controller is connected to the transmission gear position sensor, transmission clutch position sensor, transmission output shaft speed sensor, vehicle speed sensor, and auxiliary air pressure sensor. The controller is also connected to the vehicle bus. It also includes a redundant circuit, which connects the controller and the actuator to control the actuator through the redundant circuit in case of controller failure; a gear control switch and a power take-off control switch are provided between the controller and the redundant circuit, and the gear control switch and the power take-off control switch are connected to a solenoid valve; The actuator controls the transfer case to engage and disengage by being energized by a two-position three-way solenoid valve. It controls the switching of various transfer cases by using multiple two-position three-way solenoid valves in working modes of individual energization, combined energization, and delayed de-energization. The control method includes automatic transfer case configuration, and the specific steps are as follows: The power-on system performs a self-test and determines the appropriate transfer case for the current controller by checking the indicator light status. If the transfer case is mismatched, activate the transfer case configuration function of the controller via the gear position control switch; After the indicator light flashes, operate the gear control switch. The controller will change the transfer case configuration according to the status of the gear control switch and the detection signal. The transfer case configuration can be confirmed by the status of the indicator light. Exit transfer case configuration function; This also includes transfer case gear control, the specific steps of which are as follows: Operate the transfer case gear control switch; Determine if the vehicle is stationary, the transmission is in neutral, the transmission output shaft is stationary, and the auxiliary air pressure is sufficient; If the conditions are met, the transfer case gear shifting operation will be executed; If the condition is not met, maintain the current gear of the transfer case; This also includes transfer case power take-off control, the specific steps of which are as follows: Operate the transfer case power take-off control switch; Determine if the vehicle is stationary, the transmission is in neutral, the transmission output shaft is stationary, the transfer case is in neutral, and the auxiliary air pressure is sufficient. If the conditions are met, the transfer case power take-off operation will be executed; If the condition is not met, maintain the current state of the power take-off.
2. The method for preventing misoperation of a transfer case in an off-road vehicle according to claim 1, characterized in that, It also includes a debugger, which connects to the controller and has a communication interface for data communication with the controller. It is used for status display, transfer case configuration, and parameter modification, making it convenient for vehicle use.
3. The method for preventing misoperation of a transfer case in an off-road vehicle according to claim 1, characterized in that, The actuator indicates the current operating mode of the transfer case by having an indicator light that is constantly on; if there is a fault, the indicator light will flash, with the flashing indicator light taking priority.