Three-position electromagnetic gear shifting synchronizer structure

Abstract

This invention discloses a three-position electromagnetic shift synchronizer structure, relating to the field of reducer technology. The three-position electromagnetic shift synchronizer structure includes a gear seat and a coil fixing seat. A low-gear assembly and a high-gear assembly are respectively connected to both sides of the gear seat. A gear sleeve for abutting the low-gear assembly and the high-gear assembly is movably connected to the circumference of the gear seat. The coil fixing seat is fitted outside the gear sleeve, and a permanent magnet is provided on the circumference of the gear sleeve. Several coils cooperating with the permanent magnet are provided on the inner wall of the coil fixing seat. This invention uses a spring-slider mechanical holding mechanism for neutral gear and permanent magnet attraction for high / low gears. No coil energization is required in any of the three steady-state positions, resulting in zero static power consumption and significantly improving energy efficiency and coil lifespan. By combining the current directions of the three coils, synergistic pulling / pushing and resisting forces can be flexibly generated to adapt to the resistance characteristics of different shift directions, resulting in smooth and shock-free shifting.

Description

Technical Field

[0001] This invention relates to the technical field of speed reducers, and in particular to a three-position electromagnetic shift synchronizer structure. Background Technology

[0002] Currently, in commercial vehicle new energy reducers, there are two technical approaches for gear shifting: power interruption and non-interruption. Non-interruption shifting is generally technically complex and costly, and is only used in a small number of vehicles operating under special conditions. Power interruption remains the mainstream technical approach. How to shorten the power interruption time, i.e., shorten the shifting time, is a problem that the industry is constantly trying to overcome. The current mainstream commercial vehicle reducer shifting logic is as follows: the motor torque drops to zero, the shift motor actuator operates, disengaging the gear from the current gear via the fork shaft, shift fork, and gear sleeve; the drive motor speed is adjusted so that the speed of the target gear is the same as the speed of the gear sleeve; the shift motor actuator operates again, engaging the target gear, completing the entire shifting action. Currently, the entire shifting time is approximately 0.7 seconds, meaning the power interruption time is approximately 700 milliseconds. The entire shifting actuator includes the shift motor, ball screw, fork shaft, shift fork, position sensor, etc. Summary of the Invention

[0003] Purpose of the invention: The purpose of this invention is to provide a three-position electromagnetic shift synchronizer structure to solve the problem of slow shifting in existing equipment.

[0004] Technical Solution: A three-position electromagnetic shift synchronizer structure includes a gear seat and a coil fixing seat. A low-gear assembly and a high-gear assembly are respectively connected to both sides of the gear seat. A gear sleeve for abutting against the low-gear assembly and the high-gear assembly is movably connected to the circumferential surface of the gear seat. The coil fixing seat is sleeved on the outside of the gear sleeve. A permanent magnet is provided on the circumferential surface of the gear sleeve. A plurality of coils cooperating with the permanent magnet are provided on the inner wall of the coil fixing seat.

[0005] Preferably, at least three coils are provided, and the coils are arranged in an axial array.

[0006] Preferably, the gear sleeve and the gear seat are splinedly connected, and the gear sleeve and the gear seat are slidably connected along the axial direction.

[0007] Preferably, the inner wall of the toothed sleeve is provided with a radial slider groove, and a slider that abuts against the slider groove is movably connected to the toothed seat.

[0008] Preferably, the side wall of the gear seat is provided with a mounting hole, and a spring is embedded in the mounting hole. One end of the spring is connected to the gear seat, and the other end of the spring is connected to the slider.

[0009] Preferably, the toothed seat has elastic retaining ring grooves on both sides of the mounting hole.

[0010] Preferably, the slider and the slider groove are provided in several groups, and the slider and the slider groove are respectively arranged in an array on the periphery of the tooth seat and the tooth sleeve.

[0011] Preferably, the coil holder is provided with a pin for connecting to the housing.

[0012] Beneficial effects: Neutral is held by a spring-slider mechanical mechanism, while high / low gears are held by permanent magnet adsorption. No coil energization is required in any of the three steady-state positions, resulting in zero static power consumption and significantly improved energy efficiency and coil lifespan. The combination of current directions in the three coils flexibly generates synergistic pulling / pushing and resisting forces, adapting to the resistance characteristics of different shift directions, ensuring smooth and shock-free shifting. The permanent magnet adsorption force combined with the mechanical limiting surface ensures reliable gearing and adapts to the high-torque impact conditions of electric vehicles. The integrated design of electromagnetic drive and mechanical holding results in a short axial dimension, suitable for compact electric drive transmission layouts. Real-time adjustment of the current in each coil based on position feedback enables fast, precise, and repeatable automatic shifting. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0014] Figure 2 This is a schematic diagram of the low-end structure of the present invention.

[0015] Reference numerals in the attached diagram: 1 Low-gear assembly, 2 Cylindrical spring, 3 Slider, 4 Coil 1, 5 Coil 2, 6 Coil 3, 7 Coil fixing seat, 8 Hexagonal flange bolt, 9 Permanent magnet, 10 Gear sleeve, 11 High-gear assembly, 12 Elastic retaining ring for hole, 13 Gear seat, 14 Reducer housing, 15 Locating pin. Detailed Implementation

[0016] To make the technical solution of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0017] Example 1

[0018] like Figure 1-2 As shown, this embodiment provides a three-position electromagnetic shift synchronizer structure, including a low-gear assembly 1, a cylindrical spring 2, a slider 3, a coil 1 4, a coil 2 5, a coil 3 6, a coil fixing seat 7, a hexagonal flange bolt 8, a permanent magnet 9, a gear sleeve 10, a high-gear assembly 11, a hole elastic retaining ring 12, a gear seat 13, a positioning pin 15, and a reducer housing 14.

[0019] The low-gear assembly 1 and the high-gear assembly 11 are respectively arranged on both sides of the gear holder 13 along the axial direction, and are both welded together by gears and synchronous cones. The outer circle of the cone is machined with external splines as a torque transmission surface; the end face is machined with a flat limiting surface for limiting the axial movement of the gear sleeve 10. The two gear assemblies are supported on the journal of the gear holder 13 by needle roller bearings and can rotate freely relative to the gear holder 13.

[0020] The inner hole of the gear sleeve 10 is machined with an involute internal spline, which forms a clearance fit with the external spline of the gear seat 13, achieving both radial support and axial sliding. Permanent magnets 9 are embedded in the outer circumferential surface of the gear sleeve 10, with 4-6 magnets evenly arranged circumferentially and radially magnetized. A slider groove is machined on the inner wall of the gear sleeve 10 for mating with the slider 3.

[0021] The gear seat 13 serves as the support base for the entire synchronizer, with its central through-hole connected to the gearbox shaft via a spline. External splines are machined on the outer circumferential surface of the gear seat 13 to mate with the gear sleeve 10. Radial mounting holes are machined on the sidewalls of the gear seat 13 for mounting the cylindrical spring 2 and the slider 3. Elastic retaining ring grooves are machined at both axial ends of the gear seat 13 to accommodate the elastic retaining rings 12, preventing the slider 3 and the cylindrical spring 2 from dislodging during axial movement of the gear sleeve 10.

[0022] The slider 3 is installed in the mounting hole of the gear seat 13, and its top abuts against the slider groove of the gear sleeve 10. The cylindrical spring 2 is embedded in the mounting hole of the gear seat 13. During initial installation, the cylindrical spring 2 is in a pre-compressed state, generating a continuous spring force that presses the slider 3 against the slider groove of the gear sleeve 10, so that the gear sleeve 10 is axially fixed in the neutral position and cannot move freely, ensuring the stability of the neutral position.

[0023] The coil mounting base 7 is sleeved on the outside of the gear sleeve 10, maintaining an air gap with the outer circumferential surface of the gear sleeve 10. The coil mounting base 7 is fixed to the reducer housing 14 by hexagonal flange bolts 8 and locating pins 15, ensuring accurate circumferential and axial positioning.

[0024] Coils 4, 5, and 6 are arranged in an axial array within the annular groove on the inner wall of the coil mounting base 7, corresponding to the low gear, neutral, intermediate, and high gear positions of the gear sleeve 10, respectively. Each coil is wound with enameled copper wire, and the magnitude and direction of the current are independently controlled by the gearbox control unit.

[0025] This embodiment achieves precise switching of the gear sleeve 10 between three positions: low gear, neutral gear, and high gear through a multi-coil coordinated energizing strategy. Furthermore, the coils can be de-energized in all three steady-state positions, and the gears can be maintained by mechanical structure or permanent magnet force, thereby reducing system energy consumption and improving lifespan.

[0026] In neutral, coils 4, 5, and 6 are all de-energized. The preload of the cylindrical spring 2 acts on the slider groove of the toothed sleeve 10 through the slider 3, generating sufficient frictional resistance to axially fix the toothed sleeve 10 in the neutral position, preventing it from shifting due to vibration or gravity. At this time, the system consumes zero energy, and the mechanical locking of the slider 3 ensures the reliability of the neutral position.

[0027] After receiving the command to engage a lower gear, the control structure executes the following control strategy: Coil 4 is energized with a forward current, generating an electromagnetic attraction pulling towards the lower gear assembly 1; Coil 5 and Coil 6 are energized with a reverse current, generating an electromagnetic thrust pushing towards the higher gear assembly 11, forming a synergistic pulling force with Coil 4. The combined electromagnetic force generated by the multiple coils overcomes the preload of the cylindrical spring 2 and the frictional resistance of the slider 3, pushing the gear sleeve 10 to the left. The slider 3 slides within the slider groove of the gear sleeve 10, simultaneously further compressing the cylindrical spring 2. When the gear sleeve 10 moves to the left and contacts the end face limiting surface of the lower gear assembly 1, the control structure de-energizes all coils. At this time, the gear sleeve 10 relies on the magnetic attraction between the permanent magnet 9 and the limiting surface of the lower gear assembly 1, firmly adhering to the limiting surface to prevent disengagement due to vibration during driving. The permanent magnet attraction force is designed to be greater than the maximum axial impact load to ensure reliable gear position maintenance.

[0028] Both the low-gear assembly 1 and the high-gear assembly 11 have flat limiting surfaces machined on their end faces, which serve as mechanical stops for the axial movement of the gear sleeve 10.

[0029] When the gear sleeve 10 reaches the low or high gear position, its end face is in contact with the limiting surface of the gear assembly. At this time, the permanent magnet 9 embedded in the outer periphery of the gear sleeve 10 forms a magnetic circuit with the limiting surface of the gear assembly made of ferromagnetic material, generating a continuous axial attraction force. The direction of this force is opposite to the disengagement direction.

[0030] The holes at both ends of the gear seat 13 form a physical barrier with elastic retaining rings 12, which restricts the maximum axial displacement of the slider 3 and prevents the cylindrical spring 2 from becoming unstable due to excessive compression or extreme displacement of the gear sleeve 10. Even if the slider 3 completely exits the slider groove after the gear sleeve 10 is engaged, it is blocked in the gear seat 13 by the elastic retaining rings 12 in the holes and will not fall into the gear meshing area and cause mechanical failure.

[0031] When shifting from a low gear to neutral: Coil 4 is energized with a reverse current, generating an electromagnetic thrust pointing to the right, opposite to the direction when shifting to a low gear; Coil 5 is energized with a forward current, generating an electromagnetic attraction pointing to the left, working in conjunction with Coil 4 to form a synergistic thrust; Coil 6 is energized, generating an electromagnetic thrust pointing to the right, acting as a blocking force to prevent the gear sleeve 10 from directly overtaking the neutral position and rushing to a higher gear due to inertia. Under the synergistic action of the three coils, the gear sleeve 10 overcomes the magnetic attraction between the permanent magnet 9 and the low gear assembly 1, moving to the right. When the gear sleeve 10 reaches the neutral position, the slider 3, under the action of the cylindrical spring 2, re-engages into the positioning position of the gear sleeve 10 slider groove. The TCU controls all coils to be de-energized, and the gear sleeve 10 is stabilized in the neutral position by the mechanical holding force of the cylindrical spring 2 and the slider 3, completing the shifting action.

[0032] Before engaging a higher gear, the drive motor needs to adjust its speed to synchronize the rotational speed of the high-gear assembly 11 with that of the gear sleeve 10, reducing shift shock. After speed synchronization, the control structure executes the following control: Coil 3 6 is energized with a positive current, generating an electromagnetic attraction pointing towards the high-gear assembly 11; Coil 1 4 and Coil 2 5 are energized in conjunction, generating a synergistic electromagnetic force that pushes the gear sleeve 10 to the right. After the gear sleeve 10 moves to the right and contacts the end face limiting surface of the high-gear assembly 11, all coils are de-energized. The gear sleeve 10 remains in the high-gear position due to the magnetic attraction between the permanent magnet 9 and the limiting surface of the high-gear assembly 11, preventing disengagement.

[0033] The control logic for shifting from high gear to neutral is symmetrical to that for shifting from low gear: Coil 3 (6) receives a reverse current, generating an electromagnetic thrust pointing to the left; Coil 2 (5) is energized in conjunction, generating a synergistic electromagnetic force to overcome the permanent magnet attraction force; Coil 1 (4) is energized, acting as a blocking force to prevent the gear sleeve 10 from crossing the neutral position. After the gear sleeve 10 returns to the neutral position, the coils are de-energized, and the cylindrical spring 2 and slider 3 maintain a stable neutral state.

[0034] The direction of the current in each coil is dynamically adjusted according to different working conditions to overcome the motion resistance of the gear sleeve 10 with the optimal combination of electromagnetic forces. Specifically, when shifting from neutral to low gear, the main resistance is the spring preload and the slider friction. At this time, coil 4, with forward current, generates attraction, while coils 5 and 6, with reverse current, generate thrust, forming a synergistic pulling force. When shifting from low gear to neutral, the main resistance is the permanent magnet attraction and inertial force. At this time, coil 4, with reverse current, generates thrust, coil 5, with forward current, generates attraction, and coil 6, with reverse current, generates thrust as a blocking force, forming a synergistic thrust and preventing overshifting. When shifting from neutral to high gear, the resistance characteristics are symmetrical to those when shifting to low gear. Coil 6, with forward current, generates attraction, while coils 4 and 5, with reverse current, generate thrust, forming a synergistic pulling force. When shifting from high gear to neutral, the resistance characteristics are symmetrical to those when shifting to low gear. Coil 6, with reverse current, generates thrust, while coil 5, with reverse current, generates thrust, and coil 4, with forward current, generates attraction as a blocking force, forming a synergistic thrust and preventing overshifting. In the above current directions, the forward current generates an attractive force, and the reverse current generates a thrust force. The actual direction is determined based on the polarity of the permanent magnet and the winding direction of the coil.

[0035] Based on the position and speed feedback of the toothed sleeve 10 detected by the Hall sensor, the coils are adjusted in real time to achieve the following: during the start-up phase, a large current is used to quickly establish electromagnetic force to overcome static friction; during the movement phase, a medium current is used to maintain acceleration; when approaching the target position, a small current is used to decelerate and buffer; after reaching the target position, the current returns to zero, and mechanical or permanent magnet holding is switched.

[0036] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A three-position electromagnetic shift synchronizer structure, characterized in that, The device includes a gear base and a coil fixing base. A low-gear assembly and a high-gear assembly are respectively connected to both sides of the gear base. A gear sleeve for abutting against the low-gear assembly and the high-gear assembly is movably connected to the circumferential surface of the gear base. The coil fixing base is sleeved on the outside of the gear sleeve. A permanent magnet is provided on the circumferential surface of the gear sleeve. A plurality of coils cooperating with the permanent magnet are provided on the inner wall of the coil fixing base.

2. The structure of a three-position electromagnetic shift synchronizer according to claim 1, characterized in that, The coils are provided in at least three and are arranged in an array along the axial direction.

3. The structure of a three-position electromagnetic shift synchronizer according to claim 1, characterized in that, The gear sleeve and the gear seat are splinedly connected, and the gear sleeve and the gear seat are slidably connected along the axial direction.

4. The structure of a three-position electromagnetic shift synchronizer according to claim 3, characterized in that, The inner wall of the toothed sleeve is provided with a radial slider groove, and a slider that abuts against the slider groove is movably connected to the toothed seat.

5. The structure of a three-position electromagnetic shift synchronizer according to claim 4, characterized in that, The toothed seat has a mounting hole on its side wall, and a spring is embedded in the mounting hole. One end of the spring is connected to the toothed seat, and the other end of the spring is connected to the slider.

6. The structure of a three-position electromagnetic shift synchronizer according to claim 5, characterized in that, The toothed seat has elastic retaining ring grooves on both sides of the mounting hole.

7. The structure of a three-position electromagnetic shift synchronizer according to claim 4, characterized in that, The slider and the slider groove are provided in several groups, and the slider and the slider groove are respectively arranged in an array on the periphery of the tooth seat and the tooth sleeve.

8. The structure of a three-position electromagnetic shift synchronizer according to claim 1, characterized in that, The coil mounting base is provided with a pin for connecting to the outer casing.

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