Electromagnetic two-stage shifting mechanism
By using an electromagnet-driven shift fork and a spherical hinge structure, combined with an angle sensor, the accuracy and lifespan issues of traditional two-speed shifting mechanisms are solved, achieving efficient and low-cost shifting control and improving the stability and safety of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- HENAN YUKE POWER SYSTEM CO LTD
- Filing Date
- 2025-09-09
- Publication Date
- 2026-06-23
AI Technical Summary
Traditional two-speed shifting mechanisms have a long transmission chain, resulting in large cumulative errors that affect shifting accuracy. The lead screw and nut wear out severely, the synchronizer is prone to damage, increasing maintenance costs, and frequent shifting shortens the equipment's lifespan.
The shift fork is driven by an electromagnet, combined with a spherical hinge and an angle sensor to achieve fast response and precise control. This reduces high-cost components, simplifies the structure, avoids tooth tipping and wear, and uses a moving block and spring to achieve mechanical limit, thus reducing energy consumption.
It improves shifting efficiency and accuracy, reduces equipment costs, extends equipment life, meets the requirements of high shifting speed conditions, and ensures gear stability and safety.
Smart Images
Figure CN224397111U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of gear shifting device technology, and in particular to an electromagnetic two-speed gear shifting mechanism. Background Technology
[0002] In the field of mechanical transmission and power conversion, the two-speed shift mechanism, as a key device for realizing power transmission and speed switching, is widely used in various scenarios such as automobiles, construction machinery, and new energy equipment. Its core function is to change the transmission ratio so that the equipment can obtain matching power output and energy efficiency performance under different working conditions (such as starting, high-speed operation, load changes, etc.).
[0003] Traditional devices have long transmission chains, which directly leads to increased cumulative errors, affecting shifting accuracy and making it difficult to meet the requirements of high-precision transmission. Under frequent shifting conditions, the lead screw and nut wear significantly, greatly shortening the system's service life and increasing the maintenance and replacement costs of the equipment. More importantly, when tooth knocking occurs, the synchronous device is easily damaged due to the rigid connection of the motor drive system, further increasing the system complexity and cost. Utility Model Content
[0004] To overcome the technical defects of existing technologies, this utility model provides an electromagnetic two-speed shifting mechanism. An electromagnet drives the shift fork for shifting, resulting in fast response, shorter shifting time, improved efficiency, and suitability for high-speed shifting conditions. It eliminates the need for a motor and torque sensor, reducing high-cost components and manufacturing costs. The simplified mechanism and easy-to-manufacture, easy-to-assemble, and easy-to-repair parts further reduce production, installation, and maintenance costs. It also avoids problems such as synchronizer wear from top gears and wear on the screw nut from frequent shifting, extending equipment life and reducing overall operating costs. After shifting, a movable block fixes the shift fork's rotational position, preventing backshifting and ensuring gear stability. The shift fork is fitted with a strong magnetic material via a spherical hinge, enhancing the attraction with the electromagnet and eliminating the influence of manufacturing and installation errors on attraction, improving shifting accuracy and stability. An angle sensor monitors the rotation angle of the sensor shaft in real time, accurately determining the gear position and providing reliable feedback for shifting, preventing shifting malfunctions caused by gear misjudgment.
[0005] The technical solution adopted by this utility model is: an electromagnetic two-speed shifting mechanism, including a housing, in which two electromagnets are arranged, each electromagnet being connected to the left and right sides of the inner wall of the housing by screws; an electromagnet is arranged on the top of the housing; a top cover is installed on the surface of the housing by screws, and the electromagnet is connected to the top cover by screws; a movable block is provided in a groove on the top surface of the housing, and a spring abuts against the top of the movable block; the other end of the spring is connected to the bottom end of the electromagnet; a needle roller bearing is installed inside the housing, and a sensor shaft is installed inside the needle roller bearing; a shift fork is sleeved on one end of the sensor shaft, and the shift fork is fixed to the sensor shaft by a threaded pin; a vent plug is screwed onto the outer side of the housing; an angle sensor and a retaining ring are installed on the surface of the housing by screws; the angle sensor and the retaining ring... The rings fit together, and the inner side of the retaining ring is connected to the sensor shaft via a needle roller bearing. The housing serves as the overall mounting base, with screws used to fix each component, ensuring structural stability and assembly accuracy, and facilitating disassembly and maintenance. Two electromagnets are positioned on the left and right sides, providing bidirectional driving force for the shift fork to achieve two-gear switching, which is simpler and more efficient than single-sided driving. The second electromagnet is mounted on the top of the housing through a cover, forming a vertical layout with the left and right electromagnets, making reasonable use of space. It is linked with the spring and movable block to form the core of neutral positioning and shifting assistance. The needle roller bearing reduces the rotational friction of the sensor shaft, ensuring the flexibility of the shift fork in driving its rotation and improving shifting response. The vent plug balances the air pressure inside and outside the housing, preventing abnormal air pressure from affecting operation and preventing dust from entering. The angle sensor works with the retaining ring to achieve accurate gear detection by monitoring the rotation angle of the sensor shaft, providing reliable feedback for shifting control.
[0006] Preferably, the shift fork is fitted with a strong magnetic material via a spherical hinge at the position where it is attracted to the electromagnet. The strong magnetic material enhances the attraction between the shift fork and the electromagnet, ensuring that the shift fork is stably attached during gear shifting and preventing it from falling off or shifting. The spherical hinge can compensate for manufacturing and installation errors, allowing for slight angle adjustments when the shift fork is attracted, ensuring precise contact with the electromagnet and reducing mechanical wear.
[0007] Preferably, in the neutral position, the top of the shift fork contacts the groove below the movable block. The contact is achieved by compressing the spring fixed below the electromagnet. The spring force makes the movable block stably abut against the shift fork, reliably positioning the shift fork in the neutral position, preventing shift fork displacement caused by equipment vibration, and avoiding accidental shifting. The compressed spring stores elastic potential energy, which can be quickly released during shifting to assist the movable block in its movement and shorten the shifting response time.
[0008] Preferably, when first gear is engaged, the left electromagnet is activated, attracting and contacting the shift fork. During the attraction of the shift fork, the movable block is pushed upward by the shift fork. After the left electromagnet contacts the shift fork, the movable block falls under the influence of elasticity and gravity, restricting the rotation of the shift fork. Subsequently, the left electromagnet can be turned off. The electromagnet is only activated during gear shifting. The movable block maintains the first gear position through mechanical limiting, eliminating the need for continuous power to the electromagnet, reducing energy consumption and extending the electromagnet's service life. The mechanical limiting effect of the movable block avoids the risk of downshifting caused by the disappearance of the magnetic effect after power failure, significantly improving the stability of the first gear working state.
[0009] Preferably, when shifting from first gear to neutral, the second electromagnet is briefly activated to return the shift fork to its upright position. Simultaneously, the top of the shift fork contacts the groove below the movable block, achieving rapid stabilization of the shift fork. The brief activation of the second electromagnet can quickly lift the movable block, releasing the restriction on the shift fork and assisting in precise return of the shift fork to its upright position, ensuring accurate neutral gear alignment. After the second electromagnet is de-energized, the movable block quickly falls back to its original position, contacting the shift fork to achieve rapid stabilization, shortening the neutral gear adjustment time and improving operational efficiency.
[0010] Preferably, when shifting from first gear to second gear, the second electromagnet and the first electromagnet on the right are activated. After the shift fork contacts the first electromagnet on the right, the second electromagnet is turned off first, and then the first electromagnet on the right is turned off.
[0011] Electromagnet 2 works in conjunction with electromagnet 1 on the right to ensure a smooth transition of the shift fork from first gear to second gear, avoiding any jerking or impact during the shifting process. The operating logic of the electromagnets is shut off in sequence. First, the shift fork is mechanically limited by the moving block, and then the magnetic force of electromagnet 1 is cut off to prevent the shift fork from shifting due to inertia, thus ensuring the accuracy of the second gear position.
[0012] Preferably, the angle sensor is used to monitor the rotation angle of the sensor shaft to determine the gear position. The rotation angle of the sensor shaft provides real-time feedback on the position of the shift fork, accurately determining the current gear position and providing a reliable basis for gear shifting for the control system. The angle monitoring function can promptly detect gear shifting abnormalities, facilitate rapid fault diagnosis, and improve the safety of mechanism operation.
[0013] Preferably, the wires extending from both electromagnets one and two are connected to the positive and negative poles of the same power supply, and each of the two electromagnets one and two corresponds to an independent switch. When the switch is closed, the corresponding electromagnet generates a magnetic effect; when the switch is open, the magnetic effect of the corresponding electromagnet disappears. Sharing a power supply simplifies the circuit structure and reduces hardware costs. Independent switches enable individual control of the three electromagnets, meeting the precise control requirements of different shifting actions. The switch control method allows the magnetic effect of the electromagnets to switch quickly, responding rapidly and facilitating integration into an automated control system to achieve intelligent control of the shifting process.
[0014] The beneficial effects of this utility model are as follows: The shift fork is driven by an electromagnet for gear shifting. The electromagnet has a fast response speed, which effectively shortens the shifting response time, improves the shifting efficiency of the equipment, and meets the requirements of working conditions with high shifting speed. On the one hand, eliminating the motor and additional torque sensor reduces the use of high-cost components and lowers the manufacturing cost of the equipment. On the other hand, the simplified mechanism structure, easy-to-manufacture components, and convenient installation and maintenance reduce the production, installation, and maintenance costs of the equipment. Simultaneously, it avoids damage to the synchronizer caused by tooth-biting and severe wear on the lead screw nut due to frequent shifting, thus extending the service life of the equipment and further reducing the overall operating cost.
[0015] The movable block fixes the rotational position of the shift fork after shifting, effectively preventing downshifting and ensuring gear stability. Meanwhile, a strong magnetic material is installed on the shift fork via a spherical hinge, enhancing the attraction with the electromagnet and eliminating the impact of manufacturing and installation errors on attraction, thus improving shifting accuracy and stability. An angle sensor monitors the rotation angle of the sensor shaft in real time, accurately determining the gear position and providing reliable feedback for shifting operations, ensuring accurate shifting and avoiding shifting malfunctions caused by inaccurate gear position determination. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the structure of this utility model.
[0017] Figure 2 This utility model Figure 1 A partial cross-sectional structural diagram.
[0018] Figure 3 This is a partial cross-sectional structural diagram of the present invention 1.
[0019] Figure 4 This is a schematic diagram of the fork structure in this utility model.
[0020] Explanation of reference numerals in the attached figures: 1. Housing; 2. Electromagnet I; 3. Top cover; 4. Electromagnet II; 5. Movable block; 6. Shift fork; 7. Sensor shaft; 8. Vent plug; 9. Angle sensor; 10. Retaining ring; 11. Needle roller bearing; 12. Spring. Detailed Implementation
[0021] The present invention will be further described below with reference to the accompanying drawings:
[0022] like Figure 1-4As shown, this embodiment provides an electromagnetic two-speed shifting mechanism, including a housing 1. Two electromagnets 2 are installed inside the housing 1. Both electromagnets 2 are connected to the left and right sides of the inner wall of the housing 1 by screws. An electromagnet 4 is arranged on the top of the housing 1. A top cover 3 is installed on the surface of the housing 1 by screws. The electromagnet 4 is connected to the top cover 3 by screws. A movable block 5 is provided in a groove on the top surface of the housing 1. The top of the movable block 5 abuts against a spring 12. The other end of the spring 12 is connected to the bottom end of the electromagnet 4. A needle roller bearing 11 is installed inside the housing 1. A sensor shaft 7 is installed inside the needle roller bearing 11. A shift fork 6 is sleeved on one end of the sensor shaft 7. The shift fork 6 is fixed to the sensor shaft 7 by a threaded pin. A vent plug 8 is screwed onto the outer side of the housing 1. An angle sensor 9 and a retaining ring 10 are installed on the surface of the housing 1 by screws. The angle sensor 9 and the retaining ring 10 fit together. The inner side of the retaining ring 10 is connected to the sensor shaft 7 through the needle roller bearing 11.
[0023] The housing 1 serves as the overall mounting base, with each component fixed by screws, ensuring overall structural stability and assembly precision while facilitating disassembly and maintenance. Two electromagnets 1 and 2 are positioned on the left and right sides, providing bidirectional driving force for the shift fork 6, enabling two-gear switching. This is simpler and more efficient than a single-side drive structure. Electromagnet 2 and 4 are mounted on top of the housing 1 via the top cover 3, forming a vertical layout with the left and right electromagnets 1 and 2, making efficient use of space. They are linked to the movable block 5 via the spring 12, forming the core structure for neutral positioning and shifting assistance. The needle roller bearing 11 reduces frictional resistance when the sensor shaft 7 rotates, ensuring the flexibility of the shift fork 6 in driving the sensor shaft 7 and improving shifting response speed. The vent plug 8 balances the air pressure inside and outside the housing 1, preventing internal temperature changes from causing abnormal air pressure that could affect the mechanism's operation, while also preventing dust from entering. The angle sensor 9 works with the retaining ring 10 to accurately detect the gear position by monitoring the rotation angle of the sensor shaft 7, providing reliable feedback for shifting control.
[0024] Furthermore, a strong magnetic material is installed on the fork 6 at the position where it attracts the electromagnet 2 via a spherical hinge.
[0025] The strong magnetic material enhances the attraction between the shift fork 6 and the electromagnet 2, ensuring that the shift fork 6 can stably adhere to the electromagnet 2 during gear shifting, preventing it from falling off or shifting. The spherical hinge structure can compensate for manufacturing and installation errors, allowing the shift fork 6 to make slight angle adjustments during the attraction process, ensuring precise contact with the electromagnet 2 and reducing mechanical wear.
[0026] It should be noted that in this electromagnetic two-speed shifting mechanism, the strong magnetic material used at the attraction position between the shift fork 6 and the electromagnet 2 is neodymium iron boron permanent magnet material, ensuring sufficient attraction force between them and guaranteeing reliable attraction between the shift fork 6 and the electromagnet 2 during shifting. The spherical hinge structure is used to connect the shift fork 6 and the strong magnetic material, and its composition is as follows: Ball head: fixedly connected to the connecting base of the strong magnetic material, made of high-strength alloy steel, with a surface that has been precision ground and polished to be a smooth sphere. The diameter of the ball head is designed according to the size of the shift fork 6 and the stress conditions to ensure sufficient load-bearing capacity. Ball socket: located on the shift fork 6 at the position corresponding to the strong magnetic material, also made of high-strength alloy steel. The ball socket has a spherical concave surface that matches the ball head, with high precision, ensuring that the ball head can rotate flexibly within the ball socket.
[0027] Furthermore, in the neutral position, the top of the shift fork 6 contacts the groove below the movable block 5, and the contact state is achieved by compressing the spring 12 fixed below the electromagnet 2 4.
[0028] The elastic force of the spring 12 makes the movable block 5 stably abut against the shift fork 6, reliably positioning the shift fork 6 in the neutral position, preventing the shift fork 6 from shifting due to equipment vibration, and avoiding accidental shifting. The compressed spring 12 stores elastic potential energy, which can be quickly released during shifting, assisting the movable block 5 in its movement and shortening the shifting response time.
[0029] Furthermore, when first gear is engaged, the left electromagnet 2 is activated. The left electromagnet 2 attracts and contacts the shift fork 6. During the attraction of the shift fork 6, the movable block 5 is pushed upward by the shift fork 6. After the left electromagnet 2 contacts the shift fork 6, the movable block 5 falls due to elasticity and gravity, restricting the rotation of the shift fork 6. Then the left electromagnet 2 can be turned off.
[0030] Electromagnet 2 is activated only during gear shifting. Movable block 5 maintains the first gear position through mechanical limiting, eliminating the need for continuous power supply to electromagnet 2, thus reducing energy consumption and extending the electromagnet's lifespan. The mechanical limiting function of movable block 5 avoids the risk of downshifting caused by the disappearance of the magnetic effect after power failure, significantly improving the stability of the first gear working state.
[0031] Furthermore, when shifting from first gear to neutral, electromagnet 4 is briefly activated to return shift fork 6 to its original position. At the same time, the top of shift fork 6 contacts the groove below the movable block 5, thus achieving rapid stabilization of shift fork 6.
[0032] When electromagnet 24 is briefly activated, it can quickly lift the movable block 5, release the limit on the shift fork 6, and at the same time assist the shift fork 6 to accurately return to the center position, ensuring accurate neutral gear alignment. After electromagnet 24 is de-energized, the movable block 5 quickly falls back to its original position and contacts the shift fork 6 to achieve rapid stabilization, shortening the neutral gear adjustment time and improving operating efficiency.
[0033] Furthermore, when shifting from first gear to second gear, electromagnet 24 is activated and electromagnet 2 on the right side is activated. After shift fork 6 contacts electromagnet 2 on the right side, electromagnet 24 is deactivated first, and then electromagnet 2 on the right side is deactivated.
[0034] Electromagnet 24 works in conjunction with right-side electromagnet 12 to ensure that shift fork 6 smoothly transitions from first gear to second gear, avoiding jamming or impact during gear shifting. The operating logic of the electromagnets is shut down in sequence. First, the shift fork 6 is mechanically limited by the moving block 5, and then the magnetic force of electromagnet 12 is cut off to prevent shift fork 6 from shifting due to inertia, thus ensuring the accuracy of the second gear position.
[0035] Furthermore, the angle sensor 9 is used to monitor the rotation angle of the sensor shaft 7 to determine the gear position.
[0036] The rotation angle of sensor shaft 7 provides real-time feedback on the position of shift fork 6, accurately determining the current gear (neutral, first gear, second gear), providing a reliable basis for gear shifting for the control system. The angle monitoring function can promptly detect shifting abnormalities (such as failure to reach the target gear), facilitating rapid fault diagnosis and improving the safety of mechanism operation.
[0037] Furthermore, the wires extending from the two electromagnets 1-2 and 2-4 are connected to the positive and negative poles of the same power source, and each of the two electromagnets 1-2 and 2-4 corresponds to an independent switch. When the switch is closed, the corresponding electromagnet generates a magnetic effect, and when the switch is open, the magnetic effect of the corresponding electromagnet disappears.
[0038] The shared power supply simplifies the circuit structure and reduces hardware costs. The independent switch enables individual control of the three electromagnets, meeting the precise control requirements of different shifting actions. The switch control method allows the magnetic effect of the electromagnets to switch quickly, with a rapid response, and is easy to integrate into the automatic control system to achieve intelligent control of the shifting process.
[0039] The working principle of this utility model is as follows:
[0040] Neutral position: At this time, the top of the shift fork 6 is in contact with the groove below the movable block 5. This contact is achieved by the spring 12 fixed below the compressed electromagnet 4. Under the action of the spring 12, the movable block 5 plays a certain limiting role on the shift fork 6, keeping the shift fork 6 in the neutral position.
[0041] Engaging first gear: Activate the left electromagnet 2. The left electromagnet 2 generates a magnetic effect, attracting and making contact with the shift fork 6. As the shift fork 6 is attracted and moves, it pushes the movable block 5 upward, causing the movable block 5 to compress the spring 12 on the electromagnet 4. When the left electromagnet 2 and the shift fork 6 are in full contact, the movable block 5 falls under the force of the spring 12 and its own weight, locking in the groove on the upper side of the shift fork 6, restricting the rotation of the shift fork 6. At this point, first gear engagement is complete, and the left electromagnet 2 can be turned off. Even if the magnetic effect of the electromagnet 2 disappears, the shift fork 6 can remain in the first gear position under the action of the movable block 5 and will not shift down.
[0042] Returning to neutral from first gear: Briefly activate electromagnet 24. Electromagnet 24 generates a magnetic effect that attracts movable block 5 upward, releasing the restriction of movable block 5 on shift fork 6, allowing shift fork 6 to return to the center position. Once shift fork 6 is in the center position, electromagnet 24 is deactivated. Movable block 5 falls under the force of spring 12 and its own weight, and the top of shift fork 6 contacts the groove below movable block 5, quickly stabilizing shift fork 6 in the neutral position.
[0043] Shifting from first to second gear: Start electromagnet 24 and right electromagnet 12. Electromagnet 24 attracts movable block 5 to move upward, releasing the restriction on shift fork 6. Right electromagnet 12 generates a magnetic effect to attract shift fork 6 to move towards it. When shift fork 6 contacts right electromagnet 12, first turn off electromagnet 24. Movable block 5 falls and gets stuck in the groove on the upper side of shift fork 6, restricting the rotation of shift fork 6. Then turn off right electromagnet 12 to complete the shift from first to second gear.
[0044] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications may be made to this utility model without departing from the spirit and scope of the invention. All such changes and modifications fall within the scope of the invention as claimed, which is defined by the appended claims and their equivalents.
Claims
1. An electromagnetic two-speed shift mechanism characterized by: The device includes a housing (1), inside which are two electromagnets (2). Both electromagnets (2) are connected to the left and right sides of the inner wall of the housing (1) by screws. An electromagnet (4) is arranged on the top of the housing (1). A top cover (3) is installed on the surface of the housing (1) by screws. The electromagnet (4) is connected to the top cover (3) by screws. A movable block (5) is provided in a groove on the top surface of the housing (1). A spring (12) abuts against the top of the movable block (5). The other end of the spring (12) is connected to the bottom end of the electromagnet (4). A needle roller bearing (11) is installed inside the housing (1), and a sensor shaft (7) is installed inside the needle roller bearing (11). A shift fork (6) is sleeved on one end of the sensor shaft (7). The shift fork (6) is fixed to the sensor shaft (7) by a threaded pin. A vent plug (8) is screwed onto the outer side of the housing (1). An angle sensor (9) and a retaining ring (10) are installed on the surface of the housing (1) by screws. The angle sensor (9) and the retaining ring (10) fit together. The inner side of the retaining ring (10) is connected to the sensor shaft (7) through the needle roller bearing (11).
2. An electromagnetic two-speed shift mechanism according to claim 1, characterized in that: The fork (6) is fitted with a strong magnetic material via a spherical hinge at the position where it is attracted to the electromagnet (2).
3. An electromagnetic two-speed shift mechanism according to claim 1, wherein: In neutral, the top of the shift fork (6) contacts the groove below the movable block (5).
4. The electromagnetic two-speed shifting mechanism according to claim 1, characterized in that: When the first gear is engaged, the electromagnet on the left (2) is activated. The electromagnet on the left (2) attracts and contacts the shift fork (6). During the process of the shift fork (6) being attracted, the movable block (5) is pushed upward by the shift fork (6). After the electromagnet on the left (2) contacts the shift fork (6), the movable block (5) falls due to elastic force and gravity, restricting the rotation of the shift fork (6). Then the electromagnet on the left (2) can be turned off.
5. The electromagnetic two-speed shifting mechanism according to claim 1, characterized in that: The wires extending from the two electromagnets (2) and (4) are connected to the positive and negative poles of the same power source, and the two electromagnets (2) and (4) correspond to an independent switch.