Auxiliary-Range Transmission Actuating Torque Control
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Solution Overview
Problem
Existing group transmission devices face complexity in shiftability and synchronization, particularly during upshift and downshift processes, which complicates the structural design and customer convenience.
Innovation Solution
A group transmission device with an active actuating unit and a control/regulating unit that introduces and adapts actuating torque to the upstream transmission unit, allowing for unsynchronized shifting means and improved synchronization, especially through the use of countershaft and transmission input shaft actuating mechanisms, enabling flexible and rapid shifting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If synchronized shifting means are used in the front group transmission unit, then synchronization during shifting is improved, but the structural complexity increases due to additional synchronizing rings and associated components
Solution Approach 1:
The patent removes the synchronizing rings from the front group transmission unit's switching means, extracting the synchronization function from the mechanical structure. Instead, synchronization is achieved through the actuating unit that actively controls the countershaft speed, thereby simplifying the structure while maintaining reliable synchronization during shifting operations.
Solution Approach 2:
The patent replaces the mechanical synchronization system (synchronizing rings) with an active control system (actuating unit with electric motor or hydraulic drive). This substitution allows for more precise and reliable synchronization through active speed control of the countershaft, while reducing mechanical complexity by eliminating the need for synchronizing rings and their associated friction surfaces.
2Device complexity
If unsynchronized shifting means are used in the front group transmission unit, then the structural complexity is reduced, but the synchronization during shifting deteriorates
Solution Approach 1:
The patent replaces passive mechanical synchronization (synchronizing rings) with an active control system (actuating unit). The actuating unit uses an electric motor or hydraulic drive to actively control the countershaft speed, ensuring proper synchronization during shifting operations even though the switching means themselves are unsynchronized. This substitution maintains reliability while reducing structural complexity.
Solution Approach 2:
The actuating unit serves as an intermediary between the control system and the transmission components. It mediates the synchronization process by actively controlling the countershaft speed through electric or hydraulic means, allowing unsynchronized switching means to operate reliably without direct mechanical synchronization components.
3Productivity
If a conventional actuating unit is used without adaptive torque control, then the structure is simpler, but the shifting process duration increases due to slower synchronization
Solution Approach 1:
The control system monitors the shifting process and the state of the actuating unit, and uses this feedback information to adaptively adjust the actuating torque. This feedback control ensures optimal synchronization speed throughout the shifting process, maintaining fast shifting performance while managing the complexity through intelligent control algorithms rather than mechanical complexity.
Solution Approach 2:
The actuating torque is made dynamic and adaptive rather than fixed. The control system adjusts the torque output of the actuating unit in real-time based on the shifting phase and required synchronization speed. This dynamic control enables faster and more efficient shifting processes while managing system complexity through adaptive control strategies.
Data Source
Figure 1
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AI summary
According to the invention, an auxiliary-range transmission device is proposed, having a front-mounted auxiliary-range transmission unit (10), having at least one active positioning unit (11), which is provisioned for applying a positioning torque to the front-mounted auxiliary-range transmission unit (10), and having a control and/or regulation unit (12), which is provisioned for adjusting the positioning torque applied to the front-mounted auxiliary-range transmission unit (10) to at least one switching operation which is to be performed by way of the front-mounted auxiliary-range transmission unit (10).