Axle Assembly Gear Ratio Control via Direct Sensor Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current axle systems with electric motor modules lack efficient control mechanisms for shifting between gear ratios, leading to suboptimal torque transmission and vehicle performance.
Innovation Solution
An axle system incorporating an electric motor module, gear reduction module, shift collar, and sensors that allow for direct control of the shift collar based on rotational speed signals from speed sensors, enabling seamless gear ratio switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional axle systems without direct sensor control are used, then device complexity is reduced, but torque transmission efficiency deteriorates due to suboptimal gear ratio shifting
Solution Approach 1:
The patent implements feedback control by directly connecting speed sensors to the axle controller. The first speed sensor monitors wheel rotational speed while the second speed sensor monitors gear reduction module rotational speed. The axle controller receives these feedback signals and uses them to determine optimal shifting moments, thereby maximizing torque transmission efficiency through precise gear ratio selection.
Solution Approach 2:
The axle system performs self-service by autonomously controlling the shift collar position based on real-time speed sensor feedback. The axle controller automatically determines when to shift between first and second gear ratios without external intervention, optimizing torque transmission adaptively based on actual operating conditions detected by the sensors.
2Productivity
If gear ratio switching is not precisely controlled, then device complexity is reduced, but vehicle performance deteriorates due to suboptimal torque transmission
Solution Approach 1:
The feedback mechanism continuously monitors both wheel speed and gear module speed, enabling the axle controller to make precise, real-time decisions about gear ratio selection. This ensures optimal vehicle performance by matching gear ratios to actual driving conditions, whether accelerating, cruising, or descending.
Solution Approach 2:
The system dynamically adjusts gear ratios based on real-time operational conditions. The shift collar can transition between first and second gear ratios in response to changing speed conditions detected by the sensors, allowing the axle assembly to adapt its mechanical advantage characteristics to optimize vehicle performance across varying operating scenarios.
3Loss of energy
If direct sensor control of shift collar is implemented, then torque transmission efficiency is improved, but device complexity increases due to additional control mechanisms
Solution Approach 1:
The patent replaces traditional mechanical linkage-based gear shifting with an electronically controlled system. Electrical signals from the speed sensors directly control the shift collar actuation, eliminating the need for complex mechanical sensing and actuation mechanisms. This substitution maintains torque transmission efficiency while reducing mechanical complexity.
Data Source
AI summary
An axle system and a method of control. The axle system may include an axle controller that may be directly electrically connected to a first speed sensor and a second speed sensor. The axle controller may control movement of a shift collar that may be selectively engageable with first and second gear ratios.