Gearbox Clutch Sensor Mounting for Accurate Position Detection
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Solution Overview
Problem
Manual transmissions in commercial vehicles face challenges in accurately detecting the position of shift elements due to the inconsistent installation of position sensors, leading to inaccuracies in automated shifting processes.
Innovation Solution
A clutch device with a sensor stop and an elastic element that maintains the sensor in a predetermined reference position, eliminating air gaps and allowing for secure installation without additional fasteners, and enabling translational and rotational compensatory movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the position sensor is installed blindly during servicing without a fixed reference position, then the installation process is simple and quick, but the accuracy of position detection deteriorates
Solution Approach 1:
The sensor assembly performs its own positioning function by using the elastic element to automatically press the sensor against the stop surface, establishing its own reference position without requiring external adjustment or additional fasteners during installation
Solution Approach 2:
The sensor holder integrates multiple functions into a single component: it holds the sensor, provides the stop surface for positioning, and incorporates the elastic element for automatic reference position establishment, eliminating the need for separate mounting hardware
2Measurement precision
If additional fasteners are used to secure the sensor, then the position detection accuracy is improved, but the installation complexity and device complexity increase
Solution Approach 1:
The sensor assembly is self-securing through the elastic element that automatically presses the sensor against the stop surface, eliminating the need for additional fasteners or complex mounting procedures while maintaining accurate positioning
Solution Approach 2:
The solution removes the unnecessary element of additional fasteners from the assembly process, using only the essential components (sensor, elastic element, and stop surface) to achieve both accurate positioning and simple installation
3Device complexity
If the sensor is not held in a predetermined reference position, then the device structure is simpler, but air gaps form that negatively affect sensor accuracy
Solution Approach 1:
The elastic element acts as an intermediary between the sensor and the stop surface, providing continuous contact pressure that eliminates air gaps while allowing for simple device structure and easy installation
Solution Approach 2:
The elastic element pre-compresses the sensor against the stop surface before operation, ensuring that no air gaps form during operation while maintaining a simple mounting structure without complex fastening mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves the accuracy of position detection by ensuring the sensor maintains a fixed reference position, reducing installation complexity, and facilitating vibration compensation.
Implementation Method 1
the sensor is held in a positionally fixed relationship to the sensor stop in the distance direction by means of an elastic element
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a clutch device (1) for a gearbox of a utility vehicle, comprising: a clutch actuator (30), a sensor (50) for detecting a position of the clutch actuator (30), and a sensor stop (40) having a stop surface (41) which defines a predetermined position of the sensor (50) in a distance direction to the clutch actuator (30), wherein the sensor (50) can be held via an elastic element (60) in the distance direction in a fixed position relative to the sensor stop (40).