Clutchless Electronic Shift Transmission for Heavy Hybrid Vehicles

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Solution Overview

Problem

Current heavy truck transmissions rely on clutches for stopping, which require driver skill, lead to overheating due to slippage, and reduce the vehicle's ability to accumulate and store terrain energy efficiently.

Innovation Solution

A direct coupling assembly in a power-split series electric hybrid vehicle enables bi-directional energy transfer and power transport through an electronic shift transmission, eliminating the need for a clutch and allowing intelligent control of gear ratios for efficient energy management and regenerative braking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a clutch is used to stop the vehicle while the engine continues rotating, then the engine can maintain idle speed, but the clutch overheats due to slippage and requires driver skill for operation

Engineering Contradiction:

Improveengine continuous operationVSAvoidclutch temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent removes the clutch component entirely from the transmission system. The electronic shift transmission is designed to operate without a clutch, using electronic controls to manage power transfer and stopping, thereby eliminating the overheating and wear problems associated with clutch slippage while maintaining engine operation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical clutch system with an electronic control system. The electronic shift transmission uses electronic actuators and control modules to manage power transfer, eliminate the need for mechanical friction-based clutch engagement and disengagement, and provide seamless stopping without thermal issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If a clutch is used for hill holding to prevent backwards movement, then vehicle stability is maintained, but clutch slippage generates heat that reduces clutch longevity

Engineering Contradiction:

Improvevehicle position stabilityVSAvoidclutch service life

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of stationary object

Solution Approach 1:

The patent eliminates the clutch from the system, removing the source of heat-generating slippage entirely. Hill holding functionality is achieved through electronic controls that manage the transmission gears and power transfer without requiring mechanical friction engagement, thereby preserving clutch longevity while maintaining vehicle stability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical clutch-based hill holding system is replaced with an electronic control system that uses precisely controlled power transfer and gear selection. This electronic approach provides stable hill holding without the thermal degradation and wear associated with mechanical clutch slippage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If a clutch is retained in electronic shift manual transmissions, then power transfer between prime mover and transmission is enabled, but the clutch engages and disengages causing slippage and overheating

Engineering Contradiction:

Improvepower transfer capabilityVSAvoidenergy lost to clutch slippage

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent removes the clutch component from the electronic shift manual transmission system. Power transfer is achieved through direct electronic control of the transmission gears and actuators, eliminating the need for mechanical friction-based engagement and disengagement, thereby preventing energy loss to clutch slippage while maintaining full power transfer capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical clutch system is replaced with an electronic control system that directly manages power transfer through the transmission gears. This electronic approach provides seamless power transfer without the energy-wasting slippage inherent in mechanical clutch operation, improving overall system efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11312246B2Control of clutchless vehicle electronic shift transmissions operating as bi-directional power transfer devices

Publication Date: 2022.04.26 EPOWER ENGINE SYSTEMS INC

AI summary

Controlled clutchless shifting of multi-ratio geared electronic shift transmissions coupled directly to the electrical prime mover of a vehicle are disclosed. The adaptive control of electrically shifted manual transmissions incorporated into power-split series electric hybrid heavy vehicles operating over heavy duty drive cycles utilizes a direct coupling assembly that enables bi-directional energy transfer and power transport. An electronic shift transmission provides power amplifying or de-amplifying bi-directional intelligently controlled valve or pathway for available terrain potential or kinetic energy of a rolling mass of a vehicle, while retaining the original function of a transmission by increasing or decreasing mechanical rotating energy of the propulsion power to the rear wheels of a vehicle.