Integrated Driveline Layout for Compact Forward-Reverse Transmission
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Solution Overview
Problem
Compact lift truck material handling applications require drivelines that are highly compact, efficient, and durable to handle frequent forward and reverse operations within limited installation space, while minimizing transmission losses.
Innovation Solution
A compact driveline design featuring selectively engaging input shaft gears, countershaft gears, and an idler gear, with clutches disposed on the input shaft and countershaft, providing direct meshing engagement to minimize losses and enhance compactness, and optionally including a torque converter for powershift transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional driveline layout with primary drive device, main gearbox, group gearbox, and reversing gearbox is used, then the transmission functionality is complete, but the driveline length and installation space requirement increase
Solution Approach 1:
The patent combines the main gearbox and reversing gearbox into a single integrated transmission unit. The main gearbox contains both forward gears (first and second forward gears) and reverse gear, eliminating the need for a separate reversing gearbox. This merging reduces the overall driveline length and installation space while maintaining complete transmission functionality for forward and reverse operations.
Solution Approach 2:
The driveline is segmented into functional modules: engine, integrated transmission unit with clutch assembly, differential, and drive axles. The integrated transmission unit is further segmented into clutch assembly, main gearbox, and final drive components. This modular segmentation allows for compact arrangement and optimized space utilization while maintaining serviceability.
2Loss of energy
If multiple gearboxes are used to provide forward and reverse drive modes, then the transmission functionality is complete, but the transmission losses increase
Solution Approach 1:
By merging the reversing function into the main gearbox, the patent eliminates the need for a separate reversing gearbox and its associated gear train. This reduces the number of meshing gear pairs and minimizes transmission losses while maintaining efficient forward and reverse drive capabilities through the first and second forward gears.
3Area of stationary object
If the driveline is made compact to fit limited installation space, then the installation space requirement is reduced, but the transmission efficiency may deteriorate
Solution Approach 1:
The integrated transmission unit utilizes three-dimensional space optimization by arranging components in multiple dimensions. The clutch assembly is positioned above the main gearbox, and the final drive components are arranged vertically and horizontally to maximize space utilization. This dimensional arrangement achieves compactness without compromising transmission efficiency through direct power paths.
4Adaptability or versatility
If frequent forward and reverse operations are enabled, then the operational versatility is improved, but the wear and service life are adversely affected
Solution Approach 1:
The clutch assembly provides dynamic engagement and disengagement of the first and second forward gears, allowing smooth transitions between forward and reverse operations. This dynamic control reduces shock loads and wear on gear teeth during frequent direction changes, thereby extending service life while maintaining operational versatility.
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
The driveline achieves a high degree of compactness, efficient transmission, and extended service life, enabling reliable operation with low costs and efficient power output up to 60 kW while maintaining a short length from engine to output flange.
Implementation Method 1
The driveline may further include a torque converter. The torque converter may comprise an impeller portion and a turbine portion. The engine may be drivingly engaged with the impeller portion. The output shaft of the turbine portion may be made in one piece with the input shaft.
Data Source
AI summary
A system for a driveline is provided. In one example a driveline may include a first and a second input shaft gear disposed on an input shaft. In one example, the first input shaft gear may selectively drivingly engage with the input shaft via a first clutch and the second input shaft gear may selectively drivingly engage with the input shaft via a second clutch. In another example, a first and a second counter shaft gear may be disposed on a countershaft and drivingly engage with the countershaft, wherein the first input shaft gear drivingly engages with the first countershaft gear and the second input shaft gear is drivingly engages with the second countershaft gear via an idler gear.