CVT Control System Discrete Speed Ranges

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Operators of machines with continuously variable transmissions (CVT) face difficulty in controlling travel speed, as CVT does not provide discrete, selectable speed ranges like conventional transmissions, leading to operator fatigue in managing speeds in rough terrain.

Innovation Solution

A transmission control system with operator input devices for selecting discrete machine travel speed ranges and a controller that regulates power output to maintain the selected speed ranges, allowing for familiar speed control akin to step-change transmissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a CVT provides infinitely variable torque-to-speed output ratio within its overall range, then engine efficiency is improved, but operator control difficulty increases due to lack of discrete speed ranges

Engineering Contradiction:
Improveengine efficiencyVSAvoidoperator control difficulty
Core Design Contradiction:
Use of energy by moving objectVSEase of operation

Solution Approach 1:

The continuous speed range of the CVT is segmented into multiple discrete selectable speed ranges (e.g., first speed range, second speed range, third speed range) with different maximum speeds. This allows the operator to select appropriate speed ranges for different working conditions, providing familiar discrete control while maintaining CVT's continuous variability within each range, thus resolving the contradiction between engine efficiency and operator control ease.

Inventive Principle:
Principle #1Segmentation

2Speed

If the accelerator pedal is fully depressed in a machine with CVT, then maximum possible speed is achieved, but operator fatigue increases due to inability to easily maintain intermediate speeds

Engineering Contradiction:
Improvemaximum possible speedVSAvoidoperator fatigue
Core Design Contradiction:
SpeedVSEase of operation

Solution Approach 1:

The system dynamically adapts the accelerator pedal's function based on the selected speed range. When a speed range is selected, the pedal controls speed within that range rather than always commanding maximum speed. This dynamic adjustment allows operators to easily maintain intermediate speeds by simply selecting the appropriate range and using normal pedal input, eliminating the fatigue caused by constantly modulating pedal position for rough terrain.

Inventive Principle:
Principle #15Dynamics

3Ease of operation

If conventional transmissions use discrete gears with predefined maximum travel speeds, then operator familiarity and task-specific control are improved, but transmission complexity increases

Engineering Contradiction:
Improveoperator familiarityVSAvoidtransmission complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges the advantages of conventional discrete gear transmissions with the advantages of CVT technology. The system combines the discrete speed range selection (providing familiar gear-like control) with continuous variable transmission (providing smooth acceleration and engine efficiency). This hybrid approach gives operators the familiarity of discrete gears while eliminating the complexity and mechanical limitations of multi-gear transmissions.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS7641588B2CVT system having discrete selectable speed ranges
Publication Date: 2010.01.05 CATERPILLAR INC
  • US7641588B2 patent drawing
  • US7641588B2 patent drawing
  • US7641588B2 patent drawing

AI summary

A continuously variable transmission control system is disclosed. The control system has a first operator input device to receive operator input and produce a corresponding first signal indicative of a selected one of a plurality of available predetermined discrete machine travel speed ranges. The control system also has a second operator input device to receive operator input and produce a corresponding second signal indicative of desired machine travel. The control system also has a power source operatively coupled to drive a continuously-variable transmission, and a controller configured to regulate at least one of an output of the power source and an output of the continuously variable transmission in response to the first and second signals such that an actual machine travel speed remains within the selected one of the plurality of predetermined discrete machine travel speed ranges.