DCT Clutch Burst Prevention via Shaft Role Swapping

Solution Overview

Problem

In vehicles with double clutch transmission (DCT), the clutch on the non-drive input shaft is prone to bursting, especially when a stuck phenomenon occurs on a low gear during high-speed movement, leading to potential damage and safety risks due to abnormal RPM increases.

Innovation Solution

A clutch burst prevention method that includes monitoring RPM, reducing engine torque, determining if the vehicle is on a downward slope, and swapping the roles of the non-drive and drive input shafts to manage RPM and prevent clutch damage, specifically by releasing gears and adjusting shaft connections to limit RPM.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a low gear of the non-drive input shaft is engaged when the vehicle moves at high speed, then the shifting operation is performed, but the RPM of the clutch is abnormally increased causing clutch burst

Engineering Contradiction:

Improveshifting operationVSAvoidclutch burst

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control method performs preliminary detection of gear actuator status before completing the shifting operation. When a stuck phenomenon is detected in the low gear of the non-drive input shaft, the system preemptively switches the drive input shaft and non-drive input shaft roles, preventing the clutch from engaging at abnormally high RPM and avoiding clutch burst

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the RPM of the non-drive input shaft and compares it against predetermined thresholds. When the RPM exceeds the threshold indicating a stuck phenomenon, the feedback control mechanism triggers the shaft switching operation to prevent clutch damage

Inventive Principle:

Principle #23Feedback

2Productivity

If the RPM of the non-drive input shaft is not limited, then the shifting operation can be completed, but the clutch rotates at abnormally high speed causing damage

Engineering Contradiction:

Improveshifting operationVSAvoidclutch RPM

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The system dynamically switches the roles of the drive input shaft and non-drive input shaft based on real-time detection of stuck phenomena. This dynamic reconfiguration allows the system to adapt to abnormal conditions during shifting, preventing the clutch from rotating at dangerously high speeds while maintaining transmission functionality

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If a gear actuator fails and the low gear is not disengaged, then the shifting operation is blocked, but the probability of clutch burst is increased

Engineering Contradiction:

Improveshifting operationVSAvoidclutch burst

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The control method performs preliminary detection of gear actuator status before completing the shifting operation. When a stuck phenomenon is detected in the low gear of the non-drive input shaft, the system preemptively switches the drive input shaft and non-drive input shaft roles, preventing the clutch from engaging at abnormally high RPM and avoiding clutch burst

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system prepares alternative configurations by switching shaft roles before the clutch can engage in a damaged state. This beforehand cushioning measure protects the clutch from burst even when the gear actuator fails to disengage the low gear properly

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS9694825B2Clutch burst prevention method

Publication Date: 2017.07.04 HYUNDAI MOTOR CO LTD

AI summary

A clutch burst prevention method for preventing a non-drive input shaft clutch of a vehicle provided with a double clutch transmission (DCT) from damage may include a torque reduction operation of reducing a torque of an engine by an ECU when a stuck phenomenon occurs on a shift gear of the non-drive input shaft.