Dog Clutch Sensor Bolt Position Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dog clutches in automated manual transmissions can only determine the axial position of the piston, leading to long reaction times and inaccurate gear shift operations, and sensors in differential gear assemblies are prone to measurement errors due to external mounting.
Innovation Solution
A dog clutch design with a sleeve-shaped axially fixed and movable coupling elements, where the axially movable coupling element is actuated by a piston connected via a piston pin, and a sensor bolt integrated within the piston allows for precise measurement of the coupling element's position along its entire path, enabling accurate determination of both end and intermediate positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensor is mounted outside the shifting clutch (on the cylinder), then the sensor structure is simple and easy to access, but the measurement accuracy deteriorates due to adverse ambient influences
Solution Approach 1:
The sensor bolt is integrated within the piston structure, with the sensor mounted on the piston's end face. This nested arrangement places the sensor inside the shifting clutch assembly, protecting it from adverse ambient conditions while maintaining measurement accuracy for the axial position of the piston and coupling element
2Device complexity
If only the axial position of the piston is identified by the sensor, then the sensor structure is simple, but the reaction time of the transmission control deteriorates due to inconclusive position determination
Solution Approach 1:
The sensor bolt acts as an intermediary element that mechanically connects the piston's axial position to the sensor's measurement point. As the piston moves axially, the sensor bolt moves with it, allowing the sensor to continuously and accurately determine the position of the axially movable coupling element throughout its entire path, providing conclusive position data for rapid transmission control response
3Device complexity
If the sensor and transmitter element are mounted outside the differential gear assembly, then the assembly structure is simplified, but measurement accuracy deteriorates due to exposure to adverse ambient influences
Solution Approach 1:
The sensor and transmitter element are merged with the shifting clutch assembly by mounting the sensor on the piston, which is an integral part of the clutch mechanism. This integration ensures that the sensor operates in a protected environment within the assembly while accurately measuring the shift positions of the clutch
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
This design allows for precise control of gear shift operations and reduces reaction times by accurately determining the position of the axially movable coupling element, enhancing the engagement and disengagement of the dog clutch.
Implementation Method 1
a pressurizing medium-actuatable piston (22), wherein the pressurizing medium can be supplied to a cylinder space (60) of the cylinder housing (20)
Data Source
AI summary
A dog clutch (10) includes a piston (22) that is firmly connected to a sensor bolt (48) at one axial end of the sensor bolt (48). The piston (22) is coaxially aligned with the sensor bolt (48), and the sensor bolt (48) is configured as a sensor element for a position sensor (70) at a sensor section (52) of the sensor bolt (48) that is positioned on a free, piston-remote axial end (78) of the sensor bolt (48).