Drivetrain Overload Protection via Torque Regulation
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Solution Overview
Problem
Existing working vehicle-working device combinations lack precise and efficient mechanisms for regulating towing force, leading to inconsistent field operations and potential damage to drivetrain components due to inadequate torque regulation, especially when operating above engine-rated power during boost modes.
Innovation Solution
An overload protection system that utilizes an electric motor generator (MG) pair or continuously variable motor (CVM) with a primary power equipment torque sensor and controller to limit engine torque setpoints, ensuring torque delivered to the transmission remains within design limits, preventing damage to drivetrain components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If engine power is increased above rated power during boost modes to improve productivity, then power delivery capability is improved, but drivetrain components may be damaged due to excessive torque
Solution Approach 1:
The system implements a feedback control mechanism where the controller continuously monitors engine torque output and compares it against safe operating thresholds. When torque exceeds the threshold during boost mode operation, the controller automatically reduces the torque setpoint to prevent drivetrain damage, enabling both high productivity and component protection
Solution Approach 2:
The system dynamically adjusts torque delivery based on real-time operating conditions. The controller modulates the torque setpoint signal to the engine controller, allowing torque to vary between rated power levels and boost power levels as needed, while always maintaining operation within safe drivetrain limits through continuous adaptation
2Reliability
If torque regulation mechanisms are added to prevent drivetrain damage, then drivetrain reliability is improved, but system complexity increases
Solution Approach 1:
The controller performs multiple functions: it manages normal engine operation, handles boost mode activation, monitors torque levels, and executes torque reduction when thresholds are exceeded. By consolidating these diverse functions into a single control unit, the system achieves comprehensive torque regulation without proportionally increasing complexity
Solution Approach 2:
The system uses the existing engine controller and sensor infrastructure to implement torque regulation. The controller leverages available torque setpoint signals and engine response characteristics to self-regulate torque delivery, minimizing the need for additional dedicated hardware components while still providing robust drivetrain protection
Data Source
AI summary
Overload protection systems and methods are provided for controlling the amount of energy delivered to the drivetrain of work vehicles including axles, transmission, and other components thereof including for vehicles using power boost. A sensor in operative communication with a primary power equipment unit driving a transmission of a work vehicle generates a torque signal representative of torque delivered to the transmission by the primary power equipment unit. The overload protection method and system uses the torque signal to control the torque delivered to the transmission of a work vehicle by the primary power equipment unit.