Automated Drop Box Coupling Mechanism for Powertrain
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Solution Overview
Problem
Existing drop boxes in well service rigs are difficult to control efficiently, leading to inefficient operation and potential damage due to manual operation of couplers for coupling and decoupling drive lines.
Innovation Solution
An automated output transfer gear group with a solenoid-actuated coupling mechanism and a controller that selectively engages and disengages couplers based on user input and position sensing, ensuring precise control of the transmission's neutral, drive, and park positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation of couplers is used to couple/decouple drive lines, then device complexity is reduced, but ease of operation deteriorates and reliability worsens
Solution Approach 1:
The patent replaces manual mechanical operation of couplers with an automated solenoid-actuated coupling mechanism. The solenoid converts electrical signals to mechanical motion, automatically engaging and disengaging the coupler based on transmission position (neutral, drive, or park), eliminating the need for manual intervention and improving ease of operation.
Solution Approach 2:
The coupling mechanism is designed to automatically engage and disengage based on the transmission's position without requiring external manual control. The system self-regulates the coupling state according to whether the transmission is in neutral, drive, or park position, improving operational ease while maintaining controlled complexity.
2Reliability
If manual operation of couplers is used, then device complexity is reduced, but reliability deteriorates due to potential damage
Solution Approach 1:
The automated solenoid-actuated mechanism replaces manual mechanical coupling, providing controlled and precise engagement that prevents damage from improper manual operation. The system ensures the coupler only engages when the transmission is in the correct position (neutral), preventing mechanical damage and improving reliability.
Solution Approach 2:
The system incorporates position sensing that provides feedback about the transmission state (neutral, drive, or park). This feedback controls the solenoid activation, ensuring the coupler engages only under appropriate conditions, thereby preventing damage and improving reliability of the coupling mechanism.
3Productivity
If automated solenoid-actuated coupling mechanism is used, then productivity is improved, but device complexity increases
Solution Approach 1:
The solenoid-actuated coupling mechanism automates the coupling process, enabling rapid and reliable engagement/disengagement of drive lines based on transmission position. This automation significantly improves productivity by eliminating manual intervention and ensuring proper coupling timing, while the added complexity is justified by the operational benefits.
4Reliability
If automated solenoid-actuated coupling mechanism is used, then reliability is improved, but device complexity increases
Solution Approach 1:
The automated solenoid mechanism provides controlled, precise coupling action that eliminates the variability and potential for damage associated with manual operation. The system ensures coupling only occurs when the transmission is in neutral position, preventing mechanical damage and improving reliability, while accepting the added device complexity as necessary for this protective function.
Solution Approach 2:
Position sensing provides feedback that controls solenoid activation, ensuring the coupler engages only when transmission conditions are appropriate (neutral position). This feedback control prevents improper engagement and potential damage, significantly improving reliability while adding controlled complexity to the system.
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 solution enables efficient and reliable operation of the drop box by automating the coupling process, reducing the risk of damage and improving operational efficiency by ensuring accurate engagement and disengagement of drive lines.
Implementation Method 1
A solenoid can be arranged with the coupling mechanism to selectively move the coupling mechanism from the disengaged position to the engaged position.
Data Source
AI summary
An output transfer group, or drop box, can include a housing and a gear transfer train, rotatably supported within the housing, that includes an input gear adapted for enmeshing engagement with a transmission output shaft and a gear transfer output shaft that is rotatable upon rotation of the input gear. A coupler can be provided that includes a hub rotatively coupled with the gear transfer output shaft, a bearing carrier, a coupler output shaft rotatively coupled to the bearing carrier, and a coupling mechanism rotatively coupled to the bearing carrier. The coupling mechanism can be movable between an engaged position, wherein the coupling mechanism is rotatively coupled to the hub, and a disengaged position, wherein the coupling mechanism is disengaged from the hub. A solenoid can be arranged with the coupling mechanism to selectively move the coupling mechanism from the disengaged position to the engaged position.