Dynamic Inch/Brake Overlap Control for Vehicle Transmission
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Solution Overview
Problem
Current industrial vehicles face challenges with fixed inch/brake overlap settings, which are inadequate for varying operating conditions, leading to issues such as vehicle roll on inclines, increased maintenance due to heat buildup, and reduced controllability.
Innovation Solution
A dynamically adjustable inch/brake overlap system using sensors and a vehicle processor to vary the overlap between transmission and braking torque based on accelerator pedal position, allowing for simultaneous engagement of both systems for improved control and reduced heat buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the inch/brake overlap is manually set at a low value, then the vehicle can operate satisfactorily on level surfaces, but the vehicle will roll down hills when operating on inclined surfaces
Solution Approach 1:
The patent implements dynamic adjustment of the inch/brake overlap based on vehicle operating conditions. The system automatically varies the overlap amount in response to detected conditions such as incline angle, allowing the transmission torque to be increased when needed for hill holding while maintaining low overlap for normal operation. This transforms the static, manually-adjusted overlap into a dynamic parameter that adapts to real-time operating conditions.
2Reliability
If the inch/brake overlap is manually set at a high level for inclined surface operations, then the vehicle can maintain position on grades, but unnecessary heat buildup occurs in the transmission and braking systems
Solution Approach 1:
The system dynamically adjusts the inch/brake overlap based on actual operating conditions rather than maintaining a fixed high setting. When the vehicle is on level ground, the overlap is minimized or eliminated, preventing unnecessary heat generation. When an incline is detected, the system automatically increases the overlap to provide sufficient transmission torque for hill holding. This conditional, dynamic approach ensures heat buildup is minimized while maintaining reliability when needed.
3Reliability
If the inch/brake overlap is manually set at a high level, then the vehicle can operate on inclined surfaces, but the vehicle lurches or operates unevenly during inching operations
Solution Approach 1:
The patent implements dynamic control of the inch/brake overlap that responds to operating conditions and operator input. The system maintains minimal overlap during normal inching operations on level surfaces, providing smooth and precise vehicle control. When hill holding is required, the system automatically increases the overlap to provide sufficient transmission torque. This conditional dynamic adjustment eliminates the constant high overlap that causes lurching, while still providing the necessary torque for inclined surface operations.
Data Source
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AI summary
A motorized vehicle includes a transmission system and an inch/brake device providing at least two ranges of motion. An engagement force of the transmission system is provided in a first range of motion of the inch/brake device, and a braking force of the motorized vehicle is provided in a second range of motion of the inch/brake device. An accelerator device moves between two or more positions, wherein moving the accelerator device from one position to another position causes an amount of overlap between the first and second ranges of motion of the inch/brake device to vary.