Electromechanical Gear Selection with Sensor-Guided Shift Fork Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Core drilling machines face challenges in precisely adjusting the rotational speed and torque of drill bits to match varying drill bit diameters and material properties, leading to inefficient processes or potential damage.
Innovation Solution
A method for adjusting gears in a gearbox of a machine tool, utilizing an electric motor, control device, operating device, shift fork, and sensors to electronically change gear ratios without mechanical changes, allowing for precise speed and torque adjustments through a signal-based mechanical movement system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual gear selection is used in traditional core drilling machines, then the device structure is simple, but the adjustment precision of rotational speed and torque is insufficient
Solution Approach 1:
The patent replaces the traditional mechanical gear selection mechanism with an electronic control system. The operating device includes signal transmitters and sensors that detect gear selection signals, which are then processed by a control unit to actuate the shift fork. This substitution of mechanical operations with electronic signaling and control enables precise adjustment of rotational speed and torque while maintaining a relatively simple overall device structure.
Solution Approach 2:
The patent introduces an actuator as an intermediary component between the electronic control system and the mechanical gear shifting mechanism. The actuator converts electrical signals from the control unit into mechanical movements of the shift fork, enabling precise gear selection without requiring direct mechanical linkage between the operating device and the gears. This intermediary approach bridges the electronic control system and mechanical transmission system.
2Adaptability or versatility
If multiple gears are provided for different drill bit diameters, then the adaptability to different applications is improved, but the complexity of gear selection and adjustment increases
Solution Approach 1:
The patent incorporates sensors in the operating device that detect the position or state of gear selection and provide feedback signals to the control unit. This feedback mechanism enables the control system to accurately determine which gear is selected and make precise adjustments to the motor speed and torque accordingly, simplifying the operation for the user while maintaining high adaptability to different drill bit diameters and material conditions.
Solution Approach 2:
The control unit serves multiple functions: it processes signals from the operating device, controls the actuator for gear selection, regulates the motor speed, and adjusts the torque output. This multi-functional control system enables a single device to adapt to various drill bit diameters and material conditions through electronic control, eliminating the need for complex manual adjustment mechanisms for each specific application.
3Productivity
If electronic control system is implemented for precise speed adjustment, then the productivity and efficiency are improved, but the device complexity increases
Solution Approach 1:
The patent merges the gear selection control and motor speed control functions into a single integrated control unit. The control unit receives signals from the operating device, coordinates the actuator for gear shifting, and simultaneously adjusts the motor parameters. This consolidation of control functions into one unit improves drilling efficiency through precise coordination while avoiding the complexity that would arise from separate control systems for each function.
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
Enables precise and efficient adjustment of rotational speed and torque to match drill bit diameters and material properties, enhancing the core drilling process by allowing for fine-tuned gear changes without mechanical stress, thus preventing damage and improving work efficiency.
Implementation Method 1
an actuator (12) for converting a signal into a mechanical movement of the shift fork (13)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for setting a gear in a transmission of a machine tool (1). The machine tool (1) contains an electric motor (3) for generating and transmitting a torque to the transmission (4) and a controller (18) for setting the rotational speed of the electric motor (3), and the transmission (4) contains an operating device (7) for selecting a gear in the transmission (4), a shift fork (13) for engaging a gear in the transmission (4), and an actuator (12) for converting a signal into a mechanical movement of the shift fork (13). The operating device (7) contains at least one signal transmitter (15) and at least one sensor (16) for receiving at least one signal of the at least one signal transmitter (15). The method has the steps of: - adjusting the operating device (7) from a first position to a second position in order to select a gear in the transmission (4); - detecting a signal by means of the at least one sensor (16) according to the second position of the operating device (7); - transmitting a signal to the controller (18); - adjusting the rotational speed of the electric motor (3) from a first value to a second value by means of the controller (18); - repositioning the operating device (7) from the second position into a third position; - detecting a signal by means of the at least one sensor (16) according to the third position of the operating device (7); - transmitting a signal to the actuator (12); and - adjusting the shift fork (13) from a first position into a second position by means of the actuator (12) in order to switch from a first gear to a second gear.