Electro-mechanical Transmission Shifter with Current Monitoring
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Solution Overview
Problem
Operators experience discomfort when shifting heavy equipment transmissions due to existing mechanisms, and there is a need for a system that can detect premature failure in the transmission or electric-mechanical linkage.
Innovation Solution
An electro-mechanical transmission shifter using two electro-mechanical actuators with a current sensing device to monitor electrical current, including a programmable controller that alerts for excessive or insufficient current usage, indicating potential issues with the transmission or linkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a Bowden cable mechanism is used for shifting transmission gears, then the transmission can be shifted between ranges, but the operator experiences discomfort during the shifting operation
Solution Approach 1:
The patent replaces the traditional mechanical Bowden cable system with an electro-mechanical actuator system. The actuator uses an electric motor to drive a leadscrew mechanism, converting electrical signals into precise mechanical motion for gear shifting. This substitution eliminates the manual cable-pulling operation that caused operator discomfort while maintaining reliable gear range switching capability.
Solution Approach 2:
The patent introduces an electro-mechanical actuator as an intermediary device between the operator's control input and the transmission gear ranges. The actuator serves as a mediator that transforms the operator's simple button press or switch activation into the complex mechanical motion required for gear shifting, thereby improving ease of operation without requiring direct manual manipulation of cable mechanisms.
2Reliability
If traditional shifting mechanisms are used, then the transmission can operate, but premature failure in the transmission or electric-mechanical linkage cannot be detected until it occurs
Solution Approach 1:
The patent implements a current sensing device that continuously monitors the electrical current consumed by the electro-mechanical actuators during operation. This feedback mechanism tracks current draw patterns and compares them against expected parameters, enabling the system to detect anomalies that indicate premature wear or failure in the transmission or linkage components before they result in complete system failure.
Solution Approach 2:
The patent enables preliminary detection of potential failures by monitoring current consumption patterns during normal operation. By analyzing current draw characteristics, the system can identify early signs of problems in the transmission or linkage components and alert operators to take preventive action before actual failure occurs, thereby improving reliability through proactive maintenance.
3Ease of operation
If electro-mechanical actuators are used to shift transmissions, then operator discomfort is reduced, but the system requires monitoring of electrical current to detect potential failures
Solution Approach 1:
The patent makes the electro-mechanical actuator system self-diagnosing by incorporating current sensing capabilities directly into the control system. The actuators monitor their own electrical current consumption during operation, automatically detecting anomalies that indicate potential failures in the transmission or linkage components without requiring external inspection or complex diagnostic equipment.
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
Reduces operator discomfort by utilizing electro-mechanical actuators to smoothly shift heavy equipment transmissions and detects premature failures through current monitoring, preventing potential gear or linkage problems.
Implementation Method 1
a current sensing device for measuring electrical current to the two actuators to detect a premature failure of a heavy equipment transmission
Implementation Method 2
two electro-mechanical actuators to reduce the amount of discomfort experienced by an operator when shifting a heavy equipment transmission
Data Source
AI summary
An electro-mechanical transmission shifter preferably includes a first actuator, a second actuator, a shift linkage device, actuator mounting bracket, a programmable controller and a gear shift remote. The shift linkage device includes a mounting base plate, a first transmission shifting bracket, a second transmission shifting bracket and a linkage rod. The linkage rod couples the first and second transmission shifting brackets. The actuation rods of the first and second actuators are pivotally connected to the first and second transmission shifting brackets, respectively. A mounting end of the first and second actuators are retained on the actuator mounting bracket with first and second clevis blocks. The programmable controller receives a signal from a gear selector remote to change a gear in a transmission. The programmable controller also monitors the electrical current sent to the first and second actuators.