Flexible Shift Lever for Dead-Headed Dog-Clutch Engagement
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Solution Overview
Problem
Conventional shifting systems with dog-clutches face limitations when shifting gears in a dead-headed state, requiring continuous user force until dogs align, and lack efficient mechanisms to engage shifting gear with driving gear.
Innovation Solution
A shift lever with a flexible member that elastically deforms to provide a biasing torque, allowing the system to preload the input shaft and ensure gear engagement once dogs align, reducing the need for continuous user input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional rigid shift lever is used, then the structure is simple and easy to manufacture, but the user must continuously apply force to the shifter handle until the dogs become aligned, which increases the complexity of operation and reduces ease of use
Solution Approach 1:
The shift lever changes its physical parameter from rigid to flexible, allowing it to elastically deform during operation. This flexibility enables the lever to store and release energy, automatically providing the force needed to align the dogs and engage gears without continuous user input.
Solution Approach 2:
The flexible shift lever performs preliminary action by pre-loading the input shaft when the dogs are misaligned. The elastic deformation stores energy that is released to automatically advance the input shaft and align the dogs, preparing the system for successful gear engagement before the user releases the shifter.
2Productivity
If the user continuously applies force to the shifter handle, then the dogs can be aligned and gears engaged, but this requires constant user input and attention, reducing productivity and increasing operation time
Solution Approach 1:
The flexible shift lever serves itself by using its elastic properties to automatically provide the necessary force for aligning dogs and engaging gears. Once the user initiates the shifting action, the lever's stored elastic energy continues the process without requiring sustained user input, making the system self-sufficient during the critical engagement phase.
Solution Approach 2:
The shift lever operates through periodic action where the user applies force to deform the lever, stores elastic energy, then releases the force allowing the lever to spring back and complete the engagement. This rhythmic push-release mechanism is more efficient than continuous force application.
3Reliability
If a flexible member is added to the shift lever to provide elastic deformation, then the biasing force automatically aligns dogs and engages gears, but this increases the device complexity
Solution Approach 1:
The flexible member is merged with the shift lever body, creating an integrated component rather than separate parts. This combination maintains the lever's primary function while adding elastic properties, ensuring reliable gear engagement without significantly increasing overall device complexity.
Solution Approach 2:
The shift lever incorporates a flexible member that can elastically deform, similar to flexible shells and thin films. This flexibility allows the lever to bend and store energy during operation, providing automatic biasing force for dog alignment and gear engagement while maintaining structural integrity.
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 flexible shift lever effectively preloads the input shaft to align dogs and engage gears, simplifying the shifting process and maintaining the intended gear setting even when the transmission is initially dead-headed.
Implementation Method 1
The flexible member is resilient enough to provide a selected biasing force at a predetermined deformation angle, and flexible enough to elastically deform across a selected angular range
Data Source
AI summary
An exemplary shift lever includes a mounting assembly, a flexible member coupled to the mounting assembly, and an interface coupled to the flexible member. The flexible member is resilient so as to provide a selected biasing force at a predetermined deformation angle, and flexible enough to elastically deform across a selected angular range. The mounting assembly is configured for connection with the input shaft of a transmission, and the interface is configured for connection with an output of a drive selector.