Gear Shift Actuator Voltage Modulation for Faster Dog Clutching
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Solution Overview
Problem
Existing gear change control systems in gearboxes with parallel shafts and actuator systems require optimization to minimize gear change time without using a switch, particularly in robotic gearboxes with internal gear change control systems lacking synchronization mechanisms.
Innovation Solution
Temporarily increasing the on-board vehicle voltage during pinion uncoupling and clutching operations using a DC/DC voltage converter powered by a high-voltage battery to enhance the performance of the gearshift actuator, allowing for faster and smoother gear changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the gear change control system uses a mechanical spring-assisted mechanical system with a resistance spring to facilitate pinion engagement, then the passage comfort is improved, but the total gear change time is increased due to the synchronization phase required before dog clutching
Solution Approach 1:
The system performs preliminary compression of the resistance spring during the synchronization phase when the slider teeth are in abutment with the pinion teeth. This preliminary action stores energy that will be released to accelerate the dog clutching operation, thereby improving comfort during synchronization while preparing for faster subsequent engagement
Solution Approach 2:
The resistance spring operates in a periodic manner: it is compressed during the synchronization phase when teeth are in abutment, then releases the stored energy to accelerate the fork during the dog clutching phase. This periodic compression and release creates distinct operational phases that optimize both comfort and speed at different stages of the gear change
2Device complexity
If the actuating motor operates at normal on-board network voltage, then the system simplicity is maintained, but the gear change speed is reduced
Solution Approach 1:
The system dynamically adjusts the operating voltage of the actuating motor based on the gear change phase. During the critical dog clutching phase, the motor operates at an elevated voltage (14V-16V) to increase speed, while returning to normal voltage (12V) during other phases. This dynamic voltage adjustment optimizes speed when needed while maintaining overall system simplicity
Solution Approach 2:
The invention changes the electrical parameter (voltage) of the actuating motor temporarily during specific operations. The voltage is raised from the normal 12V to 14V-16V during uncoupling and dog clutching operations to accelerate these critical phases, then returned to normal levels, thereby improving gear change speed without permanently complicating the system
3Speed
If the resistance spring is highly compressed to store more energy for fork acceleration, then the dog clutching speed is improved, but the torque transmitted during the abutment phase increases excessively
Solution Approach 1:
The system applies a controlled amount of compression to the resistance spring - enough to store sufficient energy for accelerated dog clutching, but not so much as to create excessive torque during the abutment phase. The compression is optimized to achieve the minimum necessary energy storage for fast clutching while maintaining torque within acceptable limits
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
This approach reduces the total duration of gear shifting by approximately 20ms, making the gear change process nearly imperceptible while maintaining torque stability and pleasure, leveraging existing vehicle systems with minimal software adaptations.
Implementation Method 1
a resistance spring, capable of accumulating energy by compressing during the synchronization phase and of releasing it. at the end of this phase, to facilitate dog clutching of the pinion
Implementation Method 2
a direct current actuating motor regulating said control element in position
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for controlling a shift actuator with a sliding gear for a gearbox comprising a control element (2) for controlling a shift fork (6) responsible for disengaging and engaging gears on a shaft of the gearbox that receives the torque from a traction machine powered by the electrical system of the vehicle, said control element being positioned upstream from a mechanical spring-assistance system and regulated into position by a DC actuator motor (1), characterised in that the voltage applied to the actuator motor (1) is temporarily raised above the base voltage of the electrical system, during the operations of disengaging and engaging the gears.