Gear Shifter Warpage Reduction via All-Phase Current Control
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Solution Overview
Problem
Conventional gear shifters face issues with reference value variability due to warpage caused by abutment during the learning process, which can be influenced by temperature changes and sudden power interruptions, leading to inaccurate shift range settings.
Innovation Solution
The shift range switch device employs a direct current motor with plural phase coils, a drive object, a stopper, and a controller with a reference value learner that abuts the drive object to the stopper under preset conditions, reduces warpage by all-phase power supply and decreasing electric current, and sets the reference value when warpage is diminished, using a force detector or position sensor to determine the zero pressing force state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If abutment learning is performed to set the reference value, then the reference value can be established, but warpage occurs on the drive object and stopper causing reference value variation
Solution Approach 1:
The patent applies preliminary action by performing multiple abutment operations before finalizing the reference value. The controller repeatedly abuts the drive object to the stopper and acquires position signals, then calculates an average value from multiple measurements. This preliminary repeated action eliminates warpage-induced variations by averaging out the unstable measurements, thereby establishing a stable and accurate reference value.
Solution Approach 2:
The patent implements feedback by continuously monitoring position signals during multiple abutment operations and using this information to calculate an averaged reference value. The controller feeds back the position signal data from repeated measurements, processes it through averaging calculation, and uses the resulting stable reference value for subsequent gear shift control, thereby eliminating the harmful effect of warpage variation.
2Ease of manufacture
If the drive object is abutted to the stopper for reference value setting, then the reference position is established, but warpage causes variation in the reference value depending on temperature
Solution Approach 1:
The patent performs multiple preliminary abutment operations under the same temperature conditions before finalizing the reference value. By repeatedly abutting the drive object to the stopper and averaging the position signals obtained during these operations, the system eliminates temperature-dependent warpage effects that would otherwise cause reference value variation, thereby achieving temperature adaptability while maintaining simple reference value setting procedure.
3Reliability
If sudden power interruption occurs during travel, then memory loss occurs, but reference value must be reset causing loss of time
Solution Approach 1:
The patent performs multiple preliminary abutment operations and calculates an averaged reference value before storing it in memory. This preliminary repeated measurement and averaging process creates a more robust and reliable reference value that is less susceptible to memory loss or corruption. In case of power interruption, the system can quickly re-establish the same stable reference value through the same averaging process, reducing initialization time and improving overall reliability.
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 stabilizes the reference value, reducing variations caused by warpage, ensuring accurate shift range switching regardless of environmental changes, and maintaining consistent performance across different conditions.
Implementation Method 1
a direct current motor 3 having plural phase coils 10 for a rotation of a rotor 11 in the direct current motor 3 by a power supply of a direct electric current orderly to each of the plural phase coils 10
Data Source
AI summary
A gear shifter performs an abutment learning, having a reference value learner that sets a reference value of a position signal when abutting a drive object to a stopper, and reduces warpage by (i) an all phase power supply supplying to the electric current to all of the plural phase coils of the direct current motor, and (ii) by reducing an amount of the electric current supplied to the coils, and by decreasing a pressing force of the drive object pressing the drive object against the stopper. The reference value determined at a warpage diminish time enables a reduction of variation of the reference value due to an influence of the warpage, thereby setting a robust reference value to account for an environmental condition such as a temperature change, for an accurate shift operation of the gear shifter.