Two-Speed Gear Shifting Mechanism With Elastic Dog Clutch Cushioning
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Solution Overview
Problem
The existing gear shifting mechanisms in automobiles often result in motor stalling and subsequent burning out when the shifting fork pushes the dog clutch into a tooth-to-tooth state, leading to inefficiencies and damage.
Innovation Solution
A gear shifting mechanism that incorporates an elastic component between the outer hub and inner shaft to absorb axial forces, preventing motor stalling by maintaining engagement of the dog clutch teeth and reducing stress on the drive motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shifting fork pushes the dog clutch to be in a tooth-to-tooth state, then the gear shifting mechanism can control the engagement of dog clutch, but the drive motor continues operating causing motor stalling and burnout
Solution Approach 1:
The elastic component is pre-installed between the outer hub and inner shaft to provide cushioning before the tooth-to-tooth state occurs. When the shifting fork pushes the dog clutch teeth into engagement, the elastic component compresses to absorb the axial acting force, preventing motor stalling before it can occur.
Solution Approach 2:
The elastic component acts as an intermediary element between the outer hub and inner shaft. It mediates the force transmission during dog clutch engagement, absorbing axial forces that would otherwise be transmitted directly to the drive motor, thereby preventing motor stalling and burnout.
2Reliability
If the elastic component absorbs axial acting force during dog clutch engagement, then motor stalling is prevented, but the structure becomes more complex
Solution Approach 1:
The elastic component serves multiple functions simultaneously: it absorbs axial acting forces during dog clutch engagement, prevents motor stalling, and maintains the structural integrity of the gear shifting mechanism. This multi-functionality justifies the added structural element by providing comprehensive protection without requiring multiple separate components.
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
Prevents drive motor burnout by continuously absorbing acting forces during tooth engagement, ensuring smooth operation and extending motor lifespan.
Implementation Method 1
the elastic component can continue absorbing an acting force when a first gear shifting tooth portion and a second gear shifting tooth portion are attached to each other, to absorb an axial acting force that occurs when a dog clutch is in a tooth-to-tooth state
Data Source
AI summary
A gear shifting mechanism includes a drive motor, a shifting drum, and a first shifting mechanism. The first shifting mechanism includes a first shifting fork, an inner shaft, an outer hub, a first coupling pin, and an elastic component. The elastic component is sleeved on the inner shaft and is located between the inner shaft and the outer hub. There is a first limiting portion and a second limiting portion between the outer hub and the inner shaft. The elastic component is located between the first limiting portion and the second limiting portion. The first limiting portion is connected to one of the outer hub and the inner shaft, and the second limiting portion is connected to the other of the outer hub and the inner shaft.