External Gearbox Actuator With Integrated Shift Fork Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gear assembly actuation systems face challenges with complex integration of separate actuation assemblies and forks, leading to high force requirements, slow operation, and potential premature wear due to momentary blockages during gear alignment.
Innovation Solution
An actuator system with an integrated fork and spring assist, mounted onto the gearbox with lugs and apertures for secure integration, which utilizes a drive system and cam assembly to move the shift fork between positions with low force and high acceleration, overcoming misalignment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate actuation assemblies and forks are used, then the system can be adapted to different applications, but the integration into gearbox becomes complex and application specific
Solution Approach 1:
The patent combines the actuation assembly and fork into a single integrated unit. The actuator housing directly incorporates the fork structure, eliminating the need for separate components and complex integration procedures. This integrated design maintains adaptability to different applications while significantly reducing integration complexity.
Solution Approach 2:
The integrated actuator assembly is designed as a universal component that can be applied to various gearbox configurations. The standardized interface and modular design allow the same actuator assembly to serve multiple applications without requiring custom integration for each case.
2Reliability
If a stronger motor is used to force gear teeth into alignment, then the gear engagement can be achieved, but the system operates slower and requires larger force causing premature wear
Solution Approach 1:
The actuator assembly performs preliminary alignment of the gear teeth before full engagement. The fork structure guides the sliding gear into proper alignment with the receiving gear, ensuring that the teeth are correctly positioned before the engagement force is applied, thereby achieving reliable engagement with lower force.
Solution Approach 2:
The fork acts as an intermediary element between the actuator and the gear teeth. It provides a controlled interface that distributes and directs the actuation force, ensuring smooth and aligned engagement of the gear teeth while reducing peak force requirements and preventing premature wear.
3Ease of operation
If manual force is used to move the fork, then the system can be operated, but the gear shifts are slow and require significant human effort
Solution Approach 1:
The patent replaces manual mechanical operation with an automated actuator system. The actuator assembly uses a motor-driven mechanism to move the fork, eliminating the need for manual force while achieving fast and precise gear shifts. This substitution maintains ease of operation through automated control while dramatically improving shift speed.
Data Source
Figure 1~2
Figure 3
Figure 4A~4C
AI summary
The present teachings provide for a system comprising a gearbox including a gear assembly, the gearbox having an outer surface, the outer surface with a pair of apertures; and an actuator. The actuator including a support with a pair of lugs, with each lug having an opening; an drive system connected to the support; a shift fork including a pair of arms, the shift fork in communication with the drive system and configured to move a distance defining a stroke length between a disengaged position and an engaged position; and an actuation assembly operatively connected with the drive system to move the shift fork between a neutral position, and a shifted position, with a plurality of intermediate positions between the neutral and shifted positions. The actuator is mounted onto the outer surface of the gearbox, with the pair of lugs extending into the pair of apertures of the gearbox, and at least a portion of the shift fork extends extending through the lugs into and below the outer surface of the gearbox. The portion of the shift fork within the gearbox engages a gear assembly within the gearbox.