External Gearbox Actuator With Integrated Shift Fork for Low-Force Shifting
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Solution Overview
Problem
Existing gear assembly actuation systems face challenges with complex integration of separate actuation assemblies and forks, leading to increased costs and potential for premature wear due to high force requirements and misalignment issues during gear shifts.
Innovation Solution
An actuator system with an integrated fork and spring assist, designed for simple integration into various gearboxes, utilizing a support with lugs and a drive system to move a shift fork between positions with low force and high acceleration, thereby reducing wear and improving shift speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stronger motor is used to force gear teeth into alignment, then the gear engagement reliability is improved, but the system complexity and cost increase
Solution Approach 1:
The system uses a sensor to detect the position of the sliding gear and a controller to activate the motor in advance, ensuring precise timing for gear engagement. This preliminary detection and control action allows reliable engagement without requiring excessive force from an oversized motor.
Solution Approach 2:
The system incorporates a sensor that provides feedback on the sliding gear position to the controller. This feedback mechanism enables the controller to adjust motor activation timing precisely, achieving reliable gear engagement through intelligent control rather than brute force, thereby reducing the need for complex oversized actuators.
2Reliability
If a stronger motor is used to force gear teeth into alignment, then the gear engagement reliability is improved, but the force requirement increases causing premature wear
Solution Approach 1:
The sensor detects the sliding gear position in advance and the controller activates the motor at the optimal moment before gear contact. This timing ensures that gears engage smoothly when properly aligned, avoiding the need for high force that would cause wear and damage.
Solution Approach 2:
The sensor provides real-time feedback on gear position to the controller, enabling precise control of motor activation. This feedback ensures the motor applies force only when needed and at the correct moment, preventing excessive force and reducing wear on gear teeth.
3Ease of manufacture
If manual force is used to move the actuator between positions, then the system cost is reduced, but the operation speed decreases
Solution Approach 1:
The system uses a sensor to automatically detect gear position and a controller to automatically activate the motor, eliminating the need for manual operation. This self-service automation maintains cost-effectiveness while dramatically improving actuation speed and consistency compared to manual forcing of gears.
4Manufacturing precision
If the time window for engagement is not utilized, then the gear shift accuracy is improved, but the force requirement increases
Solution Approach 1:
The sensor detects the sliding gear position in advance and the controller activates the motor before the gear engagement window closes. This preliminary action ensures accurate gear shifting by catching the alignment moment without needing excessive force.
Solution Approach 2:
The sensor provides feedback on the sliding gear position to the controller, enabling precise timing of motor activation. This feedback ensures the motor engages the gears at the optimal moment within the time window, achieving accurate shifts with minimal force.
Data Source
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.