Gearbox Control Method for Seamless Shifting Without Torque Interruption
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Solution Overview
Problem
Current gearbox technologies face challenges in shifting gears without torque interruption, leading to increased wear, noise, and reduced acceleration, particularly in heavy vehicles, while also requiring a compact design to accommodate multiple gear steps and high forces.
Innovation Solution
A method for controlling a gearbox that shifts gears in two steps, synchronizing speed and torque between splitter and main shafts using synchronizing elements and axially displacing coupling sleeves, allowing for seamless gear changes without torque interruption and reducing component wear, noise, and enhancing vehicle acceleration, while achieving a compact design with low weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If synchronization devices are enlarged to transmit large torque, then torque transmission capability is improved, but weight increases
Solution Approach 1:
The patent extracts the synchronization function from traditional friction-based synchronization devices and relocates it to the control system. The control system commands the coupling sleeve to axially displace only after speed synchronization is achieved, eliminating the need for enlarged mechanical synchronization devices while maintaining torque transmission capability.
Solution Approach 2:
The control system acts as an intermediary between the planetary gear and the coupling sleeve. It monitors speed synchronization and coordinates the axial displacement of the coupling sleeve, enabling smooth gear shifts without requiring enlarged mechanical synchronization components.
2Force
If synchronization devices are enlarged to transmit large torque, then torque transmission capability is improved, but space requirements increase
Solution Approach 1:
The synchronization function is extracted from physical synchronization devices and transferred to the control system. This eliminates the need for enlarged mechanical components, reducing space requirements while maintaining the ability to handle large torque transmissions.
Solution Approach 2:
The patent replaces the mechanical synchronization system with a control-based system. The control system monitors speed and coordinates coupling sleeve displacement, substituting mechanical synchronization devices with electronic control while reducing space requirements.
3Force
If synchronization devices are enlarged to transmit large torque, then torque transmission capability is improved, but moment of inertia increases
Solution Approach 1:
The synchronization function is extracted from heavy mechanical devices and relocated to the control system. This eliminates the need for enlarged components with high moment of inertia, allowing the coupling sleeve to accelerate and decelerate more rapidly while maintaining torque transmission capability.
Solution Approach 2:
The mechanical synchronization system is replaced with a control-based system that monitors speed and coordinates coupling sleeve displacement. This substitution reduces the moment of inertia by eliminating heavy mechanical synchronization components.
4Power
If traditional gear shifting is used, then gear ratio change is achieved, but torque interruption occurs
Solution Approach 1:
The control system performs preliminary actions by monitoring speed synchronization before commanding the coupling sleeve to axially displace. This preliminary speed synchronization ensures that gear shifting occurs without torque interruption, maintaining continuous power transmission.
Solution Approach 2:
The control system uses feedback by monitoring the speed of the planetary gear and the coupling sleeve. Based on this feedback, the control system determines when speed synchronization is achieved and commands the coupling sleeve to displace, enabling seamless gear shifts without torque interruption.
5Speed
If traditional synchronization devices are used, then speed synchronization is achieved, but wear increases
Solution Approach 1:
The patent replaces mechanical friction-based synchronization devices with a control-based system. The control system monitors speed and coordinates coupling sleeve displacement, eliminating the wear associated with traditional mechanical synchronization while maintaining speed synchronization capability.
Solution Approach 2:
The control system acts as an intermediary that monitors speed synchronization and coordinates the timing of coupling sleeve displacement. This eliminates direct mechanical contact and friction between synchronization components, reducing wear and improving reliability.
6Adaptability or versatility
If multiple gear steps are accommodated, then gear ratio range is improved, but device complexity increases
Solution Approach 1:
The control system provides multi-functionality by handling speed monitoring, synchronization determination, and coupling sleeve displacement coordination. This universal control approach simplifies the overall gearbox structure while maintaining the capability to accommodate multiple gear steps and a wide gear ratio range.
Solution Approach 2:
The patent replaces complex mechanical synchronization devices with a control-based system. This substitution reduces device complexity while maintaining the ability to accommodate multiple gear steps and provide a wide gear ratio range through coordinated control of the coupling sleeve.
Data Source
AI summary
A method for controlling a gearbox (2) that includes a main gearbox (6) provided with a splitter shaft (16) and a main shaft (14), connectable to a power source (4). The splitter shaft (16) is connected to a lay shaft (22) by at least a first and a second splitter gear pair (42, 45). The main shaft (14) is connected to a lay shaft (22) by at least a first gear pair (60). The method includes a) preparing a shifting of gear in the gearbox (2) by transferring essentially the same speed and torque between the splitter and the main shafts (16, 14), and b) shifting gear in the gearbox (2).