Automatic Gearbox Coupling Alignment via Sensor Feedback

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Solution Overview

Problem

Existing power machines with hydrostatic drive systems face challenges in smooth gear shifting due to the need for precise alignment of gears, which can lead to inefficiencies and potential damage if not aligned correctly during shifting processes.

Innovation Solution

A drive system with a gearbox featuring multiple gear reduction sets and a coupling mechanism, controlled by a controller that provides alignment signals to ensure proper engagement of the selected gear reduction set, allowing for automatic and quick alignment without operator intervention, enabling seamless gear shifting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual gear shifting is used in hydrostatic drive systems, then operator control is maintained, but gear alignment precision deteriorates leading to grinding and wear

Engineering Contradiction:

Improvegear alignment precisionVSAvoidoperator intervention requirement

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system automatically detects gear position and actuates the coupling mechanism without operator intervention. The controller monitors sensor signals and autonomously controls the alignment and engagement of gear reduction sets, making the system self-regulating for gear shifting operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operation with an automated control system that uses sensors and electronic controllers to detect gear positions and actuate the coupling mechanism, substituting human-operated mechanical systems with automated electromechanical systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If gear shifting is performed without precise alignment, then shifting speed increases, but gear wear and damage increase

Engineering Contradiction:

Improvegear shifting speedVSAvoidgear durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary alignment of the coupling mechanism with the selected gear reduction set before actual engagement. The controller actuates the coupling mechanism to align gears in advance, ensuring proper positioning before torque is transmitted, thereby preventing grinding and wear during the shifting process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses sensors to detect the position of the coupling mechanism and provides feedback to the controller. The controller monitors this feedback signal and adjusts the actuation of the coupling mechanism accordingly, ensuring precise alignment is achieved before engagement occurs.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If the power machine is stopped for gear shifting, then gear alignment accuracy improves, but operational continuity deteriorates

Engineering Contradiction:

Improvegear alignment accuracyVSAvoidoperational interruption

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system dynamically adjusts the coupling mechanism position based on real-time sensor feedback while the machine operates. The controller continuously monitors gear position and actuates the coupling mechanism as needed, allowing gear shifting to occur during operation without requiring the machine to be stopped, thereby maintaining both alignment accuracy and operational continuity.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10260625B2Automatic shift of mechanical gearbox

Publication Date: 2019.04.16 DOOSAN BOBCAT NORTH AMERICA INC

AI summary

Disclosed are power machines, and drive systems for use thereon, as well as methods of providing automatic gear shifting. The drive system includes a controller configured to implement automatic gear shifting. Gear engagement is determined following a gear shift, and a drive pump or other drive system components is automatically controlled to rotate a gearbox gear in first and second directions until the gear is properly engaged.