Vehicle Gearbox Axial Coupling Sleeve Reverse Gear Design
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Solution Overview
Problem
Current gearboxes in vehicles, especially heavier ones like trucks, face issues with long shifting times, high energy consumption, noise, and maintenance costs due to complex designs and the need for multiple gear positions, including reverse gears that increase weight and complexity.
Innovation Solution
A gearbox design that incorporates axially movable coupling sleeves to achieve a reverse gear position, reducing the need for a traditional reverse gear in the main gearbox, thus minimizing weight, space, and fuel consumption, while allowing for quick gear shifting with reduced axial forces and lubrication needs, and utilizing a simple design with fewer components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional reverse gear is included in the main gearbox, then reverse gear functionality is achieved, but weight and complexity increase
Solution Approach 1:
The patent combines the reverse gear functionality with the planetary gear mechanism by integrating the reverse gear as part of the planetary gear assembly. The coupling sleeve engages different components (sun gear, planet carrier, ring gear) to achieve reverse gear operation, eliminating the need for a separate traditional reverse gear in the main gearbox.
Solution Approach 2:
The planetary gear mechanism is designed to perform multiple functions including forward gears and reverse gear through the axial movement of the coupling sleeve. By engaging different components of the planetary gear at different positions, the system achieves versatility without requiring separate dedicated mechanisms for each function.
2Adaptability or versatility
If a traditional reverse gear is included in the main gearbox, then reverse gear functionality is achieved, but device complexity increases
Solution Approach 1:
The patent merges the reverse gear mechanism with the existing planetary gear structure. The coupling sleeve that axially moves to engage different components serves dual purposes: controlling forward/reverse gear selection and managing the planetary gear operations, thereby reducing overall device complexity.
Solution Approach 2:
The planetary gear assembly is designed as a universal mechanism that handles both forward and reverse gear operations. The coupling sleeve's axial movement enables the same planetary gear components to serve multiple functions, simplifying the overall gearbox design.
3Object-generated harmful factors
If helical teeth are used in the planetary gear, then noise is reduced, but reaction force in the direction of rotation axis increases
Solution Approach 1:
The patent employs thrust bearings to counterbalance the reaction force generated by the helical teeth in the planetary gear. These bearings are specifically positioned to absorb and support the axial forces, allowing the use of helical teeth for noise reduction without being constrained by the increased reaction forces.
4Ease of operation
If synchronizer rings with locking angle are used, then synchronous shifting is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces synchronizer rings with specifically designed locking angles that act as intermediaries between the coupling sleeve and the planetary gear components. These locking angles facilitate smooth synchronous shifting by gradually equalizing speeds before engagement, reducing the stringent manufacturing precision requirements while maintaining ease of operation.
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
The solution results in a more efficient, lightweight gearbox with reduced energy consumption, lower noise levels, and easier maintenance, as well as increased bearing lifespan due to reduced deflection and stress on main shafts, while maintaining high torque transmission capabilities.
Implementation Method 1
The first coupling sleeve (42) may in the second gear position be arranged to connect the input shaft (16) with the planet carrier (20)... The second coupling sleeve (43) may in the second gear position be arranged to connect the ring gear (22) with the output shaft (28)
Implementation Method 2
The teeth of the sun gear, planet gears and ring gear can be helical, that is, they have an angle to a common rotation axis of the sun gear, planet carrier and ring gear. By cutting the teeth of the gears in an angle in relation to the rotation axis of the gear, the generated sound from the planetary gear is reduced.
Implementation Method 3
The planetary gear usually comprises three components, which are rotatably arranged relative to each other namely a sun gear, a planet carrier with planet gears and a ring gear... With knowledge of the number of teeth of the sun gear and the ring gear the relative speed of the three components can be determined during operation.
Data Source
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AI summary
The invention relates to a gearbox for vehicles (1), comprising a planetary gear (14) 5 with a ring gear (22), a sun gear (18) and a planet carrier (20), on which at least one planet gear (24) is rotatable mounted, which ring gear (22) and sun gear (18) en- gages with the at least one planet gear (24) by teeth (32); and a gearbox housing (12) surrounding the planetary gear (14). A first axially movable coupling sleeve (42) is in a first gear position arranged to engage the ring gear (22) with the gearbox 10 housing (12), in a second gear position arranged to engage the sun gear (18) with the planet carrier (20), and in a third gear position arranged to engage the planet carrier (20) with the gearbox housing (12). A second axially movable coupling sleeve (43) is in the third gear position arranged to engage the ring gear (22) with an output shaft (28). The invention also relates to a vehicle (1), which comprises such a gear-15 box (2).