Robotized Gearbox Fork Positioning via Dynamic Relearning
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Solution Overview
Problem
Mechanical wear and fatigue in robotic gearboxes lead to non-optimal positioning of synchronizers, causing malfunctions that require costly after-sales service and vehicle downtime.
Innovation Solution
A method and device that automatically adjust the imposed displacements of forks in a gearbox by calculating a new displacement based on the difference between learned and auxiliary displacements, allowing for on-the-fly recalibration of gear positions without user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical parts (actuators, forks, sliders) are used in a robotic gearbox, then the gearbox can perform gear changes, but wear and fatigue occur leading to non-optimal positioning of synchronizers and malfunctions
Solution Approach 1:
The system performs preliminary measurements by applying two predefined forces (maximum force and holding force) to the actuator to determine the fork's position. This preliminary action establishes a reference grid of positions that compensates for wear and fatigue before normal operation, ensuring accurate synchronizer positioning despite mechanical degradation
Solution Approach 2:
The system changes the operational parameters by applying different forces (maximum force during gear engagement, holding force during measurement) to the actuator. By measuring fork position under these different force conditions, the system calculates corrected imposed displacements that compensate for mechanical wear, maintaining positioning accuracy over time
2Reliability
If the gearbox malfunctions due to wear, then the system must be taken to after-sales service, but this wastes user time and renders the vehicle unusable
Solution Approach 1:
The supervision computer automatically detects malfunctions and triggers the relearning process without user intervention. The system self-diagnoses by detecting synchronization problems and self-repairs by automatically performing new position measurements and updating the grid of positions, eliminating the need for after-sales service and vehicle downtime
Solution Approach 2:
The supervision computer continuously monitors gearbox operation and provides feedback when malfunctions occur. Upon detecting a synchronization issue, the system initiates a corrective cycle: applying predefined forces, measuring new positions, calculating differences, and updating the grid of positions. This closed-loop feedback ensures automatic correction of wear-related positioning errors
3Manufacturing precision
If the grid of positions is learned in the factory during manufacturing, then initial positioning is accurate, but wear over time causes non-optimal positioning
Solution Approach 1:
The system transitions from a static factory-learning approach to a dynamic adaptive approach. The grid of positions is no longer fixed but is automatically updated during operation by performing new measurements with predefined forces and calculating corrected imposed displacements. This dynamic adaptation compensates for wear and maintains positioning accuracy throughout the gearbox's service life
Solution Approach 2:
Before normal operation resumes after a malfunction, the system performs preliminary measurements by applying maximum force and holding force to the actuator. These preliminary actions establish updated reference positions that account for wear, ensuring that subsequent gear changes use accurate imposed displacements
Data Source
Figure 1~3
AI summary
A device (DC) is tasked with monitoring the movements imposed on at least one fork (F) that forms part of a robotized gearbox (BV) and is able, when translated by an actuator (A), to actuate a synchronizer (SB) associated with pinions contributing to the defining of gear ratios, each imposed movement being defined as a function of at least one measurement taken following the application of two predefined forces to the actuator (A). This device (DC) is designed, in the event of a problem resulting from the actuation of a synchronizer (SB) being detected, to trigger the application of the two predefined forces to an actuator (A) and the taking of at least one other corresponding measurement in order to determine an auxiliary movement, then to determine a difference between the imposed and auxiliary movements that correspond to one another and to associate with each fork (F) a new imposed movement that is dependent on the previous imposed movement thereof and on this determined difference.