Gearbox Selector Position Sensing for 5-Degree Shift Range Detection
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Solution Overview
Problem
Existing gearbox systems with parallel shafts face challenges in precisely detecting the angular position of a rotary selection member due to insufficient precision, leading to potential gear shifting issues near transition positions between tracks.
Innovation Solution
A position detection device comprising a bi-function contactor sensor with a piston that sends distinct signals for different angular positions, allowing precise control of gear shifts by determining the piston's position relative to a target on the rotary selection member, enabling accurate detection of three consecutive angular ranges of 5 degrees each.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic target with Hall effect sensor is used to detect angular position, then the detection system is simple to implement, but the precision is insufficient (±2 degrees) to reliably distinguish three consecutive 5-degree angular ranges
Solution Approach 1:
The patent replaces the magnetic field-based Hall effect sensor with a mechanical contactor system. A movable contactor with a piston mechanically contacts a target surface on the rotary selector member, converting angular position detection into linear displacement measurement of the piston. This mechanical substitution achieves superior precision (sufficient to distinguish 5-degree ranges) while maintaining relative simplicity through direct mechanical coupling.
Solution Approach 2:
The invention changes the detection parameter from magnetic field strength (Hall effect) to mechanical contact position (contactor piston displacement). By transforming the physical quantity being measured and using a different sensing mechanism, the system achieves the required angular resolution for distinguishing consecutive speed lines without excessive complexity.
2Reliability
If the detection system uses a moving target with sensor outside housing, then the detection range is sufficient, but the reliability is insufficient near transition points between angular ranges
Solution Approach 1:
The patent introduces a movable contactor with piston as an intermediary mechanical element between the rotary selector member and the detection system. This intermediary converts rotational motion into linear piston displacement, providing a clear, reliable signal that distinguishes between different angular positions and transition states, thereby improving detection reliability near critical transition points.
Solution Approach 2:
The detection range is segmented into distinct zones corresponding to different angular positions of the rotary selector member. The movable contactor piston provides discrete position signals for each zone (first speed line, intermediate neutral position, second speed line), enabling reliable differentiation of operational states and preventing ambiguous detection near transition boundaries.
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 provides precise, reliable, and repetitive detection of the rotary selection member's position, ensuring accurate gear shifting and preventing passage refusal near transition positions, thereby enhancing gearbox control and efficiency.
Implementation Method 1
A position detection device comprising a bi-function contactor sensor with a piston that sends distinct signals for different angular positions, allowing precise control of gear shifts by determining the piston's position relative to a target on the rotary selection member
Data Source
Figure 1~1A
Figure 1B~2
Figure 3A~3B
AI summary
Device for detecting the positions of an internal control device (1) for a gearbox with parallel gear shafts, comprising a rotary selection component (2) that supports a movable target (7b), cooperating with a sensor (9) attached to the gearbox for detecting the selection position of the rotary component from at least three different angular selection positions, characterised in that the sensor (9) supports a piston (9a) which is moved by the thrust of the target (7b) through a linear retraction stroke wherein several adjacent portions are identified which correspond to successive angular selection positions of the rotary component (2).