Gearbox Intermediate Shaft Coupling and Locking for Low-Drag Synchronization
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Solution Overview
Problem
Current vehicle transmission synchronization systems, which use reversible electric machines to manage intermediate shafts during gear ratio changes, increase main engine fuel consumption and pose safety risks due to potential damage from malfunction or battery overcharge during braking phases.
Innovation Solution
A module comprising a coupling device and a blocking device that allows the reversible electric machine to be uncoupled from the intermediate shaft outside transient phases, reducing main engine consumption, and enables the coupling device to act as a gearbox brake without stressing the electric machine, particularly in failure or maximum battery charge scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reversible electric machine is permanently coupled to the intermediate shaft, then the intermediate shaft can be synchronized during transient gear change phases, but the main engine fuel consumption increases due to continuous drag torque
Solution Approach 1:
The coupling device is designed to dynamically switch between coupled and uncoupled states based on operating conditions. During transient gear change phases, the coupling device connects the reversible electric machine to the intermediate shaft for synchronization. During steady-state operation, the coupling device disconnects them to eliminate drag torque and reduce fuel consumption.
2Reliability
If the reversible electric machine is used to brake the intermediate shaft during transient phases, then synchronization is promoted, but safety risks arise when the machine malfunctions or the battery reaches maximum charge
Solution Approach 1:
The coupling device acts as an intermediary between the reversible electric machine and the intermediate shaft. It enables the system to switch between two braking modes: using the reversible electric machine during normal operation, and using the coupling device itself (as a mechanical brake) during abnormal conditions such as machine malfunction or battery overcharge, thereby eliminating safety risks.
3Adaptability or versatility
If the reversible electric machine is permanently linked to the intermediate shaft, then it can always brake the shaft, but this increases fuel consumption and creates safety problems when the battery is overcharged
Solution Approach 1:
The system dynamically adapts its configuration based on operational needs. The coupling device enables the reversible electric machine to be connected only when needed for synchronization or braking, and disconnected during steady-state operation to reduce energy loss. This dynamic adaptability resolves the contradiction between always-available braking and fuel efficiency.
Data Source
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AI summary
[The invention relates to a module (48) for a drive and synchronization system (4) of an intermediate shaft (5) of a transmission box (3), said module comprising: - a coupling device (26) comprising an input element (27) intended to be rotationally coupled to a reversible electric machine (24) and an output element (28) intended to be rotationally coupled to the intermediate shaft (5), the coupling device (26) having a coupled state in which the clutch device is able to transmit a torque between the input element (27) and the output element (28) and a discoupled state in which the input element (27) and the output element (28) are discoupled;and - a locking device (42) which has a locked state in which said locking device (42) prevents the input element (27) of the clutch device from rotating and a released state in which said locking device (42) allows the input element (27) to rotate.