Gearbox Shift Block Recovery Using ISG Crankshaft Rotation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for shifting gears in a vehicle gearbox do not effectively address gear shifting blocks, which occur when a moving part contacts the end face of another gear wheel or dog, hindering smooth gear shifting, especially when the engine is stopped.
Innovation Solution
A system that includes an electric machine to provide motor motion to the crankshaft, a clutch between the crankshaft and input shaft, and a controller that engages the clutch and starts the electric machine to eliminate gear shifting blocks during gear shifts, allowing automatic phase adjustment of gear wheels even when the engine is stopped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the engine is stopped during gear shifting, then fuel economy is improved, but gear shifting block occurs when moving parts contact end faces of gear wheels
Solution Approach 1:
The patent introduces an electric machine as an intermediary device between the engine and gearbox. When the engine is stopped, the electric machine provides motor motion to rotate the input shaft and adjust the phase of gear wheels, enabling smooth gear shifting without engine power. This mediator resolves the conflict between fuel economy (stopped engine) and gear shifting reliability.
Solution Approach 2:
The patent changes the operational parameters of the drivetrain by switching from engine-driven rotation to electric machine-driven rotation during gear shifting. The controller adjusts the motor motion parameters (speed, torque) to achieve appropriate phase adjustment of gear wheels, allowing gear shifting to proceed smoothly while the engine remains stopped.
2Reliability
If manual intervention is used to eliminate gear shifting block, then gear shifting can be corrected, but shifting time increases and productivity decreases
Solution Approach 1:
The patent implements a self-service system where the controller automatically detects gear shifting blocks and activates the electric machine to eliminate them without requiring manual intervention. The system monitors gear shifting progress, identifies blocks when moving parts fail to reach target positions, and automatically corrects the issue by adjusting gear wheel phases through electric machine-driven input shaft rotation.
Solution Approach 2:
The patent employs feedback control by monitoring the position and movement of gear components during shifting. When a block is detected (through sensors monitoring gear shaft positions and movement characteristics), the controller receives feedback and automatically activates the electric machine to correct the phase mismatch, creating a closed-loop control system that ensures reliable gear shifting completion.
3Reliability
If the electric machine rotates the input shaft to adjust gear wheel phase, then gear shifting block is eliminated, but energy consumption increases
Solution Approach 1:
The patent applies partial action by using the electric machine only for the specific duration and rotational amount needed to adjust gear wheel phases during blocking conditions. The electric machine does not continuously operate but provides targeted motor motion only when gear shifting blocks are detected, minimizing energy consumption while achieving the necessary phase adjustment.
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
Automatically eliminates gear shifting blocks in a brief time, ensuring smooth and timely gear shifting by using the electric machine to drive the crankshaft and adjust the phase of gear wheels, even when the engine is stopped, preventing the need for manual intervention.
Implementation Method 1
an electric machine configured to provide a motor motion to the crankshaft
Data Source
Figure 1
Figure 2A~2H
AI summary
A method and system for shifting between gears in a gearbox of a drivetrain in a vehicle, includes: auto engaging a clutch (31) to provide a torque transfer path from a crankshaft (2A) of an engine (2) to an input shaft (3A) of a gearbox (3) and auto starting an integrated starter generator (ISG) to provide a motor motion to the crankshaft (2A) following determination that a gear shifting block occurs during shifting between gears in the gearbox (3) while the engine (2) is being auto stopped.