Gearbox Torque Estimation for Retrofitted Auxiliary Loads
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Solution Overview
Problem
In utility vehicles, the retrofitting of auxiliary equipment like generators or climate control compressors by body builders often leads to reduced torque being tapped from the engine, which is not accounted for by the gearbox control unit, resulting in poor shifting quality, increased wear, and potential gearbox damage due to incorrect clutch pressures.
Innovation Solution
A system where the gearbox control unit determines the torque applied to the gearbox input using a parameterizable function that maps engine rotational speed to the torque diverted to auxiliary consumers, allowing adaptation of clutch pressures and enabling body builders to parameterize the function post-vehicle delivery, even if the auxiliary consumers are unknown to the manufacturer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If auxiliary consumers are retrofitted by body builders, then vehicle functionality and utility are improved, but torque information becomes unavailable to the gearbox control unit
Solution Approach 1:
The patent introduces a data transfer device (vehicle bus) as an intermediary to transmit torque information from the engine control unit to the gearbox control unit. This mediator enables communication between components that would otherwise be isolated, allowing the gearbox control unit to receive torque information without direct connection to the auxiliary consumer.
Solution Approach 2:
The system implements a feedback mechanism where the engine control unit continuously monitors torque data and transmits it to the gearbox control unit. This feedback loop ensures the gearbox control unit has real-time information about torque conditions, enabling adaptive control despite the presence of retrofitted auxiliary consumers.
2Device complexity
If the gearbox control unit does not account for torque reduction, then control simplicity is maintained, but shifting quality deteriorates and gearbox damage risk increases
Solution Approach 1:
The gearbox control unit receives torque information via the vehicle bus and uses this feedback to dynamically adjust clutch pressures. This feedback mechanism allows the system to maintain high shifting quality without requiring complex mechanical modifications, as the control unit adapts based on real-time torque data.
Solution Approach 2:
The patent employs parameter changes by adjusting clutch pressure values based on received torque information. The gearbox control unit modifies operational parameters (clutch pressures) in response to varying torque conditions, enabling adaptive control that maintains reliability while preserving control simplicity through software-based adjustment.
3Ease of operation
If clutch pressures are not adapted to torque reduction, then control procedure simplicity is maintained, but wear and damage increase
Solution Approach 1:
The system automatically adjusts clutch pressure parameters based on torque information received from the engine control unit. This parameter adaptation occurs through software control without requiring manual intervention or complex mechanical adjustments, thereby maintaining ease of operation while preventing wear and damage through adaptive pressure control.
Solution Approach 2:
The feedback mechanism enables the gearbox control unit to continuously monitor torque conditions and adjust clutch pressures accordingly. This closed-loop control prevents harmful wear and damage by ensuring clutch pressures are always appropriate for current torque conditions, while maintaining operational simplicity through automated control.
Data Source
AI summary
An arrangement comprising a motor, a transmission, a transmission control unit and an auxillary use. The motor is rotatably connected to the transmission and the auxillary user. The transmission control unit is designed to determine a torque applied to the transmission by using a parameterisable function, wherein the function maps rotational speeds of the motor to a torque applied to the auxillary user at the rotational speed.