Grade-Adaptive Clutch Pressure Control for Transmission Durability
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Solution Overview
Problem
Transmission durability is compromised in duty cycles associated with certain surface grades, necessitating costly equipment and hardware selections, such as large drive units and high axle ratios, which are not optimally addressed by existing systems.
Innovation Solution
A transmission control system that includes an input shaft, output shaft, clutches, and a control system with a sensor to measure surface grade, allowing for selective boosting of fluid pressures and torque limits based on the surface grade, enabling operation in severe duty cycles without the need for additional equipment, thereby enhancing durability and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If standardized transmission components are used, then device complexity and cost are reduced, but transmission durability deteriorates in severe duty cycles with high surface grades
Solution Approach 1:
The transmission control system dynamically adjusts clutch engagement characteristics and torque management parameters based on real-time surface grade detection. The controller modifies operating modes and torque limits adaptively, allowing standardized hardware to perform like upgraded components under severe duty cycles without actual hardware changes.
Solution Approach 2:
The system changes operational parameters (torque limits, clutch engagement pressure, shift points) based on detected surface grade conditions. By detecting high surface grades and adjusting parameters accordingly, the transmission operates within safe limits that prevent durability issues while using standardized components.
2Productivity
If torque limits are increased for severe duty cycles, then productivity is improved, but transmission durability deteriorates due to excessive stress
Solution Approach 1:
The system uses surface grade detection as feedback to dynamically adjust torque limits. When high surface grades are detected, the controller applies appropriate torque limits that balance productivity needs with durability protection. This closed-loop approach ensures torque is optimized for each specific operating condition rather than using fixed conservative or aggressive limits.
Solution Approach 2:
Torque limits are not fixed but dynamically adjusted based on real-time surface grade conditions. The system transitions between different torque management strategies depending on the severity of the duty cycle, allowing maximum productivity when conditions permit and protective limits when durability is at risk.
3Productivity
If clutch engagement characteristics are optimized for high torque, then productivity is improved, but transmission durability deteriorates due to increased stress and heat
Solution Approach 1:
Clutch engagement characteristics are dynamically adjusted based on surface grade detection. The controller modifies engagement pressure, ramp rates, and holding torque adaptively, allowing standardized clutches to handle high torque demands when necessary while protecting against excessive stress and heat generation that would compromise durability.
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 system enhances transmission durability and promotes fuel economy by allowing standardized vehicle setup for severe duty cycles, reducing the necessity for expensive hardware and improving operational efficiency.
Implementation Method 1
The controller may include a sensor configured to provide input indicative of a grade of a surface on which a vehicle is positioned
Implementation Method 2
the controller may appreciably, and selectively, boost the one or more fluid pressures applied to at least one clutch from one or more baseline values to one or more boosted values based at least partially on the input from the at least one input device
Implementation Method 3
The one or more clutches may be coupled between the input shaft and the output shaft to selectively transmit rotational power between the input shaft and the output shaft
Data Source
AI summary
Transmissions, control systems for transmissions, and methods of operating transmissions are disclosed. A transmission includes an input shaft, an output shaft, one or more clutches, and a control system. The input shaft is configured to receive rotational power supplied by a drive unit. The output shaft is coupled to the input shaft and configured to provide rotational power supplied to the input shaft to a load. The one or more clutches are coupled between the input shaft and the output shaft to selectively transmit rotational power between the input shaft and the output shaft in one or more operating modes of the transmission. Each of the one or more clutches is selectively engageable in response to one or more fluid pressures applied thereto. The control system is configured to control operation of the one or more clutches to select the one or more operating modes of the transmission.