High-Output Transmission with Helical Gears and Integrated Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high output transmission systems for vehicles, particularly trucks, face challenges with noise management, structural integrity, and complexity due to the use of steel housings and large countershafts with spur gears, which lead to design limitations and increased costs, as well as complexity in gear timing and integration with multiple system interfaces.
Innovation Solution
The proposed transmission system incorporates an integrated actuator housing with a linear clutch actuator, uses helical gear meshes for thrust management, and employs a low-loss lubrication system with a dry sump, featuring a pair of high-speed countershafts and a planetary gear assembly with helical gears, and eliminates the need for a cooler, allowing for a more compact and lightweight design with reduced noise and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If steel housing and large countershaft with spur gears are used, then structural integrity and noise management are improved, but weight and device complexity increase
Solution Approach 1:
The patent changes the material parameter of the housing from steel to aluminum, fundamentally altering the weight characteristic while maintaining structural integrity through appropriate aluminum alloy selection and design optimization
Solution Approach 2:
The patent replaces traditional spur gears with helical gears, which have curved tooth profiles that engage gradually rather than abruptly, reducing noise and vibration while transmitting power through the countershaft
2Reliability
If steel housing and traditional gear systems are used, then reliability is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent integrates the actuator housing with the transmission housing into a single unified structure, eliminating the need for separate mounting brackets, fasteners, and alignment procedures, thereby reducing assembly complexity while maintaining structural reliability
Solution Approach 2:
The aluminum housing serves multiple functions simultaneously: it provides structural support, acts as a mounting surface for actuators, and serves as part of the lubrication system housing, reducing the need for separate components
3Power
If traditional transmission design is used, then performance is maintained, but weight and space occupation increase
Solution Approach 1:
The patent employs aluminum alloys with specific mechanical properties that provide sufficient strength and durability for high-power transmission applications while maintaining low weight, achieving a favorable power-to-weight ratio
Solution Approach 2:
The patent divides the transmission into modular components including the integrated actuator housing, countershaft assembly, and gear sets that can be independently optimized and manufactured, allowing for weight reduction without sacrificing overall performance
Data Source
AI summary
A transmission includes an input shaft coupled to a prime mover, a countershaft, main shaft, and an output shaft, with gears between the countershaft and the main shaft. A shift actuator selectively couples the input shaft to the main shaft by rotatably coupling gears between the countershaft and the main shaft. The shift actuator is mounted on an exterior wall of a housing including the countershaft and the main shaft. A controller controls the shift actuator utilizing an actuating pulse and an opposing pulse.