Hydraulic Controller for Vehicle Gearbox Actuator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydraulic control systems for vehicle gearboxes are inefficient in managing the actuating force of hydraulic actuators, particularly in overcoming play and applying the necessary force for gear changes, due to the limitations in pressure regulation and volume flow between high-pressure and low-pressure circuits.
Innovation Solution
A hydraulic control system with a directional valve having multiple control positions and valve ports, allowing selective connection of high-pressure and low-pressure lines to the oil supply and return ports, enabling efficient pre-charging and force regulation by utilizing high-pressure and low-pressure hydraulic pumps in a dual-flow configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a single high-pressure hydraulic circuit is used to actuate clutches and brakes, then the actuating force is sufficient for gear changes, but the system cannot quickly overcome play and requires high energy consumption
Solution Approach 1:
The hydraulic circuit is segmented into two distinct circuits: a high-pressure circuit for generating actuating force and a low-pressure circuit for quickly overcoming play. This segmentation allows each circuit to be optimized for its specific function, reducing overall energy consumption while maintaining sufficient actuating force for gear changes.
Solution Approach 2:
The low-pressure circuit performs preliminary action by quickly overcoming play and positioning the clutch or brake before the high-pressure circuit applies the main actuating force. This preliminary action reduces the energy required by the high-pressure circuit, as it only needs to overcome the remaining resistance rather than starting from a cold state.
2Force
If a single high-pressure hydraulic circuit is used, then gear change force is adequate, but the response time to overcome play is slow
Solution Approach 1:
The hydraulic system is divided into two circuits with different pressure characteristics. The low-pressure circuit is dedicated to quickly overcoming play, while the high-pressure circuit provides the necessary force for gear changes. This segmentation enables both fast response and adequate force to be achieved simultaneously.
Solution Approach 2:
The low-pressure circuit performs the preliminary action of overcoming play before the high-pressure circuit engages. This sequence of operations ensures that when the high-pressure circuit activates, the clutch or brake is already positioned correctly, reducing the time required for the gear change operation.
3Productivity
If separate high-pressure and low-pressure circuits are used, then efficiency is improved, but the device complexity increases
Solution Approach 1:
The control valve integrates multiple functions into a single component: it controls both the high-pressure and low-pressure circuits, manages the directional flow of hydraulic medium, and coordinates the sequencing between the two circuits. This merging reduces the overall number of separate control components needed, thereby reducing system complexity while maintaining the efficiency benefits of dual circuits.
Solution Approach 2:
The control valve is designed as a multi-functional component that handles both high-pressure and low-pressure flow control, as well as directional control for both circuits. This universal design approach allows a single component to perform multiple functions that would otherwise require separate devices, reducing the overall complexity of the hydraulic control system.
4Force
If high-pressure hydraulic medium is used immediately, then actuating force is applied quickly, but energy is wasted overcoming play instead of performing useful work
Solution Approach 1:
The low-pressure circuit performs the preliminary action of overcoming play before the high-pressure circuit applies the main actuating force. This sequencing ensures that energy is not wasted by applying high pressure to overcome play, but rather that the high-pressure medium is used efficiently once the clutch or brake is properly positioned.
Solution Approach 2:
The hydraulic system segments the energy application process into two phases: a low-pressure phase for overcoming play and a high-pressure phase for performing useful work. This segmentation ensures that each pressure level is used for its appropriate function, maximizing energy efficiency while maintaining quick response time.
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
This configuration enhances the efficiency of the hydraulic control system by allowing quick pre-charging with low-pressure fluid and subsequent high-pressure actuation, effectively overcoming play and applying the required actuating force, thereby improving the overall operational reliability and efficiency.
Implementation Method 1
a first hydraulic line 7 for conducting the hydraulic medium at high pressure from a high-pressure hydraulic pump 2a to the control valve 1 and a second hydraulic line 6 for conducting the hydraulic medium at low pressure from a low-pressure hydraulic pump 2b to the control valve 1
Implementation Method 2
the control valve (1) has a first control position 1.1 for connecting the first hydraulic line (7) to the oil supply port (5) and a second control position 1.2 for connecting the second hydraulic line (6) to the oil supply port (5)
Data Source
AI summary
A hydraulic controller for a vehicle gearbox is provided. The controller includes a hydraulic actuator which has an oil supply port, a high-pressure hydraulic pump for providing a feed to a high-pressure line, a low-pressure hydraulic pump for providing a feed to a low-pressure line, a hydraulic reservoir for receiving the hydraulic medium from a return line, and a hydraulic control valve. The control valve includes at least three control positions and at least four valve ports. In a first control position, the high-pressure line is fluidly connected to the oil supply port for the regulation of the actuating force of the hydraulic actuator. In a second control position, the low-pressure line is fluidly connected to the oil supply port for the pre-charging of the hydraulic actuator. In a third control position, the hydraulic actuator is fluidly connected to the return line for the return of the hydraulic medium.