Hydraulic Synchronizer Eliminates Mechanical Actuation
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Solution Overview
Problem
Conventional synchronizer systems for work vehicles are complex and prone to mechanical failures due to the use of shift rails, forks, and actuation springs, which add weight, complexity, and susceptibility to issues like spring breaking or sticking.
Innovation Solution
A fully hydraulic synchronizer system that eliminates mechanical elements like shift rails and forks, using hydraulic pistons and fluid passages to hydraulically engage and disengage shift collars with gears, with a blocking ring mechanism to ensure proper alignment and engagement, reducing reliance on springs for actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical elements (shift rails, forks, springs) are used in synchronizer systems, then the system can achieve gear engagement and disengagement, but the device complexity and weight increase, and reliability decreases due to susceptibility to mechanical failures
Solution Approach 1:
The patent replaces conventional mechanical actuation elements (shift rails, shift forks, actuation springs) with a hydraulic actuation system. Hydraulic pistons receive hydraulic fluid through fluid passages to move shift collars into engagement and disengagement positions, eliminating the need for mechanical springs and forks that are prone to breaking or sticking.
Solution Approach 2:
The patent employs hydraulic pressure to actuate the synchronizer components. Hydraulic fluid is supplied through fluid passages to hydraulic pistons, which convert hydraulic pressure into linear motion to move the shift collars. This hydraulic approach replaces unreliable mechanical spring-based actuation with a more reliable fluid-powered system.
2Reliability
If conventional mechanical elements (shift rails, forks, springs) are used in synchronizer systems, then the system can achieve gear engagement and disengagement, but the weight of the system increases
Solution Approach 1:
The patent replaces heavy mechanical elements (shift rails, shift forks, actuation springs) with a compact hydraulic actuation system. The hydraulic pistons and fluid passages occupy less space and weigh less than the equivalent mechanical components, thereby reducing overall system weight while improving reliability.
3Device complexity
If hydraulic pistons and fluid passages are used to eliminate mechanical elements, then device complexity and weight are reduced, but the system requires a hydraulic actuation system
Solution Approach 1:
The patent utilizes standard hydraulic components (pistons, fluid passages, hydraulic fluid supply) that are well-established in the industry. These components can be manufactured using conventional hydraulic system fabrication techniques, making the transition from mechanical to hydraulic actuation feasible with existing manufacturing capabilities.
4Reliability
If hydraulic actuation is used to move shift collars, then mechanical failures from springs are eliminated, but hydraulic fluid control mechanisms are required
Solution Approach 1:
The patent employs hydraulic pistons that receive hydraulic fluid through controlled fluid passages. The hydraulic fluid supply system provides pressure-controlled actuation, replacing unreliable mechanical springs with a more dependable hydraulic system that eliminates spring breaking and sticking issues while maintaining manageable complexity through standard hydraulic control mechanisms.
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 simplifies the synchronizer mechanism, reduces weight and complexity, and enhances reliability by eliminating mechanical failures associated with springs, providing efficient and reliable gear engagement and disengagement.
Implementation Method 1
Hydraulic pressure in the first hydraulic chamber acts on the first ring to move the first ring to the first axial position and hydraulic pressure in the second hydraulic chamber acts on the first ring to move the first ring to the first neutral position
Implementation Method 2
First and second hydraulic chambers are configured to receive hydraulic fluid from the at least one fluid passage
Data Source
AI summary
A hydraulic synchronizer selectively couples one or more gears to a drive shaft. The synchronizer has a shaft hub with a splined annulus and a fluid passage. A ring is disposed about the shaft hub and movable along a rotation axis of the shaft hub. A shift collar is fixedly coupled to the ring and has a splined annulus engaged with the splined annulus of the shaft hub. The shift collar is configured to engage splines of a gear when the ring is in an engaged axial position and to disengage the splines of the gear when the ring is in a neutral position. The shift collar transmits rotational input from the shaft hub to the gear when the ring is in the engaged axial position. Hydraulic chambers receive hydraulic fluid from the fluid passage and move the ring to the engaged and neutral positions.