Lorry Transmission Module Seamless Gear Shifting
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Solution Overview
Problem
Existing transmission modules for vehicles, such as lorries, lack the ability to switch between gear ratios without interrupting torque transfer, limiting the number of available gear ratios and increasing fuel consumption, especially when shifting from high to low gears on slopes.
Innovation Solution
A transmission module with two clutch parts that can be mutually coupled, allowing seamless switching between 1:1 and higher gear ratios by operating the clutches, incorporating a bypass transmission with a claw or synchromesh clutch that does not dissipate significant power, and featuring a continuously variable transmission element like a push belt or chain variator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional transmission module is used, then the structure is simple, but the number of available gear ratios is limited and torque transfer must be interrupted during shifting
Solution Approach 1:
The transmission module is divided into two independent clutch systems: a primary clutch for traditional gear shifting and a secondary clutch for bypass transmission. This segmentation allows each clutch to handle specific functions, enabling multiple gear ratios without requiring a complete redesign of the entire transmission system.
Solution Approach 2:
The bypass transmission acts as an intermediary mechanism between the engine and the main transmission. By introducing this intermediate path with its own clutch control, the system can achieve additional gear ratios (including direct 1:1 ratio) without disrupting the main transmission's operation.
2Reliability
If gear shifting is performed in traditional transmission, then the structure is simple, but torque transfer is interrupted causing power loss
Solution Approach 1:
The dual-clutch design ensures continuous torque transfer by allowing one clutch to engage while the other disengages. The bypass clutch can be engaged to maintain power flow through the bypass transmission while the main clutch shifts, eliminating torque interruption and ensuring continuous useful action during gear changes.
Solution Approach 2:
The bypass transmission path is pre-configured and ready to engage before shifting is needed. By having the alternative power path prepared in advance with its own clutch mechanism, the system can smoothly transition between transmission paths without interrupting torque transfer to the wheels.
3Ease of manufacture
If the bypass transmission is designed to be cost-effective, then the further clutch cannot dissipate significant power, but this limits the clutch's ability to handle high power shifts
Solution Approach 1:
The clutch system exhibits local quality by having different power dissipation characteristics in different operational modes. The bypass clutch is designed for low-power operations such as synchronizing gear ratios and minor adjustments, while the main clutch handles high-power shifting. This division of labor allows the bypass clutch to be cost-effective while the overall system maintains high power handling capability.
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
Enables twice as many gear ratios as traditional systems, allowing power shifts without torque interruption, reducing fuel consumption by enabling lower RPM operation and efficient power transmission, while maintaining cost-effectiveness and minimizing power loss.
Implementation Method 1
a clutch that includes two clutch parts which can be mutually coupled, a first clutch part of which being capable of coupling to a drive source of a vehicle and the second clutch part of which being capable of coupling to an input shaft of a transmission of the vehicle
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A lorry 1 comprises a combustion engine 3 which is connected via the transmission module 5 to the input shaft 7 of an automatic transmission 9 with switchable gear settings. The output shaft 11 of the transmission 9 is connected to the wheels 15 of the lorry via a differential 13. The transmission module 5 comprises a clutch 17 which has two clutch parts 17A and 17B that can be coupled to each other. The transmission module 5 further comprises a part module 19 which has an input 21 and an output 23. The part module 19 comprises a bypass transmission 25 with three rotational members 27, 29, 31 of which the third rotational member 31 can be coupled to the firm world 35 via a brake 33. With this transmission module it is possible, by operating the clutch and the brake, to switch between a gear ratio of one to one and the gear ration of the bypass transmission without interruption of the torque transfer.