Modular Gear Actuator for Double Clutch Transmission

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Solution Overview

Problem

Conventional gear actuators for double clutch transmissions face issues such as complex assembly processes, increased assembly time, wiring connection failures, and reduced fuel efficiency due to misaligned gears and low operation efficiency of the lead screw, along with a complicated structure and high power consumption.

Innovation Solution

A modularized gear actuator design that integrates select solenoids, shift motors, and a controller into a single power module, eliminating the need for individual wirings and connectors, and using a ball screw mechanism to transmit rotational force directly, reducing the number of components and simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If select solenoids, shift motors, and controllers are provided as individual parts with separate wirings, then the gear actuator can be controlled independently for each stage, but the assembly process becomes complicated and assembly time increases

Engineering Contradiction:

ImproveIndependent control capabilityVSAvoidAssembly process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple individual components (select solenoids, shift motors, controllers, and wirings) into an integrated modular unit. This integration maintains the independent control capability for each stage while simplifying the assembly process by reducing the number of separate parts and connection points.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple wirings and connectors are used to connect solenoids and motors to controllers, then individual control is enabled, but connection failures and welding defects occur frequently

Engineering Contradiction:

ImproveIndividual control capabilityVSAvoidConnection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent integrates the electrical connections internally within the modular unit, eliminating the need for multiple external wirings and connectors. This internal integration maintains individual control capability while significantly improving connection reliability by removing vulnerable connection points prone to welding defects and connection failures.

Inventive Principle:

Principle #5Merging (Combining)

3Force

If reduction gearing is used to transmit rotational force from shift motor to lead screw, then torque is increased, but operating noise occurs and power consumption increases

Engineering Contradiction:

ImproveTorque transmissionVSAvoidPower consumption

Core Design Contradiction:

ForceVSLoss of energy

Solution Approach 1:

The patent removes the reduction gearing from the power transmission path, directly connecting the shift motor to the lead screw. This extraction eliminates the source of operating noise and reduces power consumption while maintaining sufficient torque through direct drive.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If lead screw mechanism is used to transmit shift operating force, then linear motion is achieved, but operation efficiency is low and power consumption increases

Engineering Contradiction:

ImproveLinear motion capabilityVSAvoidPower consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The patent replaces the traditional lead screw mechanism with a ball screw mechanism. This substitution maintains the linear motion capability while significantly improving operation efficiency and reducing power consumption through reduced friction between the ball bearing and screw threads.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 design simplifies the assembly process, enhances operational stability, reduces power consumption, and improves fuel efficiency by eliminating the need for reduction gearing and minimizing wiring-related issues, resulting in a more compact and reliable gear actuator.

Implementation Method 1

using a ball screw mechanism to transmit rotational force directly

Methodology Applied

Scientific EffectBall screw mechanism: Screw

Implementation Method 2

select solenoids, and shift motors directly to control shafts of the control shaft assembly

Methodology Applied

Scientific EffectSolenoid: Solenoid

Implementation Method 3

select solenoids, and shift motors directly to control shafts of the control shaft assembly

Methodology Applied

Scientific EffectElectric motor: Linear Motor

Data Source

PatentUS10704681B2Gear actuator for double clutch transmission

Publication Date: 2020.07.07 HYUNDAI DYMOS

AI summary

Disclosed herein is a gear actuator for a double clutch transmission, which includes a power module (100), including odd and even-numbered stage select solenoids and shift motors, a controller directly connected to them, and select levers connected to select rods of the select solenoids, shift modules (200) for transmitting the rotational forces of the shift motors to a control shaft assembly (300), the control shaft assembly (300) for transmitting the operating force of the power module (100) to a shift lug, and a body housing (400) having the power module (100), the shift modules (200), and the control shaft assembly (300) installed therein. Accordingly, the gear actuator can have a more compact structure and be easily assembled by modularization.