Powershift Transmission Output Gear Switching for Idler Bearing Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing powershift transmission systems are prone to rapid bearing defects in the second and fourth idlers due to high speeds at the output shafts, leading to potential failure of the transmission.
Innovation Solution
The solution involves a switching apparatus that securely connects the second output gear to the output shaft of the synchromesh transmission group when the second or fourth idler is coupled, and decouples the second output gear from the output shaft when the first or third idler is coupled, preventing free rotation and overload of the idlers' bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the second idler or fourth idler is coupled when the first or third idler is engaged, then the number of switchable gears is increased, but the bearings of the second and fourth idlers are overloaded due to high speeds, leading to rapid bearing defects and transmission failure
Solution Approach 1:
The patent introduces a switching apparatus as an intermediary component that controls the coupling and decoupling of the second output gear from the output shaft. This mediator prevents direct engagement of overloaded idlers by intercepting the power transmission path before it reaches the vulnerable bearings, thereby protecting the system while still enabling gear switching capability
Solution Approach 2:
The switching apparatus performs preliminary action by decoupling the second output gear from the output shaft before the overloaded idlers can engage. This preventive measure stops the harmful high-speed rotation from occurring in the first place, rather than attempting to protect the bearings after damage has begun
2Device complexity
If the second output gear remains permanently connected to the output shaft, then the structure is simple, but the second and fourth idlers rotate freely at high speeds causing bearing failure
Solution Approach 1:
The patent applies dynamics by making the connection between the second output gear and the output shaft changeable rather than fixed. The switching apparatus enables the system to dynamically adjust the coupling state based on operational requirements, transitioning between connected and decoupled states to optimize both structural simplicity and reliability
Data Source
AI summary
A powershift transmission has a split group with a plurality of powershift stages and an input shaft that can be rotatably driven by a drive shaft of a motorized drive. The input shaft transmits in a stepped-up manner to an output shaft of the split group a rotational movement corresponding to a selected powershiftable stage transmission. A synchromesh transmission group has at least four gear stages and can be rotatably driven by the output shaft of the split group via an intermediate group located therebetween, and via the output shaft of the synchromesh transmission group an axle transmission of the motor vehicle can be rotatably driven. The intermediate group has first and second switching elements each having an output shaft that can be coupled by means of a switchable clutch to an idler. First and second output gears are arranged on the output shaft of the synchromesh transmission group.