Powertrain Gear Shift Efficiency Control
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Solution Overview
Problem
Existing powertrain systems for work machines, such as tractors and motor graders, often operate inefficiently due to operator-selected gear ratios that may not be optimal for fuel efficiency, leading to increased noise and reduced fuel efficiency, even when automatic shifting is disabled for tasks like overcoming obstacles or traveling on inclines.
Innovation Solution
A powertrain system with an electronic controller that determines and compares efficiency metrics for current and alternative gear settings, recommending or performing gear shifts to optimize efficiency while maintaining desired ground speed and work output, using a multi-gear power-shift transmission connected to an engine and torque converter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If operator selects gear ratio for sufficient torque to overcome obstacles, then machine has sufficient torque for operational demands, but fuel efficiency is reduced and noise increases
Solution Approach 1:
The system dynamically adjusts gear ratios based on real-time operating conditions rather than using fixed operator-selected gears. The electronic controller continuously monitors machine parameters and automatically shifts gears to maintain optimal efficiency while ensuring sufficient torque is available when needed for operational demands.
Solution Approach 2:
The system changes the gear ratio parameter dynamically based on operating conditions. By continuously adjusting the gear ratio parameter according to real-time machine parameters and efficiency metrics, the system optimizes the balance between torque availability and fuel efficiency.
2Force
If automatic shifting is disabled to ensure sufficient torque, then machine has sufficient torque for tasks like overcoming obstacles, but the machine operates inefficiently at non-optimal gear ratios
Solution Approach 1:
The system performs self-service by automatically monitoring its own operating conditions and making gear selection decisions without operator intervention. The electronic controller assesses machine parameters and efficiency metrics, then automatically selects optimal gear ratios to maintain both sufficient torque and high operating efficiency.
Solution Approach 2:
The system uses feedback from machine parameters and efficiency metrics to continuously adjust gear ratios. The electronic controller receives feedback about current operating conditions and efficiency performance, then automatically shifts gears to optimize the balance between torque availability and operating efficiency.
3Ease of operation
If operator selects gear ratio for specific task, then machine can perform the task, but overall fuel efficiency is reduced
Solution Approach 1:
The system dynamically adjusts gear ratios based on real-time operating conditions rather than using fixed operator-selected gears. The electronic controller continuously monitors machine parameters and automatically shifts gears to maintain optimal efficiency while ensuring sufficient torque is available when needed for operational demands.
4Speed
If multiple gear ratios are available for desired groundspeed, then machine can maintain desired ground speed, but operator selection may not be the most efficient resulting in increased noise
Solution Approach 1:
The system changes the gear ratio parameter dynamically based on operating conditions. By continuously adjusting the gear ratio parameter according to real-time machine parameters and efficiency metrics, the system optimizes the balance between torque availability and fuel efficiency.
Data Source
AI summary
A machine has a power train including a prime mover connected to a transmission having two or more selectable gear settings. The machine includes an electronic controller configured to receive and transmit signals indicative of machine parameters. The electronic controller contains computer executable instructions for determining a current value for at least one efficiency metric of the machine at a current gear setting of the transmission. Instructions for determining a first expected value for the efficiency metric at a first alternative gear setting, instructions for comparing the current value with the first expected value to determine an optimal gear setting as between the current gear setting and the first alternative gear setting at least partially based on engine speed, and instructions for indicating a gear shift recommendation and/or performing a gear shift to select the optimal gear setting are executed during operation.