Powertrain Gear Shifting Control for Fuel Efficiency
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Solution Overview
Problem
Operators of work machines like tractors and motor graders often disable automatic shifting to maintain torque, leading to inefficient gear ratios that increase noise and reduce fuel efficiency, as the selected gear ratios may not be the most efficient for the machine's operation.
Innovation Solution
A powertrain system with a user interface that allows operators to select whole number gear identifiers, which correspond to high idle speeds, and an electronic controller that determines optimal gear settings and shifts based on machine parameters like ground speed, to improve operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If automatic shifting is disabled to maintain sufficient torque for overcoming obstacles and traveling on inclines, then machine torque availability is improved, but fuel efficiency deteriorates due to non-optimal gear ratios
Solution Approach 1:
The system dynamically adjusts gear ratios based on real-time operating conditions through automatic shifting control. The controller continuously monitors machine operation and automatically selects optimal gear ratios, eliminating the need for operators to manually disable automatic shifting while maintaining both torque availability and fuel efficiency across varying work conditions.
Solution Approach 2:
The system changes operational parameters (gear ratios) based on detected operating conditions. By monitoring factors such as engine load, speed, and work conditions, the controller adjusts gear ratios to optimize the balance between torque availability and fuel consumption, allowing the machine to adapt to different operational requirements without manual intervention.
2Force
If operators manually select gear ratios to perform machine functions, then torque requirements are met, but operating efficiency deteriorates due to non-optimal gear selection increasing noise and reducing fuel efficiency
Solution Approach 1:
The system implements feedback control by continuously monitoring operating conditions and using this information to automatically adjust gear ratios. The controller receives feedback from sensors monitoring engine parameters, machine speed, and work conditions, then automatically selects optimal gear ratios to maintain both torque requirements and operating efficiency without operator intervention.
Solution Approach 2:
The automatic shifting system performs the gear selection function autonomously based on detected operating conditions. The controller independently determines optimal gear ratios and executes shifts without requiring operator input, allowing the machine to self-optimize its performance for both torque delivery and fuel efficiency across varying work conditions.
3Use of energy by moving object
If varied gear ratios are used to reduce fuel consumption and improve operating efficiency, then fuel efficiency is improved, but operator adaptability deteriorates as operators are unwilling or unable to adjust to new arrangements
Solution Approach 1:
The automatic shifting system autonomously manages gear ratio selection based on operating conditions, eliminating the need for operators to learn or adapt to complex shifting patterns. The controller independently monitors engine parameters and work conditions, then automatically executes optimal gear selections, maintaining fuel efficiency without requiring operator intervention or adaptation.
Solution Approach 2:
The system replaces manual mechanical gear selection with an electronic control system that automatically determines optimal gear ratios. This substitution eliminates the need for operators to physically manipulate shift controls or understand gear ratio optimization, allowing fuel-efficient operation through electronic automation rather than manual mechanical adjustment.
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, and a user interface providing an operator selection of at least two gear identifiers of a whole number. Each whole number gear identifiers corresponds to high idle speeds for respective gear settings. The user interface provides a signal indicative of selected gear identifier to an electronic controller, which also receives and transmits signals indicative of machine parameters. The electronic controller contains computer executable instructions which determine an optimal gear setting and whether a gear shift should be made.