Sealed Gearbox Actuator Unit for Compact Shift Fork Actuation
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Solution Overview
Problem
Existing gearboxes with electric actuators face challenges in achieving a compact construction, long service life, and simple, rapid installation, while also requiring protection from contaminants and oil within the gearbox environment.
Innovation Solution
A gearbox actuator unit with a housing that seals the gearbox housing, incorporating a control device and actuator within a compact, fluid-tight arrangement, using a BLDC motor and pinion to actuate a shift fork, with cooling fins and a transmission for precise activation, and a radial shaft seal to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control device and actuator are integrated within a sealed housing attached to the gearbox, then protection from contaminants and fluid-tight sealing is improved, but device complexity increases
Solution Approach 1:
The control device and actuator are merged into a single integrated unit housed within a common housing that attaches to the gearbox. This consolidation provides unified protection from contaminants while reducing the number of separate components and mounting operations required
Solution Approach 2:
The housing serves multiple functions simultaneously: it protects the control device and actuator from contaminants, provides fluid-tight sealing against gearbox oil, and attaches the entire assembly to the gearbox. This multi-functionality reduces the need for additional protective structures
2Reliability
If the housing is designed to seal the gearbox and attach to the gearbox housing, then fluid-tight sealing is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is divided into a first housing portion and a second housing portion that can be manufactured separately and then assembled together. This segmentation allows each portion to be optimized for its specific manufacturing process while maintaining the overall fluid-tight sealing capability through proper joining methods
3Productivity
If the actuator is pre-assembled with the control device in a housing, then installation speed is improved, but device complexity increases
Solution Approach 1:
The control device and actuator are pre-assembled within the housing before installation into the gearbox. This preliminary assembly allows for quality control and testing to be performed on the complete actuator unit before it is mounted, ensuring proper function while reducing installation time to a single mounting operation
4Temperature
If cooling fins are added to the housing, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The housing is designed to serve both as a protective enclosure and as a heat dissipation structure through the integration of cooling fins. This multi-functionality allows the same structural component to perform thermal management without requiring separate cooling apparatus
Solution Approach 2:
Cooling fins are added to specific portions of the housing where heat dissipation is most needed, particularly in regions that contact the control device or actuator components that generate heat. This localized approach provides effective cooling while minimizing the overall structural complexity
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
The solution provides a compact, long-lasting gearbox actuator unit that can be easily installed, protecting components from contaminants and oil, and ensures rapid, precise gear shifting with reduced material and installation space requirements.
Implementation Method 1
The actuator comprises an electric motor and a pinion. The electric motor is advantageously formed as a BLDC motor, brushless DC motor, or brushless direct-current motor.
Implementation Method 2
a radial shaft seal to prevent contamination
Implementation Method 3
The actuator provides a mechanical movement suitable for shifting gears in the gearbox. In particular, the actuator comprises an electric motor and a pinion. A rotational movement of the pinion provides an axial linear movement of the shift fork.
Data Source
AI summary
A gearbox actuator unit (14) is configured to be arranged on a gearbox (10) and includes a housing (22), a control device (24), and an actuator (28, 30). The housing (22) is configured to attach to a gearbox housing (12) and to seal the gearbox housing (12). The control device (24) is electrically connected to the actuator (28, 30) and activates the actuator (28, 30). A pinon of the actuator (28, 30) is configured to actuate a rack of a shift fork (18, 20) of the gearbox (10) and can be connected to the shift fork (18, 20) of the gearbox (10). The control device (24) and the actuator (28, 30) are arranged within the housing (22), with the pinion extending through an opening of the housing. A gearbox (10) with a housing (12) having an opening (44) receives the actuator unit (14), which closes and seals the opening (44).