Sensor-Guided Gear Engagement in Transmission Clutch Mechanisms
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Solution Overview
Problem
Existing transmission mechanisms in vehicle transmissions often experience jamming or delayed engagement due to improper alignment of gear teeth, leading to noise and torque loss during shifting operations.
Innovation Solution
A transmission mechanism with a movable gear and a fixed gear that uses a clutch unit and sensor device to ensure a reliable, quick, and low-noise engagement by detecting the absolute angular relationship between the gear teeth, allowing precise control of the clutch unit to maintain a tooth-on-tooth-gap position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clutch unit is used to connect the movable gear to the transmission shaft, then the engagement can be controlled, but the alignment precision between gear teeth and clutch toothing is insufficient, causing jamming or delayed engagement
Solution Approach 1:
The sensor device detects the angular position of the movable gear relative to the transmission shaft before engagement occurs, and the control unit calculates the required rotation angle in advance. The clutch unit is then actuated to rotate the movable gear by this pre-calculated angle, ensuring that the gear teeth and clutch toothing align perfectly in the tooth-on-tooth-gap position before the connection is made. This preliminary detection and calculation eliminates jamming and delayed engagement.
2Productivity
If the clutch unit is actuated quickly to reduce shifting time, then productivity improves, but the alignment between gear teeth may be improper, causing noise and torque loss
Solution Approach 1:
The sensor device continuously monitors the angular position of the movable gear and provides feedback to the control unit. The control unit uses this feedback to calculate the precise rotation angle needed to achieve the tooth-on-tooth-gap position, and actuates the clutch unit accordingly. This closed-loop feedback control ensures that even during quick shifting operations, the gear teeth align properly, preventing noise and torque loss while maintaining high productivity.
3Manufacturing precision
If the sensor device and control unit are added to detect angular position, then engagement precision improves, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment mechanisms with a sensor-based detection system and electronic control unit. Instead of using multiple mechanical stops, guides, or adjustment mechanisms to achieve precise angular positioning, the system uses a sensor to detect the angular position and an electronic control unit to calculate and actuate the precise rotation angle. This substitution of mechanical systems with sensing and electronic control achieves high precision while actually reducing overall mechanical complexity.
Data Source
AI summary
The disclosure relates to a transmission mechanism with at least two gearwheels that can be brought into form-fitting engagement with one another. One of the gearwheels is designed as a movable gear and, in a disengaged position, is arranged in a freely rotatable manner on a transmission shaft. The other of the gearwheels is designed as a fixed gear and is arranged non-rotatably on a further transmission shaft, the movable gear is connectable non-rotatably to the transmission shaft by a clutch unit and at least one transmission gear can be engaged if a clutch toothing of the clutch unit engages in a form-fitting manner in a toothing of the movable gear in a tooth-on-tooth-gap position. A sensor device detects a rotational speed signal incoming into the other transmission shaft and a rotational speed signal outgoing from the transmission shaft.