One-Piece Shift Fork with Integrated Magnet Recess
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Solution Overview
Problem
Existing transmission systems with shift units and sensor arrangements for detecting shift fork position are costly, require significant installation space, and face challenges in reliable and precise positioning of sensor components due to assembly tolerances.
Innovation Solution
A transmission system with a one-piece shift fork body made of non-ferritic material, featuring a recess for direct integration of a magnet signal transmitter, and a sensor holder on the transmission housing for precise positioning and protection from splashing oil, along with steel support rings for secure fastening, ensures cost-effectiveness, compact design, and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the signal transmitter is mounted on the shift fork using brackets or support components, then the signal transmitter can be positioned on the shift fork, but the manufacturing cost increases and assembly tolerances accumulate leading to positioning errors
Solution Approach 1:
The signal transmitter is integrated directly into the shift fork body as a single-piece component. The shift fork body includes a recess that receives and positions the signal transmitter without requiring separate brackets or support components. This merging eliminates assembly tolerances and positioning errors while reducing manufacturing complexity and cost.
2Manufacturing precision
If multiple components are assembled to form the shift fork, then the shift fork can be manufactured with specific functions, but assembly tolerances accumulate and hinder precise positioning of the signal transmitter
Solution Approach 1:
The shift fork is manufactured as a one-piece body with the signal transmitter integrated directly into it. The recess in the shift fork body provides precise positioning for the signal transmitter without requiring multiple assembly steps. This eliminates tolerance accumulation and simplifies manufacturing while maintaining functional requirements.
3Ease of manufacture
If the signal transmitter is placed directly adjacent to the shift fork without intermediate components, then manufacturing is simplified and installation space is reduced, but the signal transmitter may be exposed to harmful factors like iron sludge
Solution Approach 1:
The signal transmitter is integrated into the shift fork body with the recess providing both positioning and protection. The recess structure shields the signal transmitter from direct exposure to iron sludge while maintaining compactness and manufacturing simplicity.
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 reduces manufacturing and assembly costs, eliminates assembly tolerances, and ensures precise and reliable detection of shift fork position with reduced risk of measurement errors from iron sludge deposition, while maintaining compactness and durability.
Implementation Method 1
The signal transmitter is a magnet arranged in a recess of the shift fork body
Implementation Method 2
The sensor arrangement is designed as a Hall sensor
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a transmission having a shifting unit (1), wherein the shifting unit (1) comprises a selector fork and a sensor arrangement (2) for detecting a selector fork position. The selector fork has two fork limbs (4, 5) and a fastening region (6) for fastening the selector fork on a selector rail (7), and the sensor arrangement (2) comprises a signal transmitter (8) on the selector fork and a signal pick-up (9) which is arranged fixedly on a transmission housing (10). It is provided that the fork limbs (4, 5) and the fastening region (6) are manufactured together as a single-piece selector fork body (3), and that the selector fork body (3) has a recess (11) for receiving the signal transmitter (8).