Manual Shift Lever Cam Lock for High-Speed Downshift Blocking
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Solution Overview
Problem
Conventional manual transmissions are prone to overload and contamination due to exposed components, leading to potential damage and noise generation when drivers shift to lower gears at high speeds, and are susceptible to external contaminants affecting the solenoid actuator.
Innovation Solution
A manual shift lever system with a shift lock unit that includes a main cam, sub-cam, spring, permanent magnet, and electromagnet, which limits gear shifting by comparing vehicle speed to a critical speed, preventing movement to lower gears at high speeds and sealing the electromagnet to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the shaft is exposed to the outside for operation, then the shift lock cam can be operated easily, but the solenoid actuator is easily contaminated by external contaminants such as moisture
Solution Approach 1:
The shaft is nested within the housing, which is filled with grease to protect it from external contaminants. The shift lock cam is nested within the shaft, allowing it to rotate along with the shaft while being protected from moisture and other contaminants that could cause corrosion or malfunction.
Solution Approach 2:
The housing acts as a protective shell that encloses the shaft and shift lock cam, isolating them from the external environment. The grease-filled housing serves as a barrier against moisture and contaminants, preventing corrosion and ensuring reliable operation of the internal components.
2Ease of operation
If the solenoid actuator is exposed to the outside, then it can be operated directly, but loud noise is generated due to its operation
Solution Approach 1:
The solenoid actuator is nested within the housing, which is filled with grease. This nesting arrangement allows the solenoid actuator to be operated directly while the grease-filled housing absorbs and dampens the noise generated during operation, reducing the loud noise that would otherwise be produced.
Solution Approach 2:
The grease-filled housing serves as an intermediary between the solenoid actuator and the external environment. It mediates the noise generated by the solenoid actuator, absorbing and dampening the sound waves, thereby reducing the noise level while still allowing the solenoid actuator to be operated directly.
3Adaptability or versatility
If the driver shifts to a lower gear at high speed, then the driver can change gears as needed, but overload is added to the manual transmission and it may be damaged
Solution Approach 1:
The system performs a preliminary check of the vehicle speed before allowing gear shifting to lower gears. When the vehicle speed exceeds a predetermined threshold, the shift lock cam prevents shifting to lower gears, thereby preventing overload and potential damage to the transmission before it can occur.
Solution Approach 2:
The shift lock cam applies a preliminary anti-action by mechanically blocking the shift lever from moving to lower gears when the vehicle speed is too high. This prevents the driver from attempting to shift to lower gears under conditions that would cause overload, thereby protecting the transmission from damage.
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
Prevents gear shifting to lower gears at high speeds, reducing the risk of overload and damage, while maintaining system integrity by limiting movement and sealing the electromagnet from external contaminants.
Implementation Method 1
an electromagnet 340 disposed adjacent to the permanent magnet 320 and arranged to have a polarity arrangement opposite to that of the permanent magnet 320
Implementation Method 2
a spring 216 which connects the main cam 212 and the sub-cam 214
Data Source
AI summary
A manual shift lever system may be provided that includes: a shift lever which includes a rod and a stopper formed on the rod; a shift lock unit which limits a movement of the rod; and a control unit which, when a speed of a vehicle is greater than a critical speed of a predetermined gear limits the movement of the rod in a shift direction of the predetermined gear. The shift lock unit includes: at least one shift lock cam part including a main cam, a sub-cam, a shaft which functions as a rotating shaft of the main cam and the sub-cam, and a spring which connects the main cam and the sub-cam; a permanent magnet which is connected to the shift lock cam part; and an electromagnet arranged to have a polarity arrangement opposite to that of the permanent magnet.