Outboard Shift Lever Control With Damper-Assisted Manual Override
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Solution Overview
Problem
Existing engine control systems for outboard motors with tiller handles face difficulties in shift operation due to high frictional resistance, which restricts movement and can lead to operational challenges, especially when the electrical system malfunctions.
Innovation Solution
An engine control apparatus comprising a lever member, output gear, motor, potentiometer, shift arm, and reduction gear mechanism, along with a damper unit that allows rotation of the input shaft without the output gear when the lever moves by a predetermined angle, enabling shift operation without torque sensors and maintaining functionality during electrical malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a force transmission member such as a push-pull cable is used to transmit force from the lever member to the shift mechanism, then the shift operation can be performed mechanically, but the operation portion cannot be easily operated when frictional resistance is large
Solution Approach 1:
The patent replaces the pure mechanical force transmission system with an electromechanical system. A torque sensor detects the operator's input torque on the lever member, and an actuator (motor) converts this electrical signal into mechanical force to drive the shift mechanism. This substitution eliminates the need for high-force mechanical cable transmission, allowing easy operation even when mechanical friction is high.
2Ease of operation
If a torque sensor and actuator are used to electrically detect and drive the force transmission member, then the operation becomes easier, but the control system becomes complicated and cost increases
Solution Approach 1:
The patent integrates multiple functions into existing components. The torque sensor serves dual purposes: detecting operator input for actuator control and providing feedback for control unit decisions. The actuator not only drives the shift mechanism but also can be controlled to assist or override manual operation. This multi-functionality reduces the need for additional dedicated components, simplifying the overall control system while maintaining ease of operation.
Solution Approach 2:
The control unit automatically determines the appropriate control mode (manual or actuator-assisted) based on detected torque conditions, without requiring complex external control logic. The system self-regulates by comparing detected torque against predetermined thresholds and autonomously selecting the optimal operation mode, reducing control system complexity while maintaining ease of use.
3Ease of operation
If electric detection with torque sensor is used, then operation assistance is achieved, but shift operation cannot be performed when actuator is inoperative due to electrical system malfunction
Solution Approach 1:
The patent creates distinct operational zones or modes: a manual operation mode for when the actuator is inoperative, and an actuator-assisted mode for normal operation. The system adapts its characteristics locally based on the operational context, allowing the shift mechanism to be operated manually through the force transmission member when electrical systems fail, while providing electrical assistance when available. This ensures reliability across different operational conditions.
Solution Approach 2:
The patent designs the system with built-in redundancy where the manual mechanical force transmission path remains intact and functional even when the electrical actuator system fails. The control unit is programmed to detect actuator inoperability and automatically switch to manual control mode, providing a backup operation path that cushions against electrical system failures and maintains shift operation capability.
4Force
If the lever member is restricted in movement due to large frictional resistance, then mechanical force transmission is maintained, but the operation portion cannot be easily operated
Solution Approach 1:
The patent replaces the direct mechanical force transmission that causes friction-related movement restrictions with an electromechanical system. The torque sensor detects the operator's input, and the actuator provides the necessary mechanical force to overcome frictional resistance in the force transmission member, allowing smooth operation of the lever without being constrained by mechanical friction limits.
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 apparatus assists shift operations using motor torque, allowing for smooth shift changes and maintaining motor control without relying on torque sensors, ensuring reliable operation even in case of electrical system failures.
Implementation Method 1
a frictional resistance is large when the force transmission member moves. Therefore, the operation portion cannot be easily operated in some cases.
Implementation Method 2
The force transmission mechanism includes a damper unit. When the lever member moves by a predetermined angle or less from the neutral position, the damper unit deforms. Thus, rotation of the input shaft is allowed in a state where the output gear stops.
Implementation Method 3
The motor rotates in a first rotational direction and a second rotational direction... the motor output... assisting the shift operation
Implementation Method 4
The reduction gear mechanism transmits rotation of the motor to the shift arm driving gear
Implementation Method 5
When the lever member moves by a predetermined angle in the first direction, the potentiometer outputs a signal causing the motor to rotate in the first rotational direction
Data Source
AI summary
An engine control apparatus includes a lever member, an input shaft, a potentiometer, an output gear, a motor, a shift arm, a reduction gear mechanism, and a force transmission mechanism. The force transmission mechanism includes a damper unit. When the lever member moves in a first direction or a second direction, the motor rotates based on an output of the potentiometer. The rotation of the motor is transmitted to the shift arm via the reduction gear mechanism. This moves the shift arm to a forward-side shift positon or a backward-side shift position. When the lever member is located within a predetermined angle from the neutral position, the damper unit deforms in a state where the output gear stops. This allows the rotation of the input axis.