Synchronous Engaging Device Damage Index Control
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Solution Overview
Problem
Conventional methods for detecting gear whine in synchronous engaging devices only determine the presence of gear whine based on differential rotation speed and cannot accurately assess the degree of damage, leading to improper disabling or replacement of gears.
Innovation Solution
A control unit that calculates a damage determination index based on differential rotation speed between the input and output rotations after synchronization completion, allowing for precise assessment of damage and appropriate measures such as disabling gears or recommending part replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If gear whine detection is performed only based on differential rotation speed threshold, then gear whine occurrence can be detected, but the degree of damage cannot be accurately assessed leading to improper gear disabling or replacement
Solution Approach 1:
The patent changes the parameter from simple binary detection (gear whine present/absent) to multi-level assessment by introducing a damage determination index that quantifies the severity of gear whine based on differential rotation speed magnitude and duration. This allows the system to distinguish between minor wear requiring monitoring and severe damage requiring immediate gear disabling or replacement.
Solution Approach 2:
The patent adds a new dimension to gear whine detection by introducing the damage determination index as a quantitative measure. Instead of only detecting presence/absence of gear whine, the system now assesses the degree of damage through this index, enabling more nuanced decision-making regarding gear usage and replacement timing.
2Productivity
If continuous operation in gear whine state is allowed to maintain productivity, then production efficiency is improved, but damage to synchronous engaging device parts increases
Solution Approach 1:
The patent implements dynamic gear management where the system continuously monitors the damage determination index and adjusts gear usability in real-time. Instead of static disablement upon first gear whine detection, the system allows continued operation when the index remains below thresholds, and only disables or recommends replacement when the index exceeds predetermined limits, thus balancing productivity with reliability.
Solution Approach 2:
The patent establishes a feedback mechanism where the damage determination index is continuously calculated from differential rotation speed data and used to adjust operational parameters. The system provides feedback on gear condition status and automatically implements control measures (continuation, disabling, or replacement recommendation) based on the feedback from the damage index, creating a closed-loop system that manages the trade-off between productivity and reliability.
3Reliability
If gear disabling is performed frequently to prevent damage, then device reliability is improved, but unnecessary gear unavailability increases affecting productivity
Solution Approach 1:
The patent introduces quantitative thresholds for the damage determination index that determine when gear disabling should occur. Instead of disabling gears based on simple occurrence counts, the system uses predetermined threshold values of the damage index to make informed decisions, allowing gears to remain in service as long as the damage level remains acceptable, thus minimizing unnecessary productivity loss while maintaining reliability.
Data Source
AI summary
When a synchronizing sleeve that is driven by an actuator in response to gear shift request is stroked from a release position to an engagement position, a differential rotation speed between an input rotation and an output rotation is calculated at stroke positions after a synchronization completion position; and when the said differential rotation speed is equal to or more than a predetermined threshold value, a damage determination index is calculated based on the said differential rotation speed. Further, when a cumulative value of the damage determination index accumulated for each gear position becomes equal to or more than a predetermined threshold value, the engagement operation of the gear position corresponding to the said cumulative value is disabled. This makes it possible to effectively determine the degree of damage when a gear whine occurs to a synchronized engaging device.