Torque Converter Control for Landfill Compactor Overheating
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Solution Overview
Problem
Landfill compactors experience inefficiency and overheating of the torque converter when operating in second gear transmission ratio due to heavy loading conditions, limiting engine speed for efficient compacting and leading to potential mechanical failures.
Innovation Solution
A control system that activates a manual or automatic mode operation, commanding the torque converter to remain in direct-drive mode during transmission shifts from first to second gear ratio, while limiting engine speed below a predetermined limit to prevent overheating and maintain optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the torque converter is used in second gear transmission ratio for heavy loading conditions, then the machine can operate in second gear for fuel efficiency, but the torque converter overheats and efficiency decreases
Solution Approach 1:
The control system dynamically switches the torque converter between locked and unlocked states based on operating conditions. In second gear under heavy loading, the system locks the torque converter to eliminate fluid coupling and prevent overheating, while allowing it to remain unlocked in conditions requiring torque multiplication, thus resolving the contradiction between fuel efficiency and temperature control
Solution Approach 2:
The system changes the operational parameters of the torque converter by selectively engaging the locking mechanism. This parameter change allows the torque converter to transition from a fluid coupling state (prone to overheating) to a direct mechanical connection state (cooling-efficient), enabling operation in second gear without excessive temperature rise
2Reliability
If the engine speed is limited in second gear to prevent torque converter overheating, then the torque converter efficiency is maintained, but the engine speed limits efficient compacting performance
Solution Approach 1:
The control system dynamically adjusts engine speed limits based on the torque converter state and transmission gear. When in second gear with the torque converter locked, the system applies a speed limit to protect reliability. When the torque converter is unlocked or in other gears, the speed limit is relaxed or removed, allowing full compacting performance. This dynamic adjustment resolves the contradiction between reliability and productivity
3Adaptability or versatility
If the torque converter allows speed variation for torque multiplication, then the machine can handle varying loads, but the torque converter overheats under heavy loading in second gear
Solution Approach 1:
The control system dynamically controls the torque converter locking mechanism based on real-time operating conditions including load demands and transmission gear. Under heavy loading in second gear, the system locks the converter to prevent overheating. Under conditions requiring torque multiplication, the system unlocks the converter to maintain adaptability. This dynamic control resolves the contradiction between load adaptation and temperature control
Data Source
AI summary
A machine having a powertrain including an engine operably connected to a torque converter and a transmission. The machine includes a control system receive an activation signal indicative of an automatic mode operation of the machine and command the torque converter to remain in a direct-drive mode while the transmission shifts from a first gear ratio to a second gear ratio. The control system also limits engine speed below a first engine speed limit when a gear ratio setting of the transmission is indicative of the second gear ratio.