Torque Converter Gearbox Heating Through Controlled Clutch Blocking

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Solution Overview

Problem

At lower temperatures, the shifting comfort and efficiency of transmissions are reduced due to the viscosity of transmission oil, and there is a non-homogeneous temperature distribution, which affects wear and useful life of components, making it difficult to deliver sufficient oil to lubrication areas.

Innovation Solution

The method involves selectively actuating clutches in a torque converter to engage different gears, blocking the transmission output, introducing drive power to generate heat through power loss, and controlling the rotation speed of a drive element to increase heat input efficiently, with a rinsing process for homogeneous heat distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the transmission is heated by increasing engine rotation speed and fixing the turbine shaft (prior art), then the transmission oil temperature increases, but the heating process is time-consuming and energy-intensive

Engineering Contradiction:

Improvetransmission oil temperatureVSAvoidheating time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The invention converts the harmful power loss (energy dissipation) in the torque converter into beneficial heat energy for heating the transmission oil. By deliberately creating a controlled power loss through specific clutch engagement patterns, the system generates heat directly within the transmission components, transforming what is typically wasted energy into a useful heating source that quickly raises transmission oil temperature.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The transmission system heats itself by utilizing its own internal power loss mechanisms rather than relying on external heating sources or engine-driven methods. The torque converter's inherent power loss, when strategically controlled through clutch management, serves the dual purpose of normal operation and self-heating, eliminating the need for separate heating systems or prolonged engine idle operations.

Inventive Principle:

Principle #25Self-service

2Temperature

If the transmission is heated by increasing engine rotation speed and fixing the turbine shaft (prior art), then the transmission oil temperature increases, but excessive energy is consumed

Engineering Contradiction:

Improvetransmission oil temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention changes the operational parameters of the transmission system by engaging specific clutches (K1, K2, K3) in predetermined patterns and controlling the drive element's rotation speed within specific ranges. These parameter changes optimize the power loss to heat conversion efficiency, ensuring energy is used effectively for heating rather than being wasted through prolonged high-speed idle operation.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If clutches are actuated to engage different gears and block the transmission output, then heat is generated through power loss, but the transmission must be precisely controlled to avoid damage

Engineering Contradiction:

Improvetransmission temperatureVSAvoidcontrol complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The transmission control unit continuously monitors the state of clutches, rotation speed, and temperature, adjusting the engagement patterns and drive element speed in real-time. This feedback mechanism ensures that the power loss remains within safe limits while generating sufficient heat, automatically preventing overheating or mechanical damage without requiring complex manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention replaces complex mechanical heating mechanisms with a control-system-based approach. Instead of using physical heaters or mechanical agitation devices, the system uses intelligent clutch management and rotation speed control to generate heat through controlled power loss, simplifying the physical hardware while relying on electronic control for precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method quickly and efficiently heats the transmission, ensuring quicker startup and improved shifting comfort and component longevity by achieving a uniform temperature distribution.

Implementation Method 1

in the torque converter a power loss in the form of heat is generated

Methodology Applied

Scientific EffectPower loss conversion: Friction

Data Source

PatentUS11994207B2Method for heating a gearbox

Publication Date: 2024.05.28 ZF FRIEDRICHSAHFEN AG

AI summary

A method for heating a transmission (3) with a torque converter (11), is disclosed. By the selective actuation of clutches (K1, K2, K3, KR, KV) various gears (R1, R2, R3, V1, V2, V3) can be engaged, so that the transmission (3) is blocked on the drive output side, whereby a turbine shaft (12) of the torque converter (11) is immobilized while a drive power is introduced into the transmission (3) by a drive element (2) Blocking the transmission is brought about by actuating the clutches (K1, K2, K3, KR, KV) in such manner that two gears (R1, R2, R3, V1, V2, V3) different from one another in the same driving direction are engaged at the same time.