Transfer Case Gear Plate with Integral Target Pattern
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Solution Overview
Problem
Current vehicle transfer cases lack precise positional control over internal components, which affects the accuracy of shift system actuation in multi-speed drivetrain systems.
Innovation Solution
A drive gear assembly with an integral target pattern readable by a contactless sensor is introduced, allowing for precise rotational position identification and feedback to optimize shift system actuation. The gear plate includes a target pattern of windows and solid areas that define sectors and zones, interpreted by switches to assign binary codes, enabling accurate positioning and operation of gear reduction and torque transfer mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a contactless sensor with integral target pattern is added to the drive gear assembly, then measurement precision of gear plate position is improved, but device complexity increases
Solution Approach 1:
The target pattern is integrated directly into the gear plate structure, merging the sensing target with the mechanical component. This eliminates the need for separate target components and reduces overall device complexity while maintaining measurement precision.
Solution Approach 2:
The gear plate itself serves dual purposes: it functions as both the mechanical transmission element and the carrier for the target pattern. The gear plate's own structure provides the reference features needed for position sensing, making the system self-sufficient.
2Measurement precision
If multiple switches are added to read the target pattern, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The target pattern is divided into multiple sectors with distinct binary codes, allowing position detection through segmented reading zones. Each sector represents a specific position state, enabling precise multi-position detection without requiring complex continuous measurement systems.
Solution Approach 2:
The system uses binary code representation (0-1 patterns) to encode positional information, transforming continuous positional data into discrete digital states. This parameter transformation simplifies the sensing requirement from measuring continuous position to detecting discrete binary patterns.
3Productivity
If the target pattern includes multiple sectors and zones with binary codes, then productivity of position identification is improved, but manufacturing precision requirements increase
Solution Approach 1:
The target pattern features periodic repetition of sector and zone structures around the gear plate circumference. This periodic arrangement allows the sensor to identify position through repeated binary code patterns, enabling fast position identification through simple pattern recognition rather than complex measurements.
Solution Approach 2:
The binary code pattern is replicated across multiple sectors in a standardized format. This copying approach allows the use of standard manufacturing processes to create the target pattern, reducing the need for high-precision custom fabrication while maintaining identification accuracy.
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 solution enhances the accuracy of shift system actuation by providing precise positional feedback, improving the operational efficiency and reliability of gear reduction and torque transfer mechanisms in vehicle transfer cases.
Implementation Method 1
a sensor that is adapted and positioned to read the target pattern to in each of the positions of the gear plate
Data Source
AI summary
A transfer case is disclosed that includes an input shaft, a primary output shaft, a secondary output shaft, a gear reduction mechanism that selectively couples the input shaft to the primary output shaft in a high range and a low range, a secondary torque transfer mechanism that operates to selectively couple the primary output shaft to the secondary output shaft to engage a four-wheel drive mode, and an actuation mechanism that operates the gear reduction mechanism and the secondary torque transfer mechanism. The actuation mechanism includes a gear plate with an integral target pattern that is rotatable through a plurality of positions corresponding to states of the gear reduction mechanism and the secondary torque transfer, as well as a sensor that is adapted and positioned to read the target pattern to in each of the positions of the gear plate.