Transfer Case Torque Determination via Housing Deformation
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Solution Overview
Problem
Existing methods for determining effective output torques in transfer cases are complex, prone to interference, and do not allow for precise load distribution monitoring, which is crucial for optimizing rolling processes and maintaining transmission components.
Innovation Solution
The method involves determining the deformation of the transfer case housing to calculate effective output torques using known functional relationships, allowing for precise measurement and regulation of load distribution between outputs, thereby enabling more stable and cost-effective monitoring and control of rolling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If torque measurements are performed on rotating output and drive shafts, then load distribution can be determined, but the measurement system becomes complex and susceptible to interference
Solution Approach 1:
The patent introduces housing deformation as an intermediary parameter to indirectly measure output torque. Instead of directly measuring torque on rotating shafts, strain gauges measure deformation of the stationary housing, which serves as a mediator between the rotating components and the measurement system. This eliminates the need for complex rotating measurement apparatus while maintaining measurement capability.
Solution Approach 2:
The patent replaces the mechanical torque measurement system on rotating shafts with a deformation measurement system on the stationary housing. By using strain gauges to measure housing deformation and converting this to torque values through calibration, the system substitutes a simple electrical measurement for a complex mechanical measurement, reducing device complexity and susceptibility to interference.
2Reliability
If traditional torque measurement methods are used on rotating parts, then load distribution data can be obtained, but the system becomes unstable and maintenance-intensive
Solution Approach 1:
The housing deformation measurement acts as a stable intermediary that does not rotate, eliminating the instability and interference problems associated with measurements on rotating parts. The strain gauges are mounted on the stationary housing, providing a reliable and maintenance-free measurement system that continuously monitors load distribution without being affected by rotation.
3Device complexity
If deformation measurement of transfer case housing is used, then measurement complexity is reduced and stability is improved, but additional sensors and calibration requirements are introduced
Solution Approach 1:
The patent performs calibration during the manufacturing process, establishing the functional relationship between housing deformation and output torque before the product is put into service. This preliminary action of calibrating the strain gauge readings against known torque values creates a lookup table or calibration curve that simplifies subsequent measurements, eliminating the need for complex real-time calculations or additional calibration steps during operation.
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 approach provides more precise, stable, and cost-effective determination of effective output torques, enabling continuous monitoring and optimization of load distribution, reducing the risk of overloading and improving the condition assessment of transmission components.
Implementation Method 1
For this purpose, it is provided by way of example with strain gauges 38
Implementation Method 2
determining the deformation of the housing of the transfer case; determining the effective output torque of the first output using a previously known functional relationship based on the determined deformation of the housing
Data Source
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Figure 2
AI summary
The invention relates to a method for determining the effective output torques of at least two outputs of a transfer case. To perform this determination in a stable, maintenance-friendly, reliable, and cost-effective manner, the method according to the invention comprises the following steps: determining the deformation of the housing 36 of the transfer case 30 and determining the effective output torque MVab1 of the first output 32 of the transfer case using a known functional relationship 40 based on the previously determined deformation of the housing 36. Optionally, the effective output torque MVab2 of the second output of the transfer case 34 can also be determined as the difference between the input torque MVein supplied to the transfer case 30 and the effective output torque MVab1 of the first output 32.