Virtual Clutch Temperature Gauge for Predictive Transmission Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-output transmission systems for vehicles, particularly trucks, face challenges with noise management, structural integrity, and complexity due to the use of steel housings and complex gear systems, which lead to increased weight, design complexity, and integration issues.
Innovation Solution
The introduction of a virtual clutch temperature gauge system that calculates clutch temperature and provides control actions based on this data, integrated with a lightweight aluminum housing and a low-loss lubrication system, using helical gear meshes to manage thrust loads and reduce noise, and employing a linear clutch actuator with near-zero dead air volume for efficient actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel housing and complex gear systems are used in high-output transmissions, then structural integrity and noise management are improved, but weight and device complexity increase
Solution Approach 1:
The patent applies composite materials by combining aluminum housing with strategically placed steel components (gears, shafts, bearings) to achieve optimal strength-to-weight ratio. The aluminum housing provides lightweight structure while steel internal components handle high-load areas, resolving the contradiction between overall weight reduction and localized structural integrity requirements.
2Strength
If steel housing and high strength spur gears are used, then structural integrity and load handling are improved, but device complexity and design time increase
Solution Approach 1:
The patent applies local quality by using steel materials and complex gear designs only in specific high-load areas (gears, shafts, bearings) while using aluminum for the housing and less critical components. This localized application of high-strength materials and complex designs reduces overall device complexity while maintaining load handling capability where needed.
3Adaptability or versatility
If multiple interfaces (electrical, air, hydraulic, coolant) are included, then system functionality is improved, but design expense and failure points increase
Solution Approach 1:
The patent applies merging by integrating multiple interface functions into unified systems. For example, the clutch actuator integrates electrical control with pneumatic actuation, and the lubrication system combines cooling and lubrication functions. This reduces the number of separate interfaces and connections required, thereby reducing integration complexity and potential failure points while maintaining comprehensive system functionality.
4Ease of operation
If concentric clutches are used, then clutch functionality is achieved, but actuation complexity and service difficulty increase
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical concentric clutch actuation systems with a simplified linear actuator system controlled by electronic controls and pneumatic power. This substitution reduces actuation complexity while maintaining clutch functionality, and also improves serviceability by reducing the number of mechanical components that require maintenance.
Data Source
AI summary
An apparatus (a controller), and systems and methods for management of inputs, determination of a calculated clutch temperature, and control of action related to the clutch of a transmission system, and notification improvements to a user associated therewith are disclosed. In particular, a clutch calculator circuit is augmented by a machine learning component that employs a machine learning technique and provides a projected clutch temperature as a basis for actions to be taken.