Wire Link Gear Shift Fork for Weight Reduction
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Solution Overview
Problem
Existing gear shift forks for axial shifting of clutch sleeves in gearboxes are heavy and costly to manufacture due to the need for post-production reworking, such as punching openings, which results in waste and energy consumption.
Innovation Solution
The gear shift fork is formed from wire or link elements, eliminating the need for post-production reworking and utilizing a link structure for reduced weight and stiffness, with optional sliding shoes or glide eyelets for improved functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If openings are punched in sheet metal gear shift forks to reduce weight, then weight is reduced, but manufacturing cost increases and environmental harm occurs due to waste and energy consumption
Solution Approach 1:
The gear shift fork is divided into multiple link elements (first link element, second link element, etc.) that are connected to form the complete structure. This segmentation allows each element to be optimized independently and eliminates the need for post-production punching operations, resolving the contradiction between weight reduction and manufacturing simplicity.
Solution Approach 2:
Instead of starting with a solid sheet metal structure and removing material (punching openings) to reduce weight, the invention inverts the approach by building the structure from thin-walled link elements that inherently provide the required functionality with minimal material, thus eliminating waste and post-production reworking.
2Ease of manufacture
If thin sheet metal is used to manufacture gear shift forks, then manufacturing is simpler initially, but post-production punching is required which increases cost and environmental impact
Solution Approach 1:
The link elements are pre-formed with the correct geometry and connections before assembly. The openings and structural features are created during the forming process of the link elements themselves, not through post-production punching, thereby eliminating material waste and the need for additional manufacturing steps.
Solution Approach 2:
The invention changes the fundamental parameter of material utilization by transitioning from a solid sheet metal approach to a thin-walled link element structure. This parameter change allows the structure to achieve the required strength and functionality with significantly less material, eliminating the need for punching and associated waste.
3Stability of the object's composition
If link elements are positioned at a distance in the forked interlock device section, then passage opening is formed and stiffness is improved, but structural complexity increases
Solution Approach 1:
The positioning and spacing of the link elements are integrated into the overall design of the gear shift fork structure. The distances between link elements are determined by the functional requirements of the passage opening and stiffness, and are incorporated into the manufacturing process of the link elements themselves, rather than being added as separate complex positioning features.
Data Source
AI summary
In the case of a gear shift fork (1) for the axial shifting of a clutch sleeve rotating around an axis in a gear box, which gear shift fork possesses two fork arm sections (4, 5) which lie opposite to each other and by their connection to each other are aligned and span an essentially semi-circular inner side (6), the fork arm sections (4, 5) and the forked interlock device section (3) shall possess a link structure.