Work Machine Eco-Mode Powertrain Control for Simultaneous Gear Shifts
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Solution Overview
Problem
Existing powertrain systems in work machines, such as landfill compactors, face inefficiencies due to overheating and loss of fuel economy during gear shifts, particularly when operating on inclines, and lack an effective control strategy for simultaneous directional and speed shifts.
Innovation Solution
A control system that receives machine conditions to determine optimal gear settings and commands simultaneous directional and speed shifts, utilizing a torque converter's direct-drive mode to maintain efficient operation and prevent overheating, thereby optimizing fuel economy and reducing component wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If torque converter is used in second gear transmission ratio for efficient fuel management, then fuel economy is improved, but torque converter overheats due to heavy loading conditions on inclination
Solution Approach 1:
The control system performs preliminary assessment of machine conditions (slope, load, speed) before commanding a gear shift. When conditions indicate risk of overheating, the system proactively plans a shift sequence that transitions out of the problematic second gear ratio before thermal damage occurs, rather than reacting after overheating begins
Solution Approach 2:
The system dynamically adjusts transmission gear ratio selection based on real-time operating conditions including slope, load, and speed. The control algorithm continuously evaluates whether to remain in second gear for fuel efficiency or shift to first gear to reduce torque converter load, adapting the gear ratio dynamically rather than using a fixed strategy
2Ease of operation
If traditional clutch-to-clutch shift control is used, then gear shifting is achieved, but directional shift and speed shift are not executed simultaneously causing inefficiency
Solution Approach 1:
The invention merges the directional shift function and speed shift function into a single coordinated control sequence. Both the off-going clutch disengagement and on-coming clutch engagement are timed to occur simultaneously during the same shift event, combining what were previously separate operations into one unified action that improves efficiency
Solution Approach 2:
The control system uses feedback from machine conditions (slope, load, speed) to determine the optimal timing for executing simultaneous directional and speed shifts. The system continuously monitors operating parameters and adjusts the shift command timing to achieve coordinated execution of both shift functions under appropriate conditions
Data Source
AI summary
A work machine having a powertrain, an engine, a torque converter operably connected to the engine, a transmission, a selector interface, and a control system. The control system is configured to: receive a machine activation signal from the selector interface indicative of operation of the work machine; receive machine conditions to determine an optimal gear for next pass; and send a gear pass signal to command execution of a directional shift and a speed shift simultaneously when a gear ratio setting of the transmission is indicative of a second gear ratio.