GB2401411A - A gearbox actuator with toothed rod connected to a rocker arm - Google Patents

Abstract

A gearbox has an actuating device with two drives (201, 205, fig 2) one of which rotates a wheel 2401 that drives a toothed rod or worm 2402 axially. The toothed rod 2402 is connected to one end of a rocker arm 2404 via an element 2403 having ball end connections 2408 which allow for angular movement. When the rocker arm 2404 is pivoted, it rotates a shift shaft 2407 which is connected to the rocker arm 2404 by a lever 2406 and an element 2405 which is rotatably fixed to the rocker arm 2404 and the lever 2406. In an alternative assembly, the element (2303, fig 23) is connected to a selection shaft (2305) via a lever element (2304). The drives (201, 205) are secured to a base plate (220) which forms part of a housing fixed to the gearbox by bearings. The base plate (220) may have recesses providing access to areas of the gearbox. Various materials such as plastics, which are cast or injection moulded, may be used for the worm, and ball end connections etc

Description

MOTOR VEHICLE WITH GEARBOX

The present invention relates to a motor vehicle with a drive motor, a torque transfer device with actuating device, a gearbox with actuating device and a control device in which the actuation of the torque transfer device and gearbox is undertaken automatically through the control device. In order to actuate gearboxes of this kind, two motion components are used as a rule, such as selecting components and shifting components.

It is known to allot each of these selecting components its own drive. The movements of these two drives are converted into a rotational and translation movement on the shift shaft of the gearbox through converting the path and force conditions.

The problem here is the connection between the drives and the shift shaft. The demands on the transmission path with regard to path and force conditions, shift speed, shift time and shift comfort lead to expensive designs which are complicated and cost-intensive with expensive assembly.

The object of the invention is therefore to provide a motor vehicle with an automated shift transmission which has a reduced number of parts, is more cost-effective and which with simple means meets the demands for the required path and force conditions, shift speed, shift time and shift comfort. The system is to have a simple compact 2 - structural shape matching the structural space available and simple to fit.

According to the invention, there is provided a motor vehicle with a drive motor, a torque transfer device, a gearbox with a gearbox actuating device and a control device, wherein the control device controls actuation of the torque transfer device and of the gearbox, the gearbox is actuated by a movement having a first movement component and a second movement component, the gearbox actuating device has a base plate connected to the gearbox, first and second drives are dedicated to the first and second movements respectively, both of the first and second movements being rotational movements, wherein one of the two drives produces a shift movement using a first gearbox stage driven by the drive and a following, second gearbox stage which converts the rotational movement into axial movement, an element for the tension- free transfer of axial movement, the vehicle also having a shift lever connected to a selection shaft.

Further preferred embodiments of the invention are the subject of the subclaims.

The actuating device for the gearbox comprises in a preferred embodiment of the invention a base plate through which it is connected to the gearbox. The base plate advantageously supports the first and second drive.

The term base plate within the scope of the present invention does not necessarily mean a plate-shaped element 3 - but rather any element formed as such which supports essential component parts of the actuating device and is connected directly or indirectly to the gearbox.

Preferably the axis of the worm wheel associated with the first and/or second drive is housed at least supported in the base plate. The socket forms a bearing for the axis.

According to a preferred advantageous development of the invention the base plate forms a housing for at least one gear stage of the shift and/or selecting kinematics, more particularly for the first gear stage of the shift kinematics formed from the spur wheel and toothed rod.

If the base plate on the gearbox were to cover an area which had to be accessible, the base plate advantageously enables access, for example through recesses. For example an oil fill screw in the gearbox can be left free through a corresponding hole so that it is possible to monitor the oil level and top up the oil when necessary.

A preferred embodiment of the invention is designed as a cast part and has ribs. It is advantageous if the ribs run at such an angle to the main tool direction, thus perpendicular to the separating plane of the casting tool, that in order to make the apertures through the ribs there is no necessity for an additional element, such as slider, core or the like but they can simply be made through the configuration of the casting tool. - 4 -

In a preferred embodiment in order to fix the base plate on the gearbox an element is used which forms at the same time the bearing for the rotatable shift lever for transferring the shift movement. This element can advantageously be formed as a pin or bolt for supporting the shift lever and in order to fix the base plate can have a stepped or collar like area for the purpose of transferring tension forces.

According to a preferred embodiment the pretensioning force for fixing the base plate on the gearbox is produced inter alla through an element such as a screw or rivet which produces the pretension and is pre-fitted secured against loss. Prior to the actual assembly this element is held readily detachable and fixable at the proposed site.

A preferred embodiment of the invention shows the follower for converting the rotational movement into an axial movement in the transmission path of the selection movement as a disc or lever like element with a connection to the following transmission element which is arranged eccentric relative to the drive axis.

In an advantageous embodiment of the invention the element following the follower for transferring the axial movement by means of ball head connections is incorporated into the kinematic stretch, by way of example to enable a tension- free force transfer and tolerance compensation. - 5

Advantageously the spur wheel which with the toothed rod forms the second gearbox stage in the transmission path of the shift movement is pushed into a corresponding recess of the shift elasticity for a positivelocking force transfer.

In a particularly advantageous embodiment of the invention the toothed rod has in the transmission path of the shift movement an area of a material having a high melting point, such as metal, which supports the teeth and a region of a material having a lower melting point, such as plastics which is provided to connect with the element for the tension- free transfer of axial movements.

According to a particularly advantageous further development of the invention the element for the tension- free transfer of axial movements has in the transmission path of the shift movement an area of a material with a higher melting point, such as metal, which is provided for connection with the toothed rod, and an area of a material with lower melting point, such as plastics, which is provided for connection with the shift lever.

In a preferred embodiment the element for the tension free transfer of axial movements in the transmission path of the shift movement is mounted axially fixed with the toothed rod but relatively movable in rotation about at least two axes. Advantageously this connection is formed as a ball head connection and is produced by casting or injecting the ball which is mounted on the element for 6 - the tension-free transfer of axial movements in the transfer path of the shift movement.

Furthermore it can be advantageous to cast the ball at the same time with the part of the toothed rod supporting the teeth and/or the part of the element provided for connection with the shift lever for the tension-free transfer of axial movements in the transfer path of the shift movement.

In another preferred embodiment the toothed rod and/or the element for the tension-free transfer of axial movements in the transfer path of the shift movement consists completely of plastics, whereby plastics having different melting points can be used.

In a preferred embodiment measures are taken so that the ball joint is fully movable in the temperature range which is provided for operation. Thus it can be advantageous prior to the injection process to surround the ball head with a separating agent such as wax. It can also be advantageous to safeguard the mobility between the ball head and socket additionally or solely through a defined cooling process.

In the embodiment the ball socket is preferably made from a plastics material which has a lower shrinkage measurement when cooling down.

For the toothed rod it is advantageous if the pitch circle plane of the teeth is in the vicinity of the toothed rod - 7 axis or, which is particularly advantageous, coincides with same.

In a particularly preferred embodiment of the invention the connection between the rotatable shift lever and an element for introducing the shift movement to the shift shaft is by means of a sliding block connection.

According to a preferred embodiment it can be advantageous if the last element in the transfer path of the selecting movement prior to entering the shift shaft is at the same time the last element in the transfer path of the shift movement prior to entering the shift shaft. Thus the selection and shift movement are coupled together through this element.

In a preferred development of the invention the change in the position of the selection drive conditioned by the mechanical coupling of the shift and selection kinematics during a shift movement is not interpreted by the control device as a position deviation.

This can be achieved for example in that the selection kinematics are attuned so that the change in the position of the selection drive during a shift movement is at least very slight and in particular is minimal.

Furthermore it is advantageous if the change in the position of the selection drive during a shift moment is less than the sum of the clearances existing in the selection kinematics. - 8 -

A preferred embodiment will now be described in further detail with reference to the advantageous designs shown in the drawings in which: Figure 1 shows a diagrammatic view of a vehicle with drive train, gearbox actuating device and control device; Figure 2 shows an exploded view of the gearbox actuating device; Figure 3 shows a gearbox actuating device fitted on the gearbox; Figure 4 shows the kinematics of a selection stretch; Figure 5 shows the kinematics of a shift stretch; Figure 6a shows the connecting and load directions in the case of a ball head connection; Figure 6b shows a ball head connection with increased possible force transfer in the connecting direction; Figure 6c shows a security bar for the ball head connections; - 9 Figure Ed shows a ball head connection for axial force transfer; Figure 7a shows a plan view of an injected ball head; Figure 7b shows a side view of an injected ball head; Figure 7c shows a section through an injected ball head; Figure 8 shows a section through a fixing spot of the base plate on the gearbox and bearing of a shift lever for transferring the shift movement; Figure 9 shows a diagram for the kinematics of a shift stretch; Figure 10 shows a diagram for the kinematics of a selection stretch; Figure 11 shows a diagram for the effect of the shift movement on the selection kinematics; Figure 12 shows a shift elasticity in plan view, with two sections; Figure 13 shows bellows; Figure 14 shows an element for fixing the base plate and bearing the shift lever; Figure 15 shows an element for transferring axial movements in the transfer path of the selection movement; Figure 16a shows a connection of a drive to a selection chain; Figure 16b shows a connection of a drive to a shift chain; Figure 17 shows a base plate in three dimensions; Figure 18 shows a side view of a base plate; Figure 19 shows a section through the unit formed from the toothed rod and push rod; Figure 20 shows a connecting plate; Figure 21 shows a support element kinematics on the gearbox; Figure 22 shows a support element with kinematics; Figure 23 shows the kinematics of a selection stretch and Figure 24 shows the kinematics of a shift stretch. - 11

Figure 1 shows diagrammatically a motor vehicle 1 with a drive train which contains a drive motor 2 formed as an internal combustion engine, a clutch 4 and a gearbox 6.

The wheels 12 of the vehicle 1 are driven through a cardan shaft 8 and differential 10. Obviously the vehicle can have one or more differently driven axles.

There is a transmission selection device 60, such as a selection lever, with sensor 61 and a control device 18, 44 as block circuit diagram. The control device 18, 44 can be formed as one unit or can be formed in structurally and/or functionally separated partial regions. If the control device 18, 44 is formed in structurally and/or functionally separated partial regions, these can be connected together for data exchange for example through a CAN bus 54 or another electrical connection. The control device 18, 44 controls by way of example the automated actuation of the gearbox 6 and/or the clutch 4 or motor 2, such as the engine torque, the selection of the gear transmission ratio, a parking position or neutral position of the gearbox or the torque transferable by the clutch.

The device for changing the transmission ratio of the gearbox comprises at least one actuator 48, 50 and a control device 44 wherein the transmission ratio can be changed by controlling the actuator 48, 50. The clutch 4 can also be actuated automatically by means of the actuator 46.

The region 44 of the control device receives signals which represent at least the transmission state of the clutch 2 - 12 and the transmission ratio set in the gearbox 6, as well as signals from a sensor 52 for the output speed and a sensor 61 on the transmission selection device 60. These signals are determined by sensors, such as a gear detection sensor or by a clutch path sensor.

Region 18 of the control device controls the internal combustion engine 2 through a displacement of the throttle valve 30 and/or the injection. Signals are received from sensors 26 for the suction intake pressure, 24 for the coolant temperature, 28 for the engine speed, 20 for the position of the throttle valve 22 and 16 for an accelerator pedal actuation 14.

The device for changing the transmission ratio of the gearbox comprises at least one actuator 48, 50 which comprises for example two electric motors wherein one electric motor is controlled for actuating the selection process and a second electric motor is controlled for actuating the shift process. For this purpose a displacement of at least a shift element on the gearbox side is actuated by means of the electric motors along the selection stretch or shift stretch.

Figure 2 shows an exploded view of the gearbox actuating device. The central element is the base plate 220 on which the drives 201 for the selection movement and 205 for the shift movement are mounted. The drive 201 is fixed by means of screws 223 and the drive 205 is fixed by means of the screws 224. The coupling rod 202 serves to transfer the selection movement to the selection arm 203. - 13

In order to prevent tensions in the kinematics the coupling rod is attached through ball head connections to the selection arm 203 and to the follower of the drive 201.

The transfer of the shift movement is through the toothed wheel 207 which engages with a toothed rod 209, the connecting element 211 and through the shift lever 215 to the selection arm 203. Plastics bearing bushes 208 are used to support the toothed wheel 207.

The drive 205 comprises an integrated shift elasticity 206 which is shown in Figure 12 and will be described in further detail.

Two bearing sleeves 210 are used for the sliding bearing of the toothed rod 209 in the base plate 220. A bellows 212 serves to protect the teeth from dirt.

The hollow cylindrical element 221 functions as the bearing bolt for the rotatable bearing of the shift lever 215 in the base plate 220. The shift lever 215 is mounted with sliding action by means of a bearing sleeve 216. At the same time the hollow cylindrical element 221 serves to tension the base plate 220 by means of the screw 222 with the gearbox.

Ball heads 213 and 217 are used to connect the element 211 and the slide block 218 to the shift lever 215. A shaped ring 214 of plastics protects the ball head connection with the element 214 from dirt. The slide block 218 is used for the tension-free force transfer in the selection arm 203. Bellows 219 made of rubber serve here to protect against dirt. The ball head connection between the selection arm 203 and the coupling rod 202 is protected from dirt by the shaped ring 204.

Figure 3 shows the gear actuating device fitted on the gearbox. The gearbox comprises a housing 303, an intermediate housing 302 as well as a cover 301. The base plate 306 is fixed on the gearbox by means of the three screws 308, 309 and 310. The screw 310 serves at the same time to tension the hollow cylindrical element which forms the bearing for the shift lever 311.

Furthermore the figure shows the shift lever 312, the coupling rod 307 and the shift shaft 313.

The present view of the embodiment shows the shift shaft 313 at the front lying horizontal underneath so that a shift movement S corresponds to a right-left movement, and a rotation about the horizontal axis corresponds to a selection movement W. The shift lever 312 engages on the right end of the shift shaft, through which both the shift movement S and selection movement W are introduced, the left end of the shift shaft is connected (not shown here) through shift fingers and shift forks to the shift sleeves.

The gearbox actuating device, comprising inter alla the base plate 306 and the drives 304 and 305, is in this view fixed at the front so that the longitudinal axis of the drives forms an angle 314 of about 45 with the axis of the shift shaft 313 and the connection of the drives to the shift lever 312 can take place through the kinematic chains. Similarly the axes of the selection drive 304 and the coupling rod 307 form an angle of about 45 , the coupling rod thus including an angle of roughly 90 with the shift shaft 313.

As the axes of the drives 304 and 305 run parallel so the axes of the transfer elements - the coupling rod 307 in the transfer path of the selection movement and the toothed rod or the element for the tensionfree transfer of the axial movement 320 in the transfer path of the shift movement - run roughly parallel so that the toothed rod or element for the tension free transfer of the axial movement 320 are arranged roughly perpendicular to the shift shaft 313.

The bearing of the shift lever 311 whose axis is formed by the screw 310 lies perpendicular to the shift shaft axis in one plane, axially relative to the shift shaft approximately level with the shift lever 312 so that rotation of the shift lever 311 about the axis formed with the screw 310 generates a selection movement W of the shift shaft 313, and an axial movement of the coupling rod 307 which is connected movable to the shift lever 312 by means of a ball joint connection 315 leads to rotation of the shift shaft, corresponding to a shift movement S. The drives 304 and 305 comprise the drive motors 318 and 319 whose pole heads are shown in the drawing, as well as regions 316 and 317 which each form a housing open on one side for the first gear stage, formed from a worm and worm wheel, in the selection or shift stretch. The drives 304 and 305 are connected to the gearbox housing 303 through the interposition of the base plate 306 so that the open side of the regions 316 and 317 faces the gearbox.

The shift drive 305 is closer than the selection drive 304 to the shift lever 312 as central element for transferring movement to the shift shaft. The kinematic chain is also correspondingly shorter which is particularly advantageous in view of the greater shift forces compared with the selection forces.

The entire assembly enables the drive motors 318 and 319 to be fixed insulated from the vibrations of the internal combustion engine, gearbox and/or vehicle operation.

Figure 4 shows the selection kinematics. A disc 401 which supports a follower 409 formed as part of a ball head connection and mounted eccentric relative to the worm wheel axis is connected to the toothed wheel 408 which is driven by the worm. The follower 401 can be a levershaped or other shaped element which is suitable for converting rotational movement into axial movement.

The rotational movement of the disc 401 is converted into an axial movement of the coupling rod 402. The movement of the coupling rod 402 is transferred free of tension through the ball head connection 410 to the selection arm 403 which is connected to the shift shaft 404. The coupling rod 402 is illustrated in Figure 15 and will be described in further detail below.

The stops in the end positions of the selection direction are produced by moving the pin 406 inside the shift gate 407. In the event of rotation of the shift shaft 404 generated by the drive for selecting the shift gate, the pin 406 is moved correspondingly inside the shift gate 407 through which the selection movement is also limited and the position of the gates is fixed.

The kinematics of the selection path is formed as a three- dimensional square joint. The lowest possible distortions are produced.

With the illustrated arrangement the axes a of the worm wheel of the first gear stage in the transfer path of the selection movement, the axis ak of the coupling rod 402 and the axis as of the shift rod 404 each include an angle of about 90 . In the Cartesian co-ordinate system 411 the axis a lies roughly parallel to the y-axis, the axis ak lies roughly parallel to the z axis and the axis as roughly parallel to the x axis.

The perpendicular spacing of the axes a and ak is provided by the spacing d between the axes a of the worm wheel of the first gear stage in the transfer path of the selection movement and the axis ae of the eccentric follower. The perpendicular spacing between the axes as and ak is determined by the length e of the shift lever 403.

The connection of the one drive to the selection kinematics is shown in Figure 16a. The drive 1601 which can be formed for example as an electric motor drives through a worm 1602 a worm wheel 1603 which is connected to a follower 1604. The follower 1604 is formed disc-like and supports eccentric with the worm wheel axis a ball head 1605 for connecting the coupling rod 402.

Accordingly the other part of the ball head connection could also be mounted on the follower 1604.

Figure 5 shows the transfer path of the shift movement.

The movement is transferred to the toothed rod 503 through the toothed wheel 502 which is connected to an axis 501.

The element 504 which is connected to the shift lever 506 through a ball head connection 505 is provided for connection with the shift lever 506. The shift lever 506 is fixed rotatable through the hollow cylindrical element 507 which is fixed on the gearbox by means of the screw 508.

The shift lever 506 is formed so that no or at least only slight distortions occur in the kinematics of the shift movement. During conversion of an axial movement into a rotational movement or vice versa there are always sinusoidal distortions which appear. Through the double conversion through the shift lever 506 the distortions are mutually cancelled out so that the movement of the toothed - 19 rod 503 can advantageously be converted here into a movement of the shift shaft 511.

A tension-free connection to the shift shaft 511 is through the selection arm 509. A slide block connected to the shift lever 506 by means of the ball head connection is used to transfer the movement in the selection arm 509.

A shift detent action 512 defines the neutral position or the positions of the engaged gears; the shoulders 510 in the shift shaft form stops inside the gearbox in the shift direction. Even during the shift movement the pin 513 is moved correspondingly in the shift gate 514.

The arrangement of the entire kinematic chain for transferring the shift movement enables a substantially distortion-free transfer of the movements.

The conversion of an axial movement of the toothed rod 503 along the axis c into an axial movement of the shift rod 511 along the axis a which is roughly perpendicular to the axis c takes place through the shift lever 506 which is able to swivel about the axis b which is roughly perpendicular to the axes a and c. Advantageously the two arms 506a and 506b of the shift lever 506 are at least approximately the same length in order to avoid distortions during the movement transfer. If a deliberate change in the transmission ratio or force is desired then it can also be advisable if the arms 506a and 506b are of different length. -

If with the shift lever 506, as in the present example there is no significant change in the transmission ratio, then it is further advantageous with the gear stage already formed by the spur wheel 502 and toothed rod 503 to generate an axial movement whose path corresponds to that of the shift shaft in the shift direction between the end positions, for example between 1st and 2nd gear.

The connection of the other drive 1610 to the shift kinematics is shown in Figure 16b. In the present example the drive formed as an electric motor 1610 drives through a worm 1611 a worm wheel 1612 which is in active connection with a shift elasticity 1613. The spur wheel 161 which is mounted rotatable on the axis 1616 by means of the slide bushes 1615 is push-fitted into connection with the shift elasticity 1613.

The axes aa and ba of the two drives 1601 and 1610 are roughly perpendicular to the axes ab and bb of the associated worm wheels. The perpendicular spacing between the axes is substantially determined by the radius of each Figure 6a shows a known ball head connection, formed from a ball socket 601 formed for example of plastics, and a ball head 602. Both parts are inserted in each other in the connecting direction 604 to connect the ball head 602 and ball socket 601 together. The collar 606 of the ball socket 601 thereby has a slightly smaller diameter than the diameter of the ball 602. By applying a certain force in the connecting direction 604 the collar 606 widens out - 21 elastically until the ball head 602 can engage completely in the ball socket 601 and then produces a certain retaining force for the connection as a result of its smaller diameter.

Usually the connecting direction 604 and the work direction 605 are at right angles to each other. With a force transfer which takes place in the work direction 605 the connection in the connecting direction is not loaded, there is only a slight holding force required for the ball 602 in the socket 601. It is clear that a force transfer in the connecting direction 604 with the present ball head connection is not possible since the ball head 602 and ball socket 601 were released from each other.

Figure 6b shows a ball head connection in which a restricted load is also possible in the connecting direction 604. This is achieved in that a separation of the ball socket 610 and ball head 611 is made difficult through an additional element 612 made for example of metal, as shown in further detail in Figure 6c.

The ball socket 610 has in the present case no collar of reduced diameter compared to the ball diameter. The fixing of the ball head 611 in the ball socket 610 is by means of the additional element 612 illustrated in Figure 6c. It has a region 613 which engages underneath the ball and can absorb force in the event of strain in the connecting direction. This force is supported through the region 614 which is formed yoke-shaped and sits on the neck of the ball socket 616. - 22

If two oblong for example cylindrical elements are to be connected together movable by means of the ball head connection then such a connection can be produced as shown in Figure 6d. For the reasons described above a separation of the work and connecting directions is necessary which here leads to an expensive design with a number of structural elements and difficult assembly. The one element is presently a toothed rod 621 which has teeth 622 for force transfer. The element 620 which embraces the ball socket 624 is to be connected movable with the teeth. The ball head 625 is here formed as an independent element and isconnected to the toothed rod 621 through a support 623.

A force transfer between the elements in which the connecting direction is at the same time the working direction is possible according to the invention advantageously with the solution illustrated in Figures 7a, 7b and 7c. This solution is particularly suitable for the movable connection between two, long, for example cylindrical, elements which undergo stress in the axial direction.

By way of example here the connection is shown between a toothed rod 702 and a push rod 701. The toothed rod has teeth 710 through which force can be introduced, the push rod 701 can have a ball socket 704 for transferring movement to further elements at its end remote from the push rod. - 23

This connection is advantageously formed through a ball socket 705 made from a thermally deformable, more particularly injection casting and/or injection moulding material such as plastics, such as PA 6.6 OF 30 or POPM< GF 30, and a ball head 703 made from a material with a higher melting point, such as for example steel, so that in order to produce the connection the ball head 703 can be cast into the ball socket 705 or can be injection moulded in the material which forms the ball socket 705.

Embodiments are also provided in which it is advantageous if the material of the ball socket 705 has a higher melting point compared with the material of the ball head 703. In each case it is advantageous to initially manufacture the component part which consists of the material with the higher melting point, and then to connect this to the other component part during its manufacture.

An embodiment is also conceivable in which it is advantageous if both elements 705 and 703 have an approximately identical melting point.

It is advantageous to provide special measures which ensure the complete mobility between the elements in the temperature range provided for the operation. This can be the application of a separating agent such as for example wax and/or a suitable defined cooling process and/or another suitable process and/or means. Also when using materials with different melting points it is advantageous or even absolutely essential to use these measures. - 24

In the present embodiment the element 705 forming the ball socket has a collar 706 which has a significantly smaller diameter d than the diameter D of the ball head 703. Thus secure fixing of the two elements 703 and 705 is guaranteed even with axial strain. The ratio of D to d preferably lies in the region 1,1 to 2, more particularly it is about 1,43. The greater the axial strain so the greater this ratio D/d whereby it is clear that embodiments can be provided where a ratio of D/d greater than 2 is advantageous.

The region 707 of the element 705 is formed funnel-shape with an angle to the axis a so that relative movement of the elements 705 and 709 is possible. The shaft 708 can adjoin the funnel-shaped region 707 in the end positions of the swivel region.

Figure 19 shows a section through the unit formed from the toothed rod and push rod. In the illustrated embodiment the part of the toothed rod 1904 supporting the teeth is made from metal and has a cast region 1903 of plastics.

Preferably at the same time the end 1908 of the push rod 1902 made from metal and designed spherical to produce a ball head connection is cast in to produce a movable connection which can be loaded in the longitudinal direction. The push rod 1902 has a cast region 1901 made from plastics which can be cast together with the region 1903 of the toothed rod or where necessary also in its own work step and enables a movable attachment with the shift lever. The groove 1905 is formed in the region 1901 of 25 the push rod to hold a bellows. The end regions of the toothed rod or push rod are preferably designed at their ends cast in the plastics so that the connection is also secured under strain. By way of example the ends are provided for this purpose with ring grooves to form undercut sections 1906 and 1907.

Figure 8 shows the hollow cylindrical element 812 in connection with the base plate 801 for fixing on the gearbox and as bearing for the shift lever 807. The base plate 801 is formed forked with two arms 813 and 814 at the point where the hollow cylindrical element is seated.

A full-length hole is formed in the arm 813 with its diameter corresponding to the diameter D of the hollow cylindrical element 812 shown in detail in Figure 14 at 1401; a through hole is formed in the arm 814 and has a diameter d so that the hollow cylindrical element 1401 sits with the region 104 in the arm 814 and with another end region in the arm 813. The surface 1403 forms a stop which is supported on the inside of the arm 814 and through which the base plate 801 can be tensioned against the gearbox housing by a screw 802 housed in the passage 1406 with its head 803 applying tension force to the surface 1402 and its thread 804 engaging into a thread in the gearbox housing.

It is advantageous if the screw 802 has a small diameter with a long length, which is particularly advantageous in view of the dynamic strains since the screw acts as an expansion screw, and more particularly the ratio of length to diameter is about 10: 1. - 26

A further advantageous feature enables the screw 802 to be prefitted secured against loss in the hollow cylindrical element 812. Between the screw 802 and the hollow cylindrical element 812 there are means through which the two elements can easily be brought into the desired relative position, wherein this position can be corrected where required and/or the elements can be released from each other again, whilst at the same time however this relative position is reliably maintained. The screw 802 can be prefitted in the hollow cylindrical element 812 so that when fitting the complete prefitted gear actuating device which is made up of the base plate, drives, kinematics elements and further elements where necessary, the screw is already located secured against loss at the proposed site and need only be moved up. An element which generates increased friction between the screw 802 and the hollow cylindrical element 812, such as for example a plastics ring 806 foamed onto the screw 802, can be provided for this purpose, but it can also be expedient to foam the plastics inside onto the hollow cylindrical element 812.

Advantageously an embodiment can also be where the element which generates increased friction between the screw 802 and the hollow cylindrical element 812 is formed as an independent element such as for example a plastics or rubber ring, and it can also be advantageous to use several such elements. - 27

The surface 1405 serves to mount the rotatable shift lever 807, advantageously by using a slide bearing bush 805.

Furthermore Figure 8 shows an arm of the shift lever 807 which produces the connection between the shift lever 807 and the selection arm. A ball journal 808 is connected to the shift lever 807. The head of the ball journal 808 supports a slide block 809 which is made of plastics for example and which forms the ball socket, is clipped onto the ball head and which is seated in the selection arm for tension-free force transfer.

A groove 810 is formed in the ball journal 808 into which a bellows 811 can be fitted to protect the slide block connection. The ball journal 808 is riveted for example to the shift lever 807 by plastically widening out its end 815. It can be advantageous if the ball journal 808 is made from a hard or hardened material in order to ensure a long service life of the ball head, it can then be advisable to produce the expansion at the end 815 of the ball journal 808 by rolling.

The axis of the ball journal is preferably parallel to the rotational axis of the shift lever 807. The other arm (not visible here) of the shift lever 807 advantageously holds a ball journal as described above for attachment.

Figure 9 shows a diagram for the kinematics of the shift path. The shift path s_SW is here entered relative to the rotational angle of the armature shaft of the shift motor phi_SM. A linear change of the shift path is reached with - 28 rotation of the armature shaft of the shift motor so that within the rotational region of the shift motor it is possible to shift without problem between the end positions of the 1st, 3rd and 5th or 2nd, 4th and reverse gears.

Figure 10 shows a diagram for the kinematics of the selection path. The rotational angle of the shift shaft is here entered relative to the rotational angle of the armature shaft of the selection motor. The conversion of the rotational movement of the selection motor takes place so that with the available rotational angle region it is possible to shift without problem between the shift gates of 1/2, 3/4 and 5/R gears.

Figure 11 shows the action of the shift movement on the selection kinematics. Conditioned by the coupling between the selection and shift movement on the selection arm a shift movement also always causes a change in the selection movement. Figure 11 shows how the rotational angle on the selection lever phi_AH changes with the shift movement s_SW for shift gates 1/2, 3/4 and 5/R.

An increment sensor unit is provided inside the drives for determining the position. If the control device establishes through the sensor unit a deviation from the ideal position then a follow-up regulation of the drives can be triggered. The threshold from which a follow-up regulation is triggered depends on the control hysteresis set in the control device and on the clearances present in the kinematic chain. - 29

The maximum deviation of the rotational angle of the selection lever during a shift movement is advantageously lower than the sum of the clearances present in the selection chain. In this way a detection of the deviation through the sensor unit contained in the drives and thus triggering of a follow-up regulation is prevented. The kinematics of both the selection and the shift path is designed so that the influence of the shift movement on the selection position is the lowest possible.

Figure 12 shows the arrangement of the elements forming the shift elasticity. The shift elasticity is formed by two element parts 1204 and 1205 which are rotatable relative to each other in a certain angular range and which are connected together elastically with damped action and of which one is in force locking and/or positive locking connection with the worm wheel 1612 and the other is in force and/or positive locking connection with the spur wheel 1614 for example by means of teeth 1207 and 1208. The springs and damper of the shift elasticity advantageously have such characteristic lines that the drive of the kinematics and the processes at the shift clutch is correspondingly active, for example is isolated from the force shocks which are caused during the shift processes. In particular in the present example four springs 1210a, 1210b, 1210c and 1210d are shown which are shifted in parallel and whose rigidities are added up accordingly. In order to reach the desired overall characteristic it can be advantageous if the springs have the same characteristics. In another embodiment it can - 30 however also be advantageous to use springs having different characteristics. The use of springs with a linear characteristic is advantageous. If necessary however the use of progressive or depressive springs can also be advantageous. Damping is carried out in the present embodiment linearly but in another embodiment it can also take place advantageously dependent on path and/or frequency.

1201 shows an embodiment in plan view, 1202 and 1203 show sections A-A and B-B. On the drive side the force transfer is through the teeth 1207 to the element 1205 on the drive side which is connected through springs 1210 to the element 1204 on the output side rotatable in a certain angular range. A toothed spline 1208 is formed in the element 1204 on the drive side into which a toothed wheel 1209 can be fitted. The toothed wheel 1209 can however also be fixedly connected to the element 1204. The ring- like element 1206 is connected to the element 1205 on the input side.

Figure 13 shows the bellows 1301 for sealing the first gearbox stage in the selection kinematics. The bellows 1301 is seated by one end 1304 in a groove on the push rod connected to the toothed rod. The other end 1303 is inserted in a groove on the base plate. The fold 1302 has a diameter which is enlarged compared to the other folds so as to make assembly easier. 31

Figure 15 shows the element for transferring axial movements in the transfer path of the selection movement.

The element is set in the transfer path with articulated connection but suitable for transferring axial movements and ball head connections are used for example. The element consists of a rod 1501 with cast parts 1502 and 1503 of a ball head connection. Here the sockets are cast but it could also be advantageous to cast the balls or to make the element in one piece from only one material.

The section 1504 shows details illustrating the design of the rod end cast in the ball socket and forming the undercut sections. The connection can be made in another suitable way. In certain cases it can also be expedient to design the connecting parts 1502 and 1503 rotatable relative to each other about the rod axis or fixed rotated relative to each other at a certain angle.

Figure 17 shows the base plate 1701 for fixing the two drives and securing on the gearbox. The first drive is fixed by means of screws which are screwed through the bores 1702 into the housing of the drive whereby the axis of the worm wheel of the drive fits in the bore 1703. The exact position of the drive on the base plate 1701 is thereby ensured and at the same time the bearing of the axis is free of any load.

The second drive is fixed by means of screws which are screwed into the thread 1704 whereby the axis of the worm wheel of the drive is seated in the bore 1705. Also here the exact tolerance-free positioning of the drive on the base plate 1701 is ensured.

The spur wheel which is mounted on the axis of the second drive is in engagement with a toothed rod which is guided longitudinally in the bores 1706 and 1707. For this gear stage which is formed by the spur wheel and toothed rod a housing is formed with the dish-shaped space 1713 in the base plate; the surface 1712 forms the sealing seat for the housing of the drive. This gear stage is protected on the outside from dirt etc by a bellows, with a groove 1708 being provided to fix same.

Fixing the base plate 1701 on the gearbox is undertaken through three fixing points of which in the present view only two 1709 and 1711 can be seen. Of special significance is the fixing point 1711 since here at the same time the selection lever is fixed with rotatable bearing by means of the element held in the passages 1710 and 1711 and thus the precision of the arrangement has to a particular extent an influence on the kinematics of the overall system.

In particular the present application ensures a low- tolerance positioning of the drives, particularly through the axial bearing of the worm wheels fixed by the bores 1703 and 1705 relative to the axis of the fixing element passing through the holes 1710 and 1711 and through the precision positioning of the complete base plate 1701 relative to the connecting point on the shift shaft.

The plane formed with the fixing points 1702 and the plane formed with the fixing points 1704 are parallel and have a certain spacing. In another embodiment it can however also be advisable if the planes have no spacing and the fixing points 1702 and 1704 thus lie in one plane.

A side view of the base plate 1801 can be seen in Figure 18. 1802, 1803, 1804 and 1805 are threads for fixing the shift drive, 1806 and 1807 are fixing points for fixing the base plate 1801 on the gearbox. With the manufacture of the base plate 1802 as a cast part the use of a slider is required only for the guide 1811, all the apertures, ribs eta can despite the non-parallel alignment of the plane 1812 for fixing the one drive and the planes 1813 and 1814 for fixing on the gearbox - be produced through the configuration of the casting tool by utilising mould inclines. More particularly the ribs which contain the apertures 1808 and 1809 can be at such an angle to the main direction of the tool that they can be made without sliders, core or the like.

During assembly the web 1810 fulfils inter alla the function of an assembly aid in that it holds the element which is pushed through the apertures 1808 and 1809 in its position for axial transfer of the selection movement.

The axis of the shift lever (not shown) and fixing screw which preferably stands roughly perpendicular to the planes 1813 and 1814 for fixing on the gearbox, is characterized by a. - 34

In one embodiment it can be advantageous to arrange the fixing device of the clutch and the control device in one structural unit, but separately from the actuating unit of the gearbox.

In this case it can be expedient to provide a connecting plate 2001, as shown in Figure 20, for connecting the structural unit to the gearbox.

The plate 2001 has as a result of technological vibration reasons a high rigidity with a small inherent mass in order to dampen the structural unit connected to same in the best possible way from the vibrations which are excited for example by the gearbox and/or drive motor and/or through the driving operation, and for this purpose a number of reinforcement ribs such as 2006, and/or a suitable material, such as cast aluminium, can be provided inter alla.

In order to fix on the gearbox the plate 2001 has fixing points 2005 and the structural unit is fixed at the fixing points 2004. Furthermore the plate 2001 can have fixing points for further components such as a recess 2002 for fixing a supply container of operating fluid or a bore 2003 for fixing a holder for supply and/or signal leads.

Depending on the arrangement of the structural unit on the gearbox it can also be advisable to provide the planes formed by the fixing points 2004 and 2005 for fixing the plate 2001 on the gearbox or structural unit on the plate 2001 non-parallel in order to enable better access to the areas such as connecting areas for the supply and/or signal leads, on the structural unit and/or on the gearbox.

A further embodiment of the invention is shown in Figures 21 and 22. A support element 2112, 2201 serves to fix the drives for the selection or shift actuation on the gearbox 211, which is insensitive to tolerance but is in particular accurately positioned relative to the selection shaft 2113 and shift shaft 2211; the support element 2112 supports at the same time the elements of the selection and shift kinematics. For fixing the drives the support element 2112 has a number of fixing spots 2109 which have advantageously a thread for holding fixing screws where it can also be advantageous if these are formed as full- length holes. The drives for the shift and selection actuation each have as in the above mentioned embodiment a first gearbox stage formed by a worm and worm wheel and integrated in the drive, a second gear stage being formed each time by a spur wheel connected directly or indirectly to the worm wheel, and a toothed rod. For these second gearbox stages housing-like regions 2209 and 2210 are formed in the support element 2112 to hold same. The drives for the selection and shift actuation are fixed on the support element 2112, 2201 in roughly parallel planes whereby the drives are opened at the their connecting spots and are tightly closed with the housing-like areas 2209 and 2210. The toothed rod for selection actuation is housed axially movable in the bore 2108, whereby a bore 2103 runs roughly at right angles thereto in a parallel plane to hold the toothed rod for the shift actuation. - 36

The plane for fixing the shift drive has in the present embodiment, conditioned by the arrangement of the shift shaft 2211 and the selection shaft 2113 at approximately right angles to each other and the position of the support element 2112, 2201, a greater distance from the gearbox housing 2111 than the plane for fixing the selection drive. With a different arrangement of the shift shaft and selection shaft relative to each other it can however also be expedient in another embodiment if the plane for fixing the shift drive has a smaller or the same distance from the gearbox housing 2111. The fixing point 2115 serves for holding a rocker arm 2101, 2204 which is able to swivel in the fixing plane of the shift drive or parallel plane and whose lever 2101a and 2101b are here roughly the same length whereby in another embodiment the kinematics can make it necessary to construct the lever 2101a longer or shorter than the lever 2101b so that a certain transmission ratio of the movement is produced.

Figure 23 shows the selection kinematics of the embodiment of the invention which is shown by way of example in Figures 21 and 22. By means of the toothed rod 2301 driven by the selection drive the toothed rod 2302 is able to move in the bore 2108. The movement is transferred by means of an element for the tension-free transfer of an axial movement 2104, 2208, 2303 which is connected to the toothed rod 2302 by way of example by means of a cast ball head connection 2306 described and illustrated in Figures 7a, 7b, 7c and 19, through a lever element 2105, 2207, 2304 to the selection shaft 2113, 2305 whereby a ball head connection 2114, 2307 is provided for the movable - 37 attachment of the element 2104, 2208, 2303 to the lever element 2105, 2207, 2304. The direction of movement of the individual elements during actuation is indicated in the drawing by arrows. The axes a, b, c each lie at approximately right angles to each other whereby in a Cartesian co- ordinate system 2308 the axis a is arranged roughly parallel to the x- axis, the axis is roughly parallel to the y-axis and the axis c is roughly parallel to the z-axis. An off-set of the connecting point between the element 2303 and the lever element 2304 relative to the axis b is currently compensated by the element 2303 which is connected with movement on both sides by means of the ball head connections 2306 and 2307.

Figure 24 shows the shift kinematics of the embodiment of the invention illustrated by way of example in Figures 21 and 22. The toothed rod 2402 is movable in the bore 2103, 2202 by means of the toothed wheel 2401 which is driven by the shift drive. The element 2403 for the tension-free transfer of axial movements is designed as described and illustrated in Figures 7a, 7b, 7c and 19 and enables through the ball head connection 2408 a tension-free movement transfer to the rocker arm 2404, from which the movement follows by means of an element 2405, 2205, 2102 to a movement to the lever element 2406, 2206 connected to the shift shaft 2407, 2211. The rocker arm 2404 has two levers 2404a and 2404b, which here are the same length, one arm 2404c enabling a rotatable fixing in that the rocker arm 2404 is fixed on the support element 2112, 2201 for example by means of a pin. With reference to a Cartesian co-ordinate system 2408 the axes a of the toothed wheel 2401 and d of the shift element 2407 lie roughly parallel to the x-axis, the axes b of the toothed rod 2402 and c of the element 2405 lie roughly parallel to the y-axisi the toothed rod 2402 with the element 2403, the rocker arm 2404 and the element 2405 lie at least approximately in one plane and move in same.

A selection movement has conditioned by the coupling of the selection and shift kinematics an influence on the shift drive. The kinematics are therefore designed so that the influence on the selection kinematics during a shift movement also in this embodiment is so slight that the rotation of the selection drive with a complete shift movement - taking into account the play in the transfer path of the selection kinematics lies below an increment of the selection drive sensor unit and this rotation is thus not detected so that a follow-up regulation of the selection drive is prevented.

Also with the embodiment illustrated in Figures 21 and 22, the same advantages are still obtained in a slightly different design with the support element 2112, 2201 as with the base plate 1701, 1801, as shown and described in Figures 17 and 18.

Furthermore the present invention relates to the earlier applications DE 19734050, DE 19804214, DE 19804217, DE 19814126, DE 19928263, DE 19930869 and DE 19937544 or their subsequent applications whose contents belong expressly to the disclosure of the present application. - 39

The patent claims filed with the application are proposed wordings without prejudice for obtaining wider patent protection. The applicant retains the right to claim further features disclosed up until now only in the

description and/or drawings.

References used in the sub-claims refer to further designs of the subject of the main claim through the features of each relevant sub-claim; they are not to be regarded as dispensing with obtaining an independent subject protection for the features of the sub-claims referred to.

Since the subjects of these sub-claims can form independent and proper inventions in respect of the prior art on the priority date the applicant reserves the right to make them the subject of independent claims or part declarations. They can also contain independent inventions which have a configuration dependent of the subjects of the preceding sub-claims.

The embodiments are not to be regarded as restricting the invention. Rather numerous amendments and modifications are possible within the scope of the invention, particularly those variations, elements and combinations and/or materials which through combination or modification of individual features or elements or process steps contained in the drawings and described in connection with the general description and embodiments and claims can be used by the expert to solve the problem posed and which through combinable features lead to a new subject or to t - 40 new process steps or sequence of process steps insofar as these refer to manufacturing, test and work processes. - 41

Claims (30)

PATENT CLAIMS

1. Motor vehicle with a drive motor, a torque transfer device, a gearbox with a gearbox actuating device and a control device, wherein the control device controls actuation of the torque transfer device and of the gearbox, the gearbox is actuated by a movement having a first movement component and a second movement component, the gearbox actuating device has a base plate connected to lO the gearbox, first and second drives are dedicated to the first and second movements respectively, both of the first and second movements being rotational movements, wherein one of the two drives produces a shift movement using a first gearbox stage driven by the drive and a following, second gearbox stage which converts the rotational movement into axial movement, an element for the tension- free transfer of axial movement, the vehicle also having a shift lever connected to a selection shaft.

2. Motor vehicle with a drive motor, a torque transfer device, a gearbox with a gearbox actuating device and a control device, wherein the control device controls actuation of the torque transfer device and of the gearbox, the gearbox is actuated by a movement having a first movement component and a second movement component, the gearbox actuating device has a base plate connected to the gearbox, first and second drives are dedicated to the first and second movements respectively, both of the first and second movements being rotational movements, wherein one of the two drives produces a shift movement comprises a first gearbox stage driven by the drive, a shift - 42 elasticity, a following second gearbox stage converting the rotational movement into translation movement, an element for the tension-free transfer of axial movement, a rocker-like transfer element, a further element for transferring axial movement, the vehicle also including a shift lever connected to a selection shaft.

3. Motor vehicle as claimed in Claim 1 or Claim 2, wherein the gearbox actuating device comprises a base which supports the first and second drive.

4. Motor vehicle as claimed in any preceding claim, wherein the first gearbox stage comprises a worm with a worm wheel and the axis of the worm wheel dedicated to the first drive and/or of the worm wheel dedicated to the second drive is housed in the base plate.

5. Motor vehicle as claimed in Claim 3 or Claim 4, wherein the base plate forms a housing for at least one gearbox stage of the shift and/or selection kinematics.

6. Motor vehicle as claimed in any one of Claims 3 to 5, wherein the base plate has recesses through which access is possible to areas of the gearbox.

7. Motor vehicle as claimed in any one of Claims 3 to 6, wherein the base plate is provided with ribs for reinforcement.

S. Motor vehicle as claimed in any one of Claims 3 to 7, wherein the base plate is a cast part which has ribs and - 43 the ribs run at such an angle to the main direction of the tool that the production of apertures through the ribs is possible without any additional element.

9. Motor vehicle as claimed in any one of Claims 3 to 8, wherein the base plate is fixed on the gearbox by a bearing for the rotatable shift lever which transfers the shift movement.

10. Motor vehicle as claimed in any one of Claims 3 to 9, wherein an element which generates pretension and is prefitted secured against loss is used for fixing the base plate to the gearbox.

11. Motor vehicle as claimed in any preceding claim, wherein a follower for converting the rotational movement into an axial movement in the transfer path of the selection movement is formed by a disc-like or leverlike element with a connection arranged eccentric relative to the drive axis for connection to the following transfer element.

12. Motor vehicle as claimed in Claim 11, wherein the element following the follower for transferring the axial movement is set by means of ball head connections in the kinematic path.

13. Motor vehicle as claimed in any preceding claim, wherein a spur wheel which, with a toothed rod, forms the second gearbox stage in the transfer path of the shift - 44 movement can be inserted in the shift elasticity for positive-locking force transfer.

14. Motor vehicle as claimed in Claim 13, wherein the toothed rod in the transfer path of the shift movement has an area of a material with a high melting point such as metal which supports the teeth and an area of a material with lower melting point such as plastics which is provided for connection with an element for the tension free transfer of axial movements.

15. Motor vehicle as claimed in Claim 14, wherein the element for tensionfree transfer of axial movements in the transfer path of the shift movement has a region of a material of a higher melting point which is provided for connection with the toothed rod and an area of a material with a lower melting point which is provided for connection with the shift lever.

16. Motor vehicle as claimed in Claim 14, wherein the element for the tension free transfer of axial movements in the transfer path of the shift movement is connected to the toothed rod axially fixed but rotationally movable about at least two axes.

17. Motor vehicle as claimed in Claim 15 or Claim 16, wherein the element for the tension free transfer of axial movements in the transfer path of the shift movement and the toothed rod are connected together by means of a ball head connection.

18. Motor vehicle as claimed in Claim 17, wherein the ball head connection is made by casting or injection moulding a ball arranged on the element for the tension free transfer of axial movements in the transfer path of the shift movement.

19. Motor vehicle as claimed in Claim 18, wherein casting the balls takes place at the same time as casting the part of the toothed rod supporting the teeth and/or the part of the element provided for connection with the shift lever for the tension-free transfer of axial movements in the transfer path of the shift movement.

20. Motor vehicle as claimed in any one of Claims 14 to 19, wherein the toothed rod and/or the element for the tension-free transfer of axial movements in the transfer path of the shift movement consists completely of plastics.

21. Motor vehicle as claimed in any one of Claims 14 to 20, wherein measures are taken so that the connection between the toothed rod and the element for the tension- free transfer of axial movements is fully movable in the temperature range provided for operation.

22. Motor vehicle as claimed in any one of Claims 18 to 21, wherein the ball head is coated with a separating agent prior to the injection process. - 46

23. Motor vehicle as claimed in any one of Claims 18 to 22, wherein mobility between the injected ball head and socket is achieved by a cooling process.

24. Motor vehicle as claimed in any one of Claims 18 to 23, wherein the material of the ball socket is a plastics with low shrinkage value during cooling.

25. Motor vehicle as claimed in any one of Claims 13 to 24, wherein the axis of the toothed rod lies substantially in the pitch circle plane of the teeth.

26. Motor vehicle as claimed in any one of Claims 14 to 25, wherein the tension-free transfer of the shift movement from the rotatable shift lever to an element for introduction to the shift shaft takes place by means of a slide block connection.

27. Motor vehicle as claimed in any preceding claim, wherein the last element in the transfer path of the selection movement before introduction to the shift shaft is at the same time the last element in the transfer path of the shift movement before introduction to the shift shaft.

28. Motor vehicle as claimed in any preceding claim, wherein the change in the position of the selection drive during a shift movement, conditioned through the mechanical coupling of the shift and selection kinematics, is interpreted by the control device not as a position deviation.

28. Motor vehicle as claimed in any preceding claim, wherein the selection kinematics are tuned so that the change in the position of the selection drive during a shift movement is very low or zero.

29. Motor vehicle as claimed in any preceding claim, wherein the change in the position of the selection drive during a shift movement is less than the sum of the clearances present in the selection kinematics.

30. Motor vehicle substantially as herein described with reference to Figures 21 to 24 of the accompanying drawings.