WO2021140361A1

WO2021140361A1 - Shared synchronizer quad- clutch gearbox

Info

Publication number: WO2021140361A1
Application number: PCT/IB2020/050194
Authority: WO
Inventors: Vahid BADORNEGIN
Original assignee: Badornegin Vahid
Priority date: 2020-01-10
Filing date: 2020-01-10
Publication date: 2021-07-15

Abstract

The quad-clutch gearbox with two sets of synchronizer for all gears is includes: two input shafts (one for the even gears and the other for the odd gears), four multi-plate clutch, two oneway clutch, two stepper motor, eleven sun gears and four planetary gears sets, one electronic control unit and differential. The systems of quad-clutches and two one-way clutches causes time of the delayed at gear shifting almost mere 0 milliseconds. Also shape and structure sun and planetary gear eliminates synchronizer and shift rail and reduces the length of the input and eliminates output shaft and makes the Ideal gearbox. All of these features make the gearbox smaller, lighter, easier and safer and more efficient.

Description

shared synchronizer quad- clutch gearbox

The quad-clutch gearbox with two sets of synchronizer for all gears is includes: two input shafts (one for the even gears and the other for the odd gears), four multi-plate clutch, two one-way clutch, two stepper motor, eleven sun gears and four planetary gears sets, one electronic control unit and differential. The systems of quad-clutches and two one-way clutches causes time of the delayed at gear shifting almost mere 0 milliseconds. Also shape and structure sun and planetary gear eliminates synchronizer and shift rail and reduces the length of the input and eliminates output shaft and makes the Ideal gearbox. All of these features make the gearbox smaller, lighter, easier and safer and more efficient.

The technical field of the invention is related to the Mechanical engineering (f) – General details of gearing (f16h 54/00)

(Manual Transmission) A type of gearbox, also known as standard gearbox, performs the torque transfer operation of motor to the wheels by a set of driven and drive gears pairs, which one on the input shaft and the other on the output shaft and the power transfer function is of the input shaft and drive gear to driven gear and output shaft. The clutch used in this type of gearbox is of the dry type and is usually operated by disconnecting the clutch pedal. These were the first gearboxes. Among the disadvantages of this gearbox are the following: Manual gearbox reduces driver dominance and Convenience, leg cramps in traffic and slipping in clutch system and damages it. Restrictions on increasing the number of gears which cause high distance between gear ratio and reduces acceleration and engine spends less time within the optimal RPM range, so it burns more fuel.

(Automated Manual Transmission) These types of gearboxes are ordinary gearboxes, which the clutch and gear assemblies have electrohydraulic or electric actuators controlled by electronic control modules (ECM). In this type of transmission, automatic gearboxes try to increase the driver's mastering on the car, and gear shifting at the right time, which in turn increases engine life and reduces fuel consumption, making it cheaper and easier to build than any other gearbox AT. They also have less maintenance costs than most other gearboxes because they have more in common with manual gearboxes. Important disadvantages of this gearbox are the Interrupted gear shifting and the limitation of increased number of gear which reduces acceleration and increased consumption.

(Dual Clutch Transmission) A dual-clutch transmission offers the function of two manual gearboxes in one. and It has two clutch which One the clutch controls the odd gears (first, third, fifth and reverse), while the other controls the even gears (second, fourth and sixth). Using this arrangement, gears can be changed without interrupting the power flow from the engine to the transmission and It has the Advantages like increasing acceleration and improved fuel economy. One of the major disadvantages of these gearboxes is the high construction cost, High weight and the limitation of increased gear number (they usually have a maximum of 7 gears).

(Continuously Variable Transmission) This type of gearbox is powered by two cones and a metal or polymer belt that connects the cones. The relative motion of the cones along their axis changes the gear ratio infinitely which the result of this continuous variability is better engine efficiency at all speeds. One of the major disadvantages of these gearboxes is this the CVTs can't handle the high torque demands of performance cars, also slipping belt on the pulley and the high maintenance cost.

(Automated Transmission) Planetary automatic transmissions are the most regular type of automatic transmission in cars and consist of important parts of sun gears, torque converter, hydraulic clutches and electrohydraulic controllers and transmits power by a set of sun and planetary gears. One of the major disadvantages of these gearboxes is the high maintenance and construction cost, High weight and high depreciation.

In this invention has tried to minimize the disadvantages of other gearboxes which such as high weight and volume, high construction and maintenance costs, low gear ratio number (Except the CVT), low vehicle acceleration, high depreciation. So that the gearbox looks similar the ideal gearbox.

Also, with search in the field of international patents, the results are as follows:

Hydraulic Automatic Chain Gearbox

Patent Number: US20020033059

The gears move automatically in a straight line. Assuming we want to move forward, we move the gear forward with the gear plate gear, rotating the actuator lever, and the actuator lever controls the pumps associated with the inlet and outlet chains left and right. Slowly, the pumps move forward to make the output chain smaller, to increase the speed of the car. There are a variety of ways to move the gearbox to the lever, so here's just one case. The goals of the new design are something between a regular and an automatic gearbox that has the benefits of each, namely power transmission. It does the automatic gear shifting as well as the special gear that is done in the automatic transmission in this new design. The above design utilizes hydraulic chains to fully transfer power, But in my design, by removing the spacing between the gears, eliminates the output shaft, sets of synchronizer (Shift rails, Shift forks, sliding sleeve, synchronizer hub), the a electrohydraulic mechanism of gear shifting, and Replacing a set of small synchronized two-sided which there is five ball and springs on each side and the stepper motor instead of the gear shifting mechanism, Has caused the gearbox becomes smaller and lighter and its efficiency is increased.

Gear Box

United States patent: US8424405

A main shaft assembly for a gearbox includes a main shaft and drive gears carried for rotation about the main shaft. First and second hubs are associated with respective drive gears, each hub being operable to selectively couple or uncouple with the drive gear causing it to rotate with the hub or with respect to the hub. A drive connection mechanism associated with each hub selectively connects the hub to the main shaft. Upon connection of the hubs to the drive gears, the drive connection operates to connect one or other of the hubs to the main shaft when torque is applied to the main shaft in a first direction or an opposite direction. This enables a gear ratio to be selected by reversing the torque being handled by the gearbox.

Device for changing the gears automatically on a synchronized gearbox

United States patent: 4140031

A processing device capable of starting the sequence of the speed change operations automatically in the gearbox of a vehicle, such as the automatic transmission of a truck. A first comparator compares the data received from a gearbox condition detecting device and that received from a speed ratio selection device. In the event of a difference, the comparator sends to a gearbox control device either a pulse for increasing by one speed ratio, or a pulse for decreasing by one speed ratio.

The structure of this gearbox resembles the dual clutch transmission (DCT) with two main differences: one in the clutches and the other in the shape and structure of the gears shown below.

Important parts of this gearbox two input shafts (one for even gears and other for odd gears), four multi-plate clutches, two one-way clutches, two stepper motors for gear shifting, eleven sun gears, four sets planet gears (each sets planetary gear has eleven integrated gears), one differential and electronic control unit (ECU) and a gearbox body. By removing the spacing between the gears and eliminates the output shaft, ring gears, sets of synchronizer (Shift rails, Shift forks, sliding sleeve, synchronizer hub), the a electrohydraulic mechanism of gear shifting, and Replacing a two set of small synchronized two-sided which there is five ball and springs on each side and the two stepper motor instead of the gear shifting mechanism, compared to the DCTs has caused the gearbox becomes smaller, lighter and its acceleration and efficiency is increased. It can also transfer higher torque and power, and is easily used in lorries and high-powered engines.

Gearboxes in a car, if not higher than the car's engine, are not lower, and play an important and direct role in determining acceleration, speed, safety, braking, driving pleasure and It plays an major impact in fuel consumption. For modern cars people have to pays a lot of money for such features, and again, they might not be ideal, as well as increased gearbox options, causes increasing the price, weight and inertia of the gearbox, and reducing vehicle acceleration. The variety of gearboxes is too much every gearbox has major disadvantages such as high weight, high construction and maintenance costs, slow to Accelerate of vehicle, high depreciation and low efficiency (in AT), high inertia, slipping in the belt during movement (in CVT). which drives the gearbox away from state of the ideal. In this design treading the major disadvantages of the gearboxes mentioned above have been reduced.

The structure of this gearbox with two main differences, resembles the dual-clutch transmission.

one in the clutches and the other in the shape and structure of the gears which that is mentioned below.

Clutch: this gearbox has four friction clutches and two one-way clutches, which the systems of quad-clutches and two one-way clutches causes time of the delayed at gear shifting almost mere 0 milliseconds. the structure of this quad frictional clutch consists of two fundamental clutch, two subsidiary clutch and two one-way clutches, that one fundamental, subsidiary and one-way clutch is related to even geares and other clutches is for odd geares. one of the frictional clutches is on the one-way clutch and operates as sets subsidiary clutch. Whenever this clutch is activated, possible to transfer speed and torque from the engine to the gearbox, and the reverse motion idler clutch operate and not doing transmits power. And the other clutch was the fundamental clutch and whenever the clutch is active, transmits power from engine to gearbox and the reverse motion is possible. the clutch operates as follows, two gears of this gearbox are engaged simultaneously, meanwhile fundamental and subsidiary clutches of one of the gears are active. when engaged to a higher gear, first disconnected fundamental clutch, then connecting another gearbox subsidiary clutch without disconnected of the first gearbox subsidiary clutch. This work leads to speed increment of first gearbox shaft which One-way clutch prevents transmit power from gearbox to engine and locks the gearbox. The performance of quad clutches leads, reduction time of the gear shifting which this design delivers up increase in relative acceleration when compared to a conventional double clutch transmission.

Gears: The gears in this gearbox consist of two types of sun and planetary gear which have been placed odd and even in one row and the tandem and there is not distance between them. planetary gear is located around the sun gear and is made integrated, and also as operate instead of the output shaft. the housing differential also are different from gearbox differentials. housing differential structure has been smaller in this invention. The pinion gear with little distance is located under the crown wheel gear. and performs the task of differential housing sets. Side gears are integrated with cv joint inner and limited slip differential have been placed inside himself which this works cause the it lighter.

Important parts of this gearbox include two input shafts (one for even gears and other for odd gears), four multi-plate clutches, two one-way clutches, two stepper motors for gear shifting, eleven sun gears, four sets planet gears (each sets planetary gear has eleven integrated gears), one differential and electronic control unit and a gearbox body.

The gears in this gearbox are similar like sun gears in automatic transmission (AT) with except that the planetary gears are integrated together for all the sun gears. and There is no any ring gear in this gearbox. The torque is transmitted to the four sets planet gears by sun gears. then output power of planet gears is delivered to last sun gear. which this gear is connected to pinion gear of differential and that is transmits power to it.

In this design, the sun and planetary gears are hollow and ring-shaped, with the geometrical shape of the gears helping to make them lighter. The output shaft has been removed in this gearbox and this gearbox has only the input shaft and Instead, the sets planetary gear performs the function of the output shaft.

the drive dogs on the input shafts, with shaft sliding motion, locks and engaging all sun gears in sequence. This way the power is transferred from the input shaft to the planet gear and output shaft. In this design, Sun gears are known as drive gears and planet gears act as driven gears.

The power transmission path in this gearbox is that the torque is transmitted from the engine to one of the clutches and from there to the input shaft connected to the clutch and then to one of the sun gears locked with the shaft and from there to the four planet gears in front of it. And since the sets planetary gears is a integrated, the torque reaches the last gear on the planetary gears shaft and from there to the last sun gear engaging with it And since the last sun gear is integrated with pinion gear of differential, engine power reaches the differential and wheels shaft. And the wheels rotate with the gear ratio of that gear.

In this design, the synchronizer consists of two parts. The first part is the synchronized drive dogs which it has duty locking the sun gears. and the second part is the synchronizer spring and ball's (which puts instead of the blocking ring), and It has duty the synchronization of shaft speed with sun gear.

on each shaft, there is a set of small synchronized two-sided which there is five ball and springs on each side which and it has the task of synchronizing the shaft speed with the sun gear. and the gear shifting mechanism is conducted automatically in two stages by input shafts sliding motion and This motion is controlled with stepper motors and by order of the ECU

Step one: move the input shaft stepper motor to the sun gear until engagement ball of the synchronizer with sun gears dogs. This operation puts balls into the sun gears dogs groove. whit the several times ball movement by force spring inner the dogs groove, leads balls fixation into the gear dogs. Finally gear and shaft speed becomes synchronized.

Step Two: with recognition of gear and shaft synchronizing speeds by gearbox speed sensor, stepper motor moves the shaft toward the gear until shaft dogs would be engaged with sun gear dogs. This leads shaft and sun gear locking, and gear shifting is operated with shaft sliding motion. These stages are also done for other gear shifting.

The synchronizer of input shaft 1 has the duty of synchronizing speeds and engagement the odd gears the respectively (first, third, fifth until eleventh) and the synchronizer of input shaft 2 has the duty of synchronizing speeds and engagement the even gears the respectively (second, fourth and sixth until tenth and reverse).

The design of this gearbox eliminates sets of synchronizer (Shift forks, sliding sleeve, synchronizer hub) and removing the spacing between the gears, eliminates output shaft, shift rails and electrohydraulic mechanism of gear shifting. small, thin and lighter all gears and Replacing a two set of small synchronizer for all gears and the stepper motor instead of the Gear shifting mechanism, has caused the gearbox becomes smaller and lighter and its efficiency is increased.

Comparison of this gearbox with Automatic transmission(AT) can lead to the conclusion that the removal of ring gears and a large number of multi-plate clutches and brake band, clutch hub and the hydraulic control unit. makes reduction volume, weight, depreciation and maintenance cost and times compared to all types of gearboxes (ATs).

Also comparing this gearbox to dual-clutch transmission (DCT) can be concluded that this gearbox has only two input shafts and the output shaft (which at DCT are has multiple shaft) has been eliminated, the weight of the gears has also been made smaller and lighter due to its special design than the (DCTs). and the gear shifting mechanism that include the hydraulic control unit, shift rail, shift fork, set synchronizer has been removed and two stepper motor and small interface have been used instead. As a result, this gearbox is smaller, lighter and less depreciation than the DCTs and less construction and maintenance costs.

Comparison of this gearbox with (CVT) shows that this is transmission has much number gears (gear number of this gearbox can be up to 11 and even more) And the quad clutch system cause It gear shifting time eliminated and the car acceleration look like a CVT, so that the driver will not feel pauses and gear shifting. And this gearbox doesn't have the disadvantages of the CVTs that includes low power transmission, slipping belt on the pulley and the high maintenance cost. And this gearbox can transmit very high torque and power and can be easily used in lorries and high-powered vehicles. and It is lighter and smaller than most CVTs and has less depreciation rate.

Increase vehicle acceleration and speed relative to all types of gearboxes
Being light and small
Increase efficiency and reduce fuel consumption
Increased gearbox oil life
Increased power and torque transferable
The cost of making and repair it is low
Implementation on all vehicles small and large

All number 1 inside the components description relate input shaft 1 and the all number 2 relate input shaft 2.

shows the overview of the quad clutch, differential, four sets planet gears, sun gears, Reverse gear, crown wheel and pinion gear.

the arrangement of the even and odd sun gears and also shows reverse gear and ball bearings between sun gears.

the broken view of the sun gears and also shows gear dogs inside sun gears.

shows the shifting gear mechanism which includes the stepper motor 1, shaft screw, shift rail input shaft 1 for odd shifting gear and stepper motor 2, stepper motor gear, input shaft 2 for even shifting gear. And synchronizers of the input shaft 1 and 2 that includes the synchronizer ball, ball spring and drive dogs. Synchronizer 1 relate odd sun gears and synchronizer 2 relate even planet gears.

shows the disassembly of the quad clutch system. That includes the clutch hubs, fundamental and subsidiary plate clutchs, one way clutchs and clutch pistons.

shows the broken view of the quad clutch system and the location of the input shafts 1 and 2.

shows the limited slip differential that includes the crown wheel and pinion gears, 10 sets pinion gears of the differential housing, side gears and limited slip plate clutches.

1. Quad-clutch 2. Input shaft 2 3. Input shaft 1 4. Planetry gears (Output shaft) 5. Even sun gears 6. Reverse planet gear 7. Odd sun gears 8. Pinion gear of differential 9. cv joint inner 10. Crown wheel gear 11. Differential 12. Odd planetry gears 13. Reverse idler gear 14. Even planetry gears 15. Gear dogs 16. Drive dogs.

17. first planet gear 18. Second planet gear 19. Third planet gear 20. Fourth planet gear 21. Fifth planet gear 22. Sixth planet gear 23. Seventh planet gear 24. Eighth planet gear 25. Ninth planet gear 26. Tenth planet gear 27. Eleventh planet gear 28. First sun gear 29. Reverse sun gear 30. Second sun gear 31. Third sun gear 32. Fourth sun gear 33. Fifth sun gear 34. Sixth sun gear 35. Seventh sun gear 36. Eighth sun gear 37. Ninth sun gear 38. Tenth sun gear 39. Eleventh sun gear 40. Ball bearing.

41. Even gears shift rail 42. Odd gears shift rail 43. Stepper motor 2

44. Clutch hub1 45. Clutch hub2 46. Spring 47. Synchronizer2 48. Synchronizer ball 49. Synchronizer1 50. Stepper motor1 51. Shift shaft.

52. Clutch hub 53. Clutch piston and hub2 54. Subsidiary plate clutchs2 55. Clutch backing plate2 56. Fundamental plate clutchs2 57. Clutch piston and hub1 58. Clutch Piston1 59. Clutch Piston2 60. Clutch piston housing 61. Fundamental plate clutchs1 62. Clutch backing plate1 63. Subsidiary plate clutchs1 64. One way clutch1 65. One way clutches 2 66. To the engine.

67. Shifting shaft

68. cover 69. inner plate 70. outer plate 71. pinion gears 72. Differential clutch hub 73. Side gear 74. piston.

Examples

This gearbox is used in all large and small cars, trains and other vehicles. Installation of this gearbox does not require modifications to the engine or chassis, but simply replaces with other gearboxes (DCT, AT, CVT and …).

The minimum industrial use of this design is that it can be installed at a lower cost than other automatic transmissions (AT, CVT, DCT, …) on the car or other vehicles and offers the most efficiency. and it took advantage of this transmission.

Claims

What it has been claimed is a quad-clutch gearbox with two sets of shared synchronizer for all gears. This Device consists of two input shafts (one for even gears and other for odd gears), four multi-plate clutches, two one-way clutches, two stepper motors for gear shifting, eleven sun gears, four sets planet gears (each sets planetary gear has eleven integrated gears), one differential and electronic control unit (ECU) and a gearbox body.
According to claim 1 The systems of quad-clutches and two one-way clutches causes time of the delayed at gear shifting almost mere 0 milliseconds.
According to claim 2, the structure of this quad frictional clutch consists of two fundamental clutch, two subsidiary clutch and two one-way clutches, that one fundamental, subsidiary and one-way clutch is related to even geares and other clutches is for odd geares.
According to claim 3, one of the frictional clutches is on the one-way clutch and operates as sets subsidiary clutch. Whenever this clutch is activated, to be possible to transfer speed and torque from the engine to the gearbox, and the reverse motion, idler clutch operate and not doing torque transmission. And whenever the other clutch (fundamental clutch) is active, torque transmission from engine to gearbox and the reverse motion is possible.
According to claim 4, the clutch operates as follows, two gears of this gearbox are engaged simultaneously, meanwhile fundamental and subsidiary clutches of one of the gears are active. when engaged to a higher gear, first disconnected fundamental clutch, then connecting another gearbox subsidiary clutch without disconnected of the first gearbox subsidiary clutch. This work leads to speed increment of first gearbox shaft which One-way clutch prevents transmit power from gearbox to engine and locks the gearbox. The performance of quad clutches leads, reduction time of the gear shifting which this design delivers up large increase in relative acceleration when compared to a conventional double clutch transmission.
According to claim 1, in this gearbox, gears are sun and planet which have been placed odd and even in one row and the tandem and there is not distance between them.
According to claim 6, Planet gear is located around the sun gears and is made integrated, and also as operate instead of the output shaft
According to claim 7, housing differential structure has been smaller in this invention. The pinion gear with little distance is located under the crown wheel gear. and performs the task of differential housing sets.
According to claim 8, Side gears are integrated with cv joint inner and limited slip differential have been placed inside himself.
According to claim 9, The torque is transmitted to the four sets planet gears by sun gears. then output power of planet gears is delivered to last sun gear. which this gear is connected to pinion gear of differential.
According to claim 10, in order to torque transmission, input shaft is engaged with each sun gears and locking them. Four sets planet gears have function of output shaft in charge of.
According to claim 11, on each shaft, there is a set of small synchronized two-sided which there is five ball and springs on each side which and it has the task of synchronizing the shaft speed with the sun gear.
According to claim 12, gear shifting mechanism is conducted automatically in two stages by input shafts sliding motion. This motion is controlled by stepper motors and by order of the ECU.
According to claim 13, first stage: move the input shaft stepper motor to the sun gear until engagement ball of the synchronizer with sun gears dogs. This operation puts balls into the sun gears dogs groove. whit the several times ball movement by force spring, inner the dogs groove leads to balls fixation into the gear dogs. Finally gear and shaft speed becomes synchronized.
According to claim 14, second stage: with recognition of gear and shaft synchronizing speeds by gearbox speed sensor, stepper motor moves the shaft toward the gear until shaft dogs would be engaged with sun gear dogs. This leads shaft and gear locking, and gear shifting is operated with shaft sliding motion. These stages are also done for other gear shifting.
According to claim15, in this gearbox torque is transmitted to the four sets planet gears by sun gears. which this operation increases the output torque portable four times more.
According to claim 16, In this design, the synchronizer consists of two parts. The first part is the synchronized drive dogs which it has duty locking the sun gears. and the second part is the synchronizer spring and ball's (which puts instead of the blocking ring), and It has duty the synchronization of shaft speed with sun gear.
According to claim 17, On each input shaft is one sets of synchronizer, which one respectively locking all even gears and other the all odd gears.
According to claim 18, The synchronizer of input shaft 1 has the duty of synchronizing speeds and engagement the odd gears the respectively (first, third, fifth until eleventh) and the synchronizer of input shaft 2 has the duty of synchronizing speeds and engagement the even gears the respectively (second, fourth and sixth until tenth and reverse).