Title of Invention

TRANSMISSION SYSTEM AND METHOD FOR CONTROLLING TORQUE IN TRANSMISSION SYSTEM

Abstract The present invention relates to a transmission system having a plurality of gear ratios, selector means for selectively engaging the gear ratios, and a control system including means for measuring deformation caused by torque in the transmission system in at least one static component or assembly (50) that is deformed due to torque in the transmission system and means for controlling the torque in the transmission system, wherein the control system is arranged to measure deformation and to adjust the torque in the transmission system according to the measured deformation and a known relationship between the gear ratios, wherein the known relationship is substantially linear and values corresponding to the measured deformation are adjusted by a scaling factor. A method for controlling torque in a transmission system is also disclosed.
Full Text TRANSMISSION SYSTEM AND METHOD FOR CONTROLLING
TORQUE IN TRANSMISSION SYSTEM
The present invention relates to transmissions having control systems for controlling the selection
of gear ratios and a method of controlling torque in the transmission. The present invention can
be used in conjunction with transmission systems of the type described in PCT/GB2004/001976,
and with the apparatus and method for measuring torque in a transmission in PCT/GB2004/
filed simultaneously herewith. The features of each of those documents are hereby incorporated
by reference, though the invention is not to be considered as being limited to transmissions of the
type described.
In conventional single clutch synchromesh transmission systems for vehicles it is necessary to
disengage the transmission from the power source, such as an engine or motor, by operating the
clutch before the current gear is deselected and the new gear is engaged. If the power is not
disengaged when attempting to engage a new gear the syncnrornesh is unable to engage the new
gear wheel or has to be forced into engagement with the risk of damaging the transmission and
creating torque spikes in the transmission. This is because in most cases the speed of the engine
is not matched to the speed of the new gear. For motor vehicles such as cars having conventional
gearboxes and powered by an engine, tie selection of a new gear ratio typically takes between
0.5 and I second to complete. So, for example, when a higher gear is selected the time delay
allows the engine to reduce its speed [due to its own inertia] to more closely match the speed of
the new gear before the clutch re-connects the engine and the transmission, thereby reducing the
possibility of torque spikes occurring when the power is reapplied-
In transmission systems where the selection of a new gear ratio takes place almost instantaneously
without substantial power interruption, such as the transmission described \n
PCT/G62004/001976, large torque spikes can be generated when the new gear Is engaged under
certain shift conditions. These torque spikes cause shock waves to propagate through the
transmission that can be heard and felt by the occupants of the vehicle. The Shockwaves can
produce a jerky ride- for the car occupants and can lead to wear of transmission components and
the possibility of components failing. Nevertheless it is desirable to use such a transmission in
vehicles since it is more efficient thereby requiring less fuel to operate, produces lower emissions
and increases the performance of the car since the application of power is substantially
uninterrupted.
For a control system to operate successfully it is important for it to incorporate ameans of sensing
operational conditions within the transmission. For example, it is often useful to measure or
calculate the magnitude and the direction of torque within the transmission to operate control
devices that can regulate the torque in the transmission. One approach for measuring torque is to
mount a torque sensor on a transmission output shaft for measuring the amount: of twist occurring
between two known points on the shaft. Torque sensors are very expensive and therefore rarely
used in practice. Another drawback is that since the sensor is mounted on the shaft signals must
be sent from the sensor to a processing unit via a wireless transmission sysstem or otherwise
contact brushes must be mounted about the shaft. There are difficulties in setting up torque
sensors using contact brushes and the brushes wear with use and therefore may lead to inaccurate
readings or failure of the sensor.
Accordingly the present invention seeks to provide transmissions having a control system for
regulating the amount of torque in the transmission during a gear change and means for
measuring the magnitude of torque within a transmission that mitigates at least some of the
aforementioned problems.
According to one aspect of the present invention there is provided a transmission system having a
plurality of gear ratios, selector means for selectively engaging the gear ratios, and a control system
including means for measuring deformation caused by torque in the transmission system in at least one
static component or assembly that is deformed due to torque in thejransmission system and means for
controlling the torque in the transmission system, wherein the control system is arranged to measure
deformation and to adjust the torque in the transmission system according to the measured deformation
and a known relationship between the gear ratios, wherein the known relationship is substantially linear
and values corresponding to the measured deformation are adjusted by a scaling factor.
Each gear ratio causes a different amount of deformation in the component or assembly at a ,
particular magnitude of torque in the transmission due to the differing physical properties and
arrangement of each gear ratio. The known relationship of the amount of deformation caused
when each gear ratio is selected allows the control system to adjust the deformation measured in
accordance with the known relationship when a new gear is selected. The control system can
thereby control the amount of torque in the transmission during the gearshift to produce smoother
gear changes without having to calculate the absolute value of torque in the transmission. Static
components and assemblies relate to components and assemblies other than the rotational
components and assemblies of the transmission. Preferably the static component or assembly
arranged is arranged to support or house rotatable components of fee transmission, a vehicle
chassis or support arrangement between the chassis and the transmission.
Advantageously the known relationship is substantially linear and values corresponding to the
measured deformation are adjusted by a scaling factor. In some embodiments the relationship will
be non-linear and algorithms can be used to adjust the measured values.
Advantageously the control system is arranged to control the rate of change of torque in the
transmission in accordance with the deformation measured.
Advantageously the means for controlling torque in the transmission includes clutch means.
Preferably the clutchmeans has first and second engagementmembers for selectively transmitting
drive from a drive source to the transmission, and control means for controlling the engagement
force between the engagement members. The control means can automatically reduce the
engagement force before the selector means selects an unengaged gear ratio to allow relative
rotational movement between the engagement members when the unengaged gear ratio is
engaged by the selector means.
Advantageously the means for controlling torque in the transmission includes means for
controlling the speed of a drive source. For example, the means for controlling the drive source
can be an engine control unit or a throttle pots mechanism.
Preferably the control system includes means for calculating the magnitude* of torque in the
transmission system and includes estimating means for estimating torque in the transmission
when, the selector means engages an unengaged gear ratio. Preferably the estimating means
predicts torque in the transmission when the selector means selects an unengaged gear ratio in
accordance with the measured deformation immediately prior to a gear change and the known
relationship between the engaged gear ratio and the unengaged gear ratio.
The control system includes sensor means for sensing the position of the selector means. The
sensor means can be used to accurately measure the position of the selector assembly to identify
which gear ratio is engaged, and which gear ratio is being selected. This enables the control
system to determine which known relationship should be used to control the torque in the
transmission during a gear change.
Preferably the transmission includes means for identifying fluctuations in the deformation
measurements due to factors other than driveline torque. For example, factors such as vehicle
movement due to undulations in road. Preferably the control system is arranged to record a
plurality of readings and calculate the difference between the measurements, and to control the
torque to account for fluctuations in the deformation measurements [due to factors other than
drive line torque.] If deformation measurements are affected by, for example loading due to an
uneven road surface the control system would control the level of torque to pirevent fluctuations
in the torque in the transmission.
Advantageously the control system may include at least one of means for measuring engine
speed, means for measuring road speed or a vehicle-amounted accelerometer.
Preferably the means for measuring deformation measures the amount of torsional deformatioa
in the component or assembly.
Advantageously the means for measuring deformation determines the direction of torque in the
transmission.
Preferably the component or assembly comprises at least one of a transmission bearing, casing,
support member, mounting, or mounting bolts. Preferably the casing comprises one of the
gearbox casing and the tail shaft casing.
Preferably the means for measuring deformation includes at least one load cell, and preferably
a plurality of load cells, In one embodiment the means for measuring deformation is mounted on
a casing having a longitudinal axis and the casing is arranged such that torque in the transmission
twistingly deforms the casing about the longitudinal axis. Preferably first and second load cells
are mounted on the casing such that the deformation of the casing causes the first and second load
cells to generate different outputs. Preferably the bad cells are arranged in a Wheaistone bridge
circuit
In one embodiment the means for measuring deformation measures the amount of strain in the
component or assembly. The means formeasuring deformation includes at least one strain gauge.
Preferably the strain gauge is arranged in a Wheatstone bridge circuit
According to another aspect of the present invention there is provided a method for controlling torque
in a transmission system having a plurality of gear ratios and selector means for selectively engaging
the gear ratios, including measuring the deformation caused by torque in at least one component or
assembly arranged to support or house rotatable components of the transmission system, selecting an
unengaged gear ratio, adjusting the torque in the transmission system in accordance with the measured
deformation and a known relationship between the gear ratios, wherein the known relationship is
substantially linear and adjusting values corresponding to the measured deformation by a scaling factor.
Preferably the method includes controlling the rate of change of torque.
Preferably the method includes estimating the amount of torque in the transmission when an
unengaged gear ratio will be engaged.
Preferably the transmission system includes first and second rotatable shafts, and means for
transferring drive from one of the shafts to the other shaft including first and second gear wheels
each rotatably mounted on the first shaft and having drive formations formed thereon, selector
assembly for selectively transmitting torque between the first shaft and the first gear wheel and
between the first shaft and the second gear wheel, wherein the selector assembly includes an
actuator, assembly and first and second sets of engagement members that are moveable into and
out of engagement with the first and second gear wheels independently of each other, said
selector assembly being arranged such that when a driving force is transmitted, one of the first
and second sets of engagementmembers drivingly engages the engaged gear wheel, and the other
set of engagement members is then in an unloaded condition, wherein the actuator assembly is
arranged to move the unloaded set of engagement members into driving engagement with, the
unengaged gear wheel to effect a gear change.
The selector assembly can be arranged such that when a braking force is transmitted the first set
of engagement members drivingly engages the engaged gear wheel, and the second set of
engagement members is in an unloaded condition, and when a driving force is transmitted the
second set of engagement members drivingly engages the engaged gear wheel, and the second
set of engagement members is then in an unloaded condition.
The actuator assembly can be arranged to bias the loaded set of engagement meanbers towards
the unengaged gear wheel without disengaging the loaded set of engagement members from the
engaged gear wheel.
The first and second sets of engagement members can be arranged to rotate, in use, -with the first
shaft. Preferably the first shaft is an input shaft and the second shaft is an output shaft and drive
is transferred from the input shaft to the output shaft.
An embodiment of the present invention will now be described, by way of example only, with
reference to the accompanying drawings in which like references indicate equivalent features,
wherein:
Figure 1a is a sectional general arrangement of a transmission system in accordance with
the present invention;
Figure 1b is aperspective view of the outer casings of the transmission of Figure la;
Figure 1c is a schematic of a control system in accordance with the current invention;
Figure 1d is a graph of torque v time for a gear change from first to second gear,
Figure 2 is a perspective view of part of a selector assembly;
Figure 3 illustrates the arrangement of a group of dogs on a side-of a gear;
Figure 4 is a plan view of a disc spring;
Figures 5a-f illustrate diagrammatically operation of the selector assembly;
Figure 6 is a schematic showing operation of the control system when selecting a higher
gear;
Figure 7 is a graph showing clutch pressure against tirne;
Figure 8 is a schematic showing operation of the control system when selecting a lower
gear;
Figure 9 shows a circuit diagram for a strain gauge;
Figure 10 is a sectional view of an output shaft showing an alternative arrangement for
attaching the engagement bars to the output shaft; and
Figure 11 is a plan view of a disc spring for a second embodiment of the invention;
Figures la and lb show a transmission system atrange4 for use in a vehicle such as a motor car
and Figure 1 c is a schematic of a control system for controlling the selection of gear ratios. The
transmission system comprises an output shaft 1 having first and second gear wheels 3,5 mounted
thereon, an input shaft 7 having third and fourth gear wheels 9,11 mounted thereon and a selector
assembly 13. The first and second gear wheels 3,5 are rotatably mounted on the output shaft 1
and the third and fourth gear "wheels 9,11 are formed integrally with the input shaft 7 and are
locked for rotation therewith. The first and second gear wheels 3,5 mesh with third and fourth
gear wheels 9,11 respectively, which are formed integrally with the input shaft, to form first and
second gear wheel pairs 15,17. The input shaft 7 is connected to a clutch 2 having first and second
clutch plates 4,6. The first clutch plate 4 is connected by a first shaft 8 to the output of an engine
10 and the second clutch plate 6 is connected by a second shaft 12 to the input shaft 7 via a fifth
gear wheel 14. The fifth gear wheel 14 is locked for rotation with the second shaft 12. The
arrangement is such that the clutch 2 can selectively apply drive from the engine 10 to the
transmission output shaft 1, via the input shaft 7 and gear ratios 15,17.
First and second sensors 16,18 are located in.the clutch 2 to measure the rotational speeds of the
first and second clutch plates 4,6 respectively. The first and second sensors 16,18 are Hall Effect
type sensors but other types of sensor such as optical sensors or gear wheel speed measurement
devices can be used. The first and second sensors 16,18 are connected to a computer processor
20 that controls the operation of the control system. Optionally, a third sensor 18b can be used
to measure the rotational speed of the engine output shaft The clutch 2 includes an actuator 22
for controlling the pressure, and hence the amount of friction, between the first and second clutch
plates 4,6 and hence the torque that can be transmitted from the engine 10 to the transmission.
The actuator 22 is controlled electronically by signals received from the computer processor 20
to increase or decrease the pressure between the first and second clutch plates 4,6 and thereby
control whether the first and second clutch plates rotate at the same speed (fully engaged) or
whether they move relative to each other (slip occurring). The computer processor 20 can detect,
slip in the clutch 2 from the measured speed of the engine output shaft by detecting changes in
the speed and known properties of the transmission, such as which gear ratio is engaged and the
number of teeth each gear wheel has. Similarly the computer processor 20 can detect clutch slip
by comparing the speed sensors on either side of the clutch. The processor 20 can determine
which gear is engaged by reading the speed sensors on the output side of the clutch (gearbox
input speed) and gearbox output speed.
The computer processor 20 is also connected to a throttle control mechanism 24 for controlling
the speed and torque output of the engine 10. The throttle control mechanism 24 is a throttle pots
mechanismjhat is arranged to. selectively override the driver's control of the engine to enable the
control system to more closely control the torque output of the engine to assist with, maintaining
a target gearbox output torque gradient during rapid gear engagement. Signals sent from the
computer processor 20 to the throttle pots 24 can increase or decrease the engine speed or torque
in accordance with the control signals received, thereby controlling the rotational speed of the
first shaft 8 and the first clutch plate 4. The speed of the engine 10 is measured using a
conventional sensor the output of which is connected to the computer processor 20.
The effect of torque spikes caused when tine selector assembly 13 engages a new gear ratio can
be reduced to an acceptable level, that is to a level that cannot be detected by the occupants of the
vehicle, by reducing the pressure between the first and second clutch plates 4,6 before the new
gear ratio is selected without fully disengaging the plates to allow the clutch plates to slip
(relative rotational movement between the clutch plates) when the selector assembly 13 engages
the new gear wheel and generates a torque spike in the transmission. Preferably the pressure
between the clutch plates 4,6 is reduced to approximately the onset of slip immediately after a
gear change has been initiated, for example manually by the driver moving a gear stick 26 or
automatically by the control system after measuring a certain engine speed, but before the new
gear is engaged. The torque spike generated by the selector assembly 13 engaging the new gear
wheel is dissipated because it causes rapid slip between the clutch plates 4,6 since the clutch
plates are already at the onset of slip before receiving the additional load caused by the torque
spike. This also allows the engine 10 time to adjust its speed to match the speed of the new gear
ratio.
The clutch 2 is housed in a first casing 32, commonly known as a bell housing , and the
transmission is housed in a second casing 34, known as the gearbox casing. The bell housing 32
comprises is a substantially frustum tubular member and the gearbox casing 34 comprises a
tubular member having a rectangular cross-section. First and second end plates 36,33 are each
attached to the gearbox casing 34 by bolts. The end plates 36,38 can be detached from the
gearbox casing 34 to allow maintenance work to be undertaken. The bell housing 32 is fixed to
first end plate 36 by bolts (not shown). The first end plate 36 has a through hole 40 and the
second shaft 12 extends from the second clutch plate 6 through the hole 40 and into the gearbox
casing 34. The first shaft 8 is supported by a bearing 42 within the gearbox casing for rotational
movement relative to the gearbox casing. The bearing 42 is press fit into the first end plate 36.
Tte input shaft 7 is supported by two bearings 44 for rotational movement relative to the gearbox
casing 34. The bearings 44 are press fit into the first and second end plates 36,38.
The second end plate 38 has a through hole 48 and the output shaft 1 extends through the hole
48, into a third casing 50, also known as a tail shaft casing. The output shaft 1 is supported by a
bearing 52 that is press fit in the second end plate 38 for rotational movement relative to the
gearbox casing 34. The tail shaft casing 50 is fixed to the second end plate 38 by a sleeve 52 that
is welded to the second end plate. The tail shaft casing 52 comprises a substantially cylindrical
tube with a closed end 54 that is arranged co-axially with, the output shaft 1. There is a hole 56
in the end' of the tail shaft casing 50 and the output shaft 1 extends through the tail shaft casing
50 and through the hole 56 for connection with a differential (not shown). The output shaft 1 is
supported for rotational movement relative to the tail shaft casing 50 by a bearing 58.
A substantially rigid support arrangement 60 for supporting first and second load cells 62,64 is
mounted on the underside of the tail shaft casing. The support arrangement 60 is mounted
perpendicularly to the longitudinal axis of the tail shaft casing and hence the output shaft 1. The
load cells 62,64 rest on a chassis bar (not shown), which is a structural member of the chassis
extending laterally across the chassis, but are not attached to the chassis bar.
When the output shaft 1 is driven by the engine 10 via the transmission system, torque is
transmitted from the input and output shafts 7,1, along a load path including the bearings
42,44,52,58, the gearbox casing 34, first and second end plates 36,3 8 and the tail shaft casing 50.
The torque in the input and output shafts 7,1 causes thebearings 42,44,52,58, iiie gearbox casing
34, the first and second end plates 36,38 and the tail shaft casing 50 to deform. The extent of the
deformation is proportional to the magnitude of the torque in the output shaft 1 and therefore fee
extent of deformation measured can be used to control the amount of torque applied to the
transmission when selecting between gear ratios. The direction of torque is important since it
indicates whether the engine, vehicle or transmission is under going acceleration or deceleration
(braking).
In the present embodiment the magnitude and fee direction of the torque in the transmission is
measured using the load cell arrangement shown in Figure 1b. When torque is transmitted to the
tail shaft casing 50, the casing deforms by twisting. The support arrangement 60 twists with the
tail shaft casing 50 thereby causing one of the first and second load cells 62,64, to increase the
force applied to the chassis bar and the other load cell to reduce the load applied to the chassis
bar. Readings can be taken from the load cells 62,64. The magnitude of the difference between
the readings from the first and second load cells 62,64 is proportional to the amount of
deformation of the tail shaft casing 50 and hence the magnitude of the torque in the transmission.
Direction of the torque is established by determining which of the first and second load cells
62,64 -has the larger reading.
The tail shaft casing 50 deforms by a different amount for a given magnitude of torque in the
output shaft 1 when different gear ratios are engaged by the selector mechanism 13. This is
because of the different relative positions of the gear wheels along the shafts 1,7, the physical
properties of the gear wheels such as size, geometry, materials used, tooth form etc. Therefore
it is necessary to adjust the values of deformation measured when comparing measured values
generated when different gear ratios are engaged by the selector mechanism. Otherwise
equivalent measured values would relate to different values of torque in the output shaft 1.
The relationship between the amount of deformation caused in the tail shaft casing 50 when the
selector assembly 13 engages different gear ratios, for example the first and second gear ratios
15,17, is known and therefore the amount of torque in the transmission can be controlled by
measuring deformation in the tail shaft casing 50, or some other component or assembly that
supports or houses rotatable transmission components. Typically the relationship is substantially
linear and therefore the amount of deformation measured when the first gear ratio 15 is engaged
can be multiplied by a scaling factor for comparison with deformation measured when the second
gear ratio 17 is engaged. In some embodiments the relationship may be non-linear.
It is necessary for the control system to know the correct relationship to apply when selecting
between gear ratios. When more than one selection can be made and hence a plurality of
relationships exist between different ratios, it is necessary for the control system to know the
position of the selector assembly 13 so that it can Identify the gear ratio currently engaged, the
gear ratio newly selected and the relationship between those gear ratios for adjusting the amount
of deformation measured. This can be- achieved using position sensors 70. The sensors 70 can be
Hall Effect sensors, mechanical switches or optical sensors. The sensors 70 are connected to the
computer processor 20 to accurately inform the processor of position of the bar sets and hence
which gear ratio is engaged. It also provides additional means for controlling actuation of the
selector rod 35 and provides a means of confirming that a gear change has taken place.
When an unengaged gear ratio is selected the amount of torque in the transmission changes and
is determined by the gear ratio selected. For example, a lower gear (e.g. 1 sl gear in a vehicle)
produces more torque in the transmission than selection of a higher gear (e.g. 2nd gear in a
vehicle). When the new gear ratio is selected the torque in the transmission has to adjust from that
determined by the old gear ratio to that determined by the new gear ratio.. It is preferable to
control the increase ot decrease in torque in the transmission to provide a smoother gear
transition.
This is achieved by measuring the deformation in the tail shaft casing 50 immediately after a gear
change has been initiated but before the gear selection is made, and after the new gear ratio has
been selected. The control system uses the known relationship between the two gear ratios to
adjust the deformation measurements made. The first and second load cells 62,64 are connected
to the computer processor 20. The computer processor controls the magnitude of Ihe torque in the
transmission by monitoring the amount of deformation in the tail shaft casing 50 and controlling
the pressure between the clutch plates 4,6 with the clutch actuator 22 and the engine speed and
torque •with the throttle pots 24 to allow the torque to increase or decrease in a controlled manner,
for example at a predetermined rate, to provide a smooth gear change. The control system can
maintain the torque within a predetermined tolerance range of a selected value.
The control system minimises the effect of the torque spike caused when a new gear ratio is
engaged.by adjusting the torque to the level it was prior to the gear change so that the control
system follow a torque gradient to a target torque for the new ratio.
It is also possible to calibrate the torque in the output shaft 1 with the defoicmation measured,
which may be measured for calibration purposes only with a conventional torque sensor. Hence
mere is a known relationship between the amount of deformation measured and the magnitude
of torque acting on the output shaft 1. However, this is not necessary for the control system to
obtain smooth gear changes since it is only necessary to maintain and / or control the rate of
change of torque rather than control the- absolute magnitude of torque, which can be achieved by
monitoring the amount of deformation in the tail shaft casing 50 as the control system adjusts the
clutch pressure and throttle.
Rotational drive is transferred from the input shaft 7 to the output shaft 1 via either the first or
second gear wheel pairs 15,17, with selection of the gear wheel pairs being determined by die
position of the selector assembly 13. The selector assembly 13 engages first and second groups
of drive formations 19,21 located on the first and second gear wheels 3,5 respectively.
The drive formations each comprise groups of dogs. The first dog group 19 is located on one side
of the first gear wheel 3. The dogs are preferably formed integrally with the first gear wheel, but
this is not essential. The first dog group 19 comprises threes dogs evenly circumferentially
distributed about the gear face, i.e. the angle subtended between the centres of a pair of dogs is
approximately 120 degrees (see Figure 3). The second dog group 21, comprises three dogs and
is similarly arranged on one side of the second gear wheel. Three dogs are used because this
arrangement provides large engagement windows, that is the spaces between the dogs, to receive
the selector assembly 13. Large engagement windows provide greater opportunities for the
selector assembly to fully engage the gear wheels 3,5 before transmitting drive thereto. If the
selector assembly 13 drives a gear wheel when only partially engaged it can lead to damage of
the dogs and / or the selector assembly 13.
The first and second gear wheels 3,5 are mounted spaced apart on the output shaft 1 on roller
bearings 23,25 and are arranged such that the sides including the first and second dog groups face
each other.
The selector assembly 13 includes first and second sets of engagement bars 27,29 and an actuator
assembly 31 in the form of a fork assembly 33 and a selector rod 35.
The first and second sets of engagement bars 27,29 are mounted on the output shaft 1 between
the first and second gearwheels 3,5. Referring specifically to Figure 2; the first set of engagement
bars 27 comprises three bars 28 attached to a first connector ring 37, for example using grub
screws. The first connector ring 37 holds the bars 28 in a fixed arrangement The bars 28 are
evenly distributed about the inner circumference of the first connector ring 37 such that their
bases face inwards, and the bars 28 are arranged substantially parallel. The second set of
engagement bars 29 comprises three bars 30 which are held in a similar fixed arrangement by a
i . . . .
second connector ring 39.
The first and second engagement bar sets 27,29 are mounted on the output shaft 1 between the
first and second gear wheels 3,5. The sets of engagement bars 27,29 are arranged to rotate with ,
the output shaft 1 but are able to slide axially along the shaft in response to a switching action of
the actuator assembly 31. To facilitate this, the output shaft 1 includes six keyways 41 formed in
its curved surface with each engagement bar 28,3 0 having a complementary formation in its base.
. The arrangement of the bar sets 27,29 is such that bars of a particular set are located in alternate
keyways 41 and the bar sets 27,29 can slide along the output shaft 1. Each bar set 27,29 moves
as a unit and each bar set can move independently of the other. When there is relative movement
between the first and second sets of bars 27,29, the second connector ring 39 slides over the first
set of bars 27 and the first connector ring 37 slides over the second set of bars 29.
Each bar 28 in the first bar set 27 has a first end 28a arranged to engage the first group of dogs
19 attached to the first gear wheel 3 and a second end 28b arranged to engage the second group
of dogs 21 on the second gear wheel 5. The first and second ends 28a,28b typically have the same
configuration but are opposite handed, such that (he first end 28a is arranged to engage the first
group of dogs 19 during deceleration of the first gear wheel 3 and the second end 28b is arranged
to engage the second group of dogs 21 during acceleration of the second gear wheel 5. Each bar
30 in the second bar set 29 is similarly arranged, except feat the first end 30a is arranged to
engage the first group of dogs 19 during acceleration of the first gear wheel 3 and the second end
30b is arranged to engage the second group of dogs 21 during deceleration of the second gear
wheel 5.
When both the first and second sets of engagement bars 27,29 engage a gear wheel drive is
transmitted from the input shaft 7 to the output shaft 1 whether the gear is accelerating or
decelerating.
The first and second ends 28a,30a,28b,30b of each bar include a substantially vertical face 43 for
engaging dogs 19,21 and a ramp 45 that slopes in the direction of the engagement face 43 to
ensurethatthebars28,30disengagefi'omthedogs 19,21 to prevent the transmission from locking
up; When the bars of the first and second sets 27,29 are interleaved, as in Figure 2, the dog
engagement faces 43 of the first end 28a of the first set of bars 27 are adjacent the dog
engagement faces 43 of the first end 30a of the second set of bars: 29. When the first and second
sets of bars 27,29 are fully engaged with a gear a dog is located between each pair of adjacent
engagement faces 43. The dimensions of the dogs 19,21 and the ends of the biars are preferably
such that there is little movement of a dog between the engagement face 43 of the acceleration
bar and the engagement face 43 of the deceleration bar when the gear moves from acceleration
to deceleration, or vice versa, to ensure mat there is little or no backlash in the gear.
Preferably the bars are configured to be close to the output shaft 1 to prevent significant cantilever
effects due to large radial distances of loaded areas thus reducing the potential for structural
failure.
The actuator assembly 31 is arranged such that the fork assembly 33 is mounted on the selector
rod 35, and the selector rod is provided parallel to the output shaft 1 and adjacent thereto. The
fork assembly 33 includes a fork 46 and first and second annular disc springs 47,49 mounted
about the output shaft 1 (see Figure 1 a). The first and second disc springs 47,49 have three arms,
with each aim having a first part that extends circumferentially around a part of the spring and
a second part that extends radially inwards (see Figure 4).
The fork 46 has afirst pair of arcuate members 51 arranged to engage the first disc spring 47. The
arcuate members 51 are arranged such that the first disc spring 47 can rotate with the output shaft
1 between the arcuate members 51 and such that axial movement of the fork 46 parallel to the
output shaft 1 moves the arcuate members 51 and hence the first disc spring 47 axially along the
shaft if the first disc spring 47 is free to move, or biases the first disc spring 47 to move in the
same direction as the fork 46 if the first disc spring 47 is unable to move. The fork 46 has a
second pair of arcuate members 53 arranged to engage and act upon the second disc- spring 49 in
a similar manner.
The position of the fork 46 relative to the first and second gear wheels 3,5 can be adjusted by
movement of the selector rod 35 in the axial direction.
The inner edges of the first disc spring 47 are fixed to the bars 28 in the first bar set 27 and the
inner edges of the second disc spring 49 are fixed to the bars 30 in fee second bar set 29. When
the fork 46 moves, thereby moving or loading the disc springs 47,49 the engagement bar sets
27,29 are likewise moved or biased to move.
The transmission can be arranged as manual gear shift wherein gears are selected by moving a
gear stick between predetermined positions (as shown in Figure lb), a semi-automatic
transmission wherein the driver initiates a gear change by controlling electronic switches, for
example paddles mounted adjacent the steering wheel, or fully automatic wherein the control
system causes the transmission system to change gear according to certain predetermined
conditions, including for example engine speed and torque.
The processes of selecting a higher gear (i.e. second gear wheel pair 17) when a vehicle is
accelerating (so called up shift) and a lower gear (i.e. first gear wheel pair 15) when the vehicle
is decelerating (so called breaking down shift) using the control system" will now be described
withreference to Figures 5a-5f which for clarity illustrate diagrammatically the movement of the
first and second bar sets 27,29 by the relative positions of only one bar from each set, Figures 1 a-
c and Figures 6 to 9.
Figure 5c shows a condition when the first gear wheel 3 is fully engaged, that is, the bars 28,30
are interleaved with the first group of dogs 19. The selector rod 35 is located such that the fork
46 maintains the first and second bar sets 27,29 in engagement with the first gear wheel 3.
Accordingly, drive is transferred to the output shaft 1 via the first gear wheel pair 15 by the first
bar set 27 when decelerating and the second bar set 29 when accelerating.
Whilst accelerating (first gear wheel 3 rotating in the direction of arrow B in Figure 5c) using the
first gear wheel pair 15, the engagement faces 43 of the bars of the first bar set 27 are not loaded,
whilst the engagement faces 43 of the bars of the second bar set 29 are loaded. When a user, or
the control system, initiates selection of the second gear wheel pair 17, the computer processor
takes measurements from the first and second load cells 62,64 and compares the values measured.
If the value measured by the second load cell 64 is greater than that measured by the first load cell
62 this indicates to the control system that the engine is accelerating and the gear change is
allowable. The processor 20 then sends control signals to the clutch actuator 22 to adjust the
pressure between the first and second clutch plates 4,6. The rotational speed of each clutch plate
is measured by the clutch plate sensors 16,18. Whilst the clutch plates are fully engaged the
sensors 16,18 will show that they are rotating at the same speed. As the pressure between the
clutch plates 4,6 reduces a condition will be reached where the torque transmitted by the clutch
2 will overcome the friction between the first and second plates 4,6 causing the first and second
plates 4,6 to move relative to each other (onset of slip B see Figure 7). The computer processor
20 will detect the onset of slip when there is a measured difference between the rotational speeds
of the first and second clutch plates 4,6. The processor 20 then instructs the actuator 22 to
maintain this pressure (the "slip pressure").
After the computer processor 20 has measured deformation prior to the shift, the processor 20
calculates the amount by which the measurement from the load cells 62,64 needs to be adjusted
to cause the torque value in the transmission to match the torque prior to the shift when the new
ratio is engaged (each ratio causes a different reading in the load cells 62,64 even when output
torque is maintained during a shift as the moment forces change due to the different axial
position, gear diameter, and ratio of each gear). This becomes the first target value upon
engagement of the new ratio.
The processor 20 sends control signals to actuate the selector rod 35 such that the fork 46 acts on
the first disc spring 47, causing the bars of the first bar set 27 to slide axially along the keyways
41 in the output shaft 1 thereby disengaging the bars from the first gear wheel 3 (see Figure 5d).
The fork 46 also acts on the second disc spring 49 to bias the bars of the second bar set 29 to
move towards the second gear wheel 5. However, because the bars of the second bar set 29 are
loaded, i.e. are driving the first gear wheel 3, they cannotbe disengaged from the first gear wheel
3, and therefore the bars of the .second bar set 29 remain stationary.
When the bars of the first bar set 27 slide axially along the output shaft 1, the engagement faces
43 engage Ihe second group of dogs 21 (see Figure 5e) on the second gear wheel 5. As this occurs
the rotation of the second gear wheel 5 is substantially instantaneously locked to the rotation of
the output shaft 1 which generates a torque spike in the transmission. The torque spike causes
substantial slip between the first and second clutch plates 4,6 since the clutch plates 4,6 were
being maintained at the slip pressure, thus dissipating the energy in the torque spike. At the same
time the computer processor 20 measures the amount of deformation in the tail shaft casing 50,
and sends control signals to the clutch actuator 22 and to the throttle pots 24 to adjust the pressure
between the first and second clutch plates 4,6 and to adjust the speed and torque of the engine 10
to cause the deformation measured by the load cells 62,64 to adjust to the final target value for
the new ratio in a controlled manner, for example at a predetermined rate. The control system
prioritises restoring the clutch 2 to full pressure to limit clutch wear and adjusts the engine speed
and torque to allow this to happen, without exceeding the target load cell value at any time until
the final target value is reached. When the clutch 2 is fully engaged control of the throttle is then
returned to the driver as quickly as possible without exceeding the target load cell value set
tolerances at any time until the final target value for the new ratio is achieved whereupon throttle
is returned to driver control and the clutch is restored to full in gear pressure.
The bars of the first bar set 27 then begin to drive the second gear wheel 5 in the direction of
Arrow C inFigure 5e and energy is transmitted from the output shaft 1 to the input shaft 7 by way
of the second gear wheel pair 17. As this occurs, the bars of the second bar set 29 cease to be
loaded, and are free to disengage frorn the first group of dogs 19. Since fee second disc spring 49
is biased by die fork 46, the bars of the second bar set 29 slide axially along the keyways 41 in
the output shaft 1 thereby completing the disengagement of the first gear wheel 3 from the output
shaft 1. The bars of the second bar set 29 slide along the keyways 41 in the output shaft 1 until
they engage the second gear wheel 5} thereby completing engagement of the second gear wheel
5 with the output shaft 1 (see Figure 5f). This method of selecting gear wheel pairs substantially
eliminates torque interruption since the second gear wheel pair 17 is engaged before the first
wheel pair 15 is disengaged, thus momentarily, the first and second gear wheel pairs 15,17 are
simultaneously engaged.
When a gear wheel is engaged by both the first and second bar sets 27,29 it is possible to
accelerate or decelerate using a gear wheel pair with very little backlash occurring when
switching between the two conditions. Backlash, is the lost motion experienced when the dog
moves from the engagement face 43 of the acceleration bar to the engagement face 43 of the
deceleration bar when moving from acceleration to deceleration, or vice versa. A conventional
dog-type transmission system has approximately 30 degrees of backlash. A typical transmission
system for a car in accordance with the current invention has backlash of less than four degrees.
Backlash is reduced by minimising the clearance required between an engagement bar and a dog
during a gear shift: that is, the clearance between the dog and the following engagement bar (see
measurement'A' inFigure 5b). The clearance between the dog and the following engagement bar
is in the range 0.5mm - 0.03mm and is typically less than 0.2mm. Backlash is also a function of
the retention angle, that is, the angle of the engagement face 43, which is the same as the angle
of the undercut on the engagement face of the dog. The retention angle influences whether there
is relative movement between the dog and the engagement face 43. The smaller the retention
angle, the less backlash that is experienced. The retention angle is typically between 2.5 and 15
degrees, and preferably is 15 degrees.
Transition from the second gear wheel pair 17 to the first gear wheel pair 15 whilst decelerating
is achieved by a similar process.
Whilst decelerating in the second gear wheel pair 17 the engagement surfaces 43 of the bars of
the first bar set 27 are not loaded, whilst the engagement surfaces 43 of the bars of the second bar
set 29 are loaded. When a driver or the control system initiates a gear change to engage the first
gear wheel pair 15, the processor 20 sends control signals to the clutch actuator 22 to adjust the
pressure between the first and second clutch plates 4,6. The speed of each clutch plate 4,6 is
measured by the clutch plate sensors 16,18. Whilst the clutch plates 4,6 are folly engaged the
sensors will show that they are rotating at the same speed. As ihe pressure between the clutch
plates 4,6 reduces a condition will be reached where the torque transmitted by the clutch will
overcome the friction between the first and second plates 4,6 causing the first and second plates
to move relative to each other (onset of slip B see Figure 7). The computer processor 20 will
detect the onset of slip when mere is a measured difference between the rotational speeds of the
first and second clutch plates.. The processor men instructs the actuator 22 to maintain the
pressure at the slip pressure. The processor then takes measurements from the first and second
load cells 62,64 and compares the values measured. The computer processor 20 records the
amount of deformation in the tail shaft casing 50 and the direction of the torque.
After the computer processor 20 has measured deformation prioi to the shift, the processor 20
calculates the amount by which the measurement from the load cells 62,64 needs to be adjusted
to cause the torque value in the transmission to match the torque prior to the shift when the new
ratio is engaged (each ratio causes a different reading in the load cells 62,64 even when output
torque is maintained during a shift as the moment forces change due to the different axial
position, gear diameter, and ratio of each gear). This becomes the first target value upon
engagement of the new ratio.
If the value measured by the first loadcelL 62 is greater than the second load cell 64 this indicates
mat the engine 10 is decelerating and an engine braking down shift has been initiated. The
processor then sends control signals to actuate the selector rod 35 such that the fork 46 slides
axially relative to the output shaft L The fork 46 acts on the first disc spring; 47 attached to the
first bar set 27, causing the bars of the first bar set 27 to slide axially in the keyways 41 along the
output shaft 1 in the direction of the first gear wheel 3, thereby disengaging the first bar set 27
from the second gear wheel 5.
The fork 5 also acts on the second disc spring 49 but since the bars of the second bar set 29 are
loaded, i.e. they are drivingly engaged with the dogs 21 on the second gear wheel, the second bar
set 29 remains stationary, however the second disc spring 49 is biased by the fork 46 to move the
second bar set 29 towards the first gear wheel 3.
As the bars of the first bar set 27 slide axially in the keyways 41, the bars 28 engage the dogs 19
on the first gear wheel 3. As this occurs the rotation of the first gear wheel 3 is substantially
instantaneously locked to the rotation of the output shaft 1 which generates a torque spike in the
transmission. The torque spike causes substantial slip between the first and second clutch plates
4,6 since the clutch places were being maintained at the slip pressure, thus dissipating the energy
in the torque spike. At the same time the computer processor 20 measures the amount of
deformation in the tail shaft caging 50, and sends control signals to the clutch actuator 22 and to
the throttle pots 24 to adjust the pressure between the first and second clutch plates 4,6 and to
adjust the speed and torque of the engine 10 to cause the deformation measured by the load cells
62,64 to adjust to the final target value for the new ratio in a controlled manner, for example at
a predetermined rate. The control system prioritises restoring the clutch 2 to full pressure to limit
clutch wear and adjusts the engine speed and torque to allow this to happen, without exceeding
the target load cell value at any time until the final target value is reached. When the clutch 2 is
fully engaged control of the throttle is then returned to the driver as quickly as possible without
exceeding the target load cell value set toleraaces at any time until the final target value for the
new ratio is achieved whereupon throttle is returned to driver control and the clutch is restored
to full in gear pressure.
When the bars 28 engage the dogs 19 on the first gear wheel 3 they begin to drive the first gear
wheel 3 such that energy is transmitted from the input shaft 7 to the output shaft 1 by way of the
first gear wheel pair 150. As this occurs, the bars of the second bar set 29 ceases to be loaded. The
second disc spring 49 acts on the bars of the second bar set 29, causing it to slide axially within
the keyways 41 along the output shaft 1 towards the first gear wheel 3, thereby completing
disengagement of the second gear wheel 5. The second bar.set 29 continues to slide within the
keyways 41 along the output shaft 1 until it engages the first gear wheel 3, thereby completing
engagement of the first gear wheel 3 with the output shaft 1.
If the second load cell 64 has a higher value than the first load cell 62 there is engine acceleration
and the driver / control system, is trying to perform a kick down gear change, that is a gear shift
from a higher gear to a lower gear to accelerate the vehicle, for example when a vehicle is
travelling up a hill and the driver selects a lower gear to accelerate up the bill. In this instance the
engagement surfaces 43 of the bars of the second bar set 29 are not loaded, whilst the engagement
surfaces 43 of the bars of the first bar set 27 are loaded. Under these circumstances it is not
possible to engage the new gear until the previous ratio is fully disengaged. To achieve this, the
computer processor 20 momentarily cuts the fuel supply to the engine to allow the previous gear
ratio to fully disengage before engaging the lower gear. The control system then uses the
engagement bars of the second bar set 29 to engage the first gear wheel 3 in a similar manner, as
described above. The gear change is then made in a similar fashion to the engine braking down
shift.
Figure 5a shows the first and second bar sets 27,29 in a neutral position, that is, neither bar set
is engaged with a gear wheel, the engine is idling. Figure 5b shows the first and second bar sets
moving into engagement with the first gear wheel 3 under the action of the fork 46. The process
of moving from aneutral position into engagement with the first gear wheel 3 is substantially the
same as an accelerating up shift.
Use of the transmission system leads to improved performance, lower fuel consumption and
lower emissions since drive interruption has substantially been eliminated. Also the system is a
more compact design than conventional gearboxes leading to areductionin gearbox weight. The
control system reduces the effects of torque spikes by preventing Shockwaves from propagating
throughout the transmission, leading to smooth gear changes.
It will be appreciated by the skilled man that various modifications can be made to the above
embodiment that are within the scope of the current invention, for example a plurality of selector
assemblies can b e mounted on the output shaft with correspondingpairs of gear wheels to provide
a larger number of gear ratios between the output shaft and the input shaft It is also possible to
have transmission systems with more than two shafts to provide additional gear ratios.
A torque converter can be used instead of a clutch, or in combination with a clutch or in
combination with a plurality of clutches. For example, the output from an engine can be
connected in series to a torque converter and then to a clutch. Alternatively, the output from an
engine can be connected in series with a torque converter and then in parallel to a network of
clutches. The term clutch means should be understood to include all of the above-mentioned
combinations.
The load cells may be mounted on the gearbox casing or some other component or assembly that
supports or houses rotatable transmission components.
Figure 9 shows a strain gauge 66 and a Wheatstone bridge circuit 68 that can be used to measure
the magnitude of torque in the output shaft 1. The strain gauge 66 works on a similar principle
to the load cells in that it measures strains in components or assemblies that house or support
rotatable transmission components along the torque load path such as bearing casings, bearing
mountings, the gearbox casing 34, the gearbox casing end plates 36,38, the bolts used to attach
the endplates 36,38 to the gearbox casing 34 and the tail shaft casing 50. Strain gauges 66 may
also be located on a differential.
Strain is the ratio of the change in a dimension to the original dimension. The strain gauge 66 is
fixedly attached to a component or assembly mat houses or supports rotatable transmission
components for example by using a cement or adhesive. Any distortion in the component /
assembly caused by torque within the transmission will also cause a distortion of the strain gauge
66. The gauge 66 contains conducting material and the distortion therefore results in a change in
its resistance. By measuring this change in resistance the strain can be determined. The change
in resistance is measured through the Wheatstone bridge circuit 68. This has 4 arms, arranged in
a square. Each arm contains either a resistor 70 of known resistance, or a strain gauge 66 - strain
gauges will occupy one, two or four of the arms.
Taking the case of one strain gauge 66 in the Wheatstone bridge, a so called quarter bridge
arrangement, power lines are connected to opposite comers of the bridge, see A and C in Figure
9, to provide an excitation voltage. A measurement is made across the other comers of the bridge,
see B and D in Figure 9. If the resistanceof the strain gauge changes, the current across the bridge
will change (according to Ohms law, V-IR). This change is measured and the amount of strain
can be determined.
The magnitude of fee strain detected in those components or assemblies is proportional to the
magnitude of the torque in the output shaft 1 and therefore the strain gauge 6(5 can be calibrated
in a similar way to the load cells 62,64 for example by using a conventional torque sensor. If
more than one strain gauge is used it is possible to determine the direction of the torque.
Sensors 72 can be used to measure the relative rotational speeds and / or the relative rotational
positions of the sets of engagement bars and the gear wheel to be engaged. This enables the
control system to control the movement of the engagement bars such mat the engagement bars
do not crash into the dogs on gear wheels but rather engage the gear wheels by entering into the
spaces between the dogs. This substantially reduces the amount of wear to the dogs and the
engagement bars. The detectors can be Hall Effect sensors, optical sensors or ;any other suitable
type of sensor for determining the. rotational speed or position of a body.
Rather than using a throttle pots mechanism 24 for controlling the speed of the engine, an engine
control unit 74 can be used to prevent certain pistons from firing and thereby reducing the output
of the engine.
The sensors 70,72 for detecting the positions and / or rotational speeds of the sets of engagement
bars the gear wheels can be used in conjunction with the engine control unit 74 to prevent a
piston, or a plurality of pistons, from firing at the time when the engagem ent bar« engage the dogs
on the side of a gearwheel. This momentarily reduces the amount of torque in the transmission
at the instant when the engagementbars contact the dogs and thereby reduces the effect of torque
spikes in the transmission. The torque in the transmission at that instant is then largely be due to
the inertia of the transmission components. The timing of the misfiring of a piston is accurately
controlled by the computer processor 20 in response to position and / or speed measurements
made by the sensors 70,74.
Optionally, the control system can include a traction control mechanism (not shown) to prevent
wheel spin.
The keyways 41 can be arranged to have dovetailed profiles such that the bars are radially
restrained within the keyways (see Figure 10). Alternatively, the keyways can have a slotted or
T-shaped profile to radially restrain the bars. This provides a significant advantage since it
obviates the need for the first and second connector rings 37,39 to connect the bars together in
the first and second bar sets. This arrangement is preferred since it provides an improved means
of restraining the radial position of thebars 28,3 0 relative to the output shaft 1,, leading to greater
structural integrity of the transmission system. Since the connector rings 37,39 are no longer
required it is possible to reduce the length of the engagement bars 28,30 thereby producing more
compact transmission systems. The alternative keyways can be formed in the output shaft 1 or
can be formed in a separate component from the output shaft which is then fixedly attached to the
output shaft, for example by using a splined arrangement.
Furthermore, it allows embodiments of the invention to be used having only one disc spring 147
(see Figure 11) connecting all six bars together, i.e. bars firorn the first and second sets, with the
actuator arrangement being adapted accordingly. In use, three of the bars would be loaded when
the first gear is accelerating and three not loaded, and moving the fork to bias the disc spring
towards the second gear will move the three unloaded bars out of engagement with the first gear
wheel, leaving three bars still in engagement Once the bars have engaged with the second gear
wheel, the remaining three bars will disengage from the first gear wheel, and under the loading
of the disc springmove into engagement with the second gear wheel. This configuration provides
a highly compact arrangement leading to smaller, lighter gearboxes.
The axial space between the first and second gears to accommodate the selector assembly may
be reduced to around 20mm fortypical road car applications.
Figure 5a shows a recessed 28c in the top of each bar of fee first bar set and a recess 30c in the
top of abar from the second bar set. The recesses 2Sc,30c allow connections to be made between
the bars of the first and second bar sets 27,29 with the arms of the first and second disc springs
47,49 respectively. The shape of the recesses 2Sc,30c is such that the recesses allow each spring
arm to move to a non-perpendicular angle relative to the bars 28,30 during a gear shift. The
recesses 28c,30c shown in Figure 5a are for a two disc spring configuration. For embodiments
having only one disc spring 147 the recesses 28c,30c are located more centrally along the length
of the bars 28,30.
When a ring is not used to fix fee positions of the bars in a set, the bars in. a set can move a small
amount relative to each other in the axial direction. This is because the only connection between
the bars in a set is provided by a deformable disc spring. A single bar is attached to each disc
spring arm and each arm can deform independently of the others, thereby allowing fhe relative
movement between the bars. The bars in a set will nevertheless essentially move in unison.
The number of dogs on. each of the gear wheels is not limited to three, for example any
practicable number of dogs can be used. It has been found that two to eight dogs are suitable for
most applications. Similarly, the number of bars in a bar set can be any practicable rmrxiber but
most preferably the number of bars in a set equals the number of dogs in a group.
It will also be appreciated by the skilled person that fhe transmission system can be adapted such
that the selector assembly and the first and second gear wheels are mounted on the input shaft and
the fixed gear wheels are mounted on the output shaft.
The transmission, system can be used in any vehicle for example, road cars, racing cars, lorries,
motorcycles, bicycles, earth removal vehicles such as bulldozers, cranes, military vehicles,
aircraft such as aeroplanes and helicopters, watercraft such as boats, ships and ho vercrafts. The
system can also be used in any machine that has first and second rotatable bodies wherein drive
is to be transmitted from one of the rotatable bodies to the other, for example in lathes and milling
machines.
WE CLAIM:
1. A transmission system having a plurality of gear ratios, selector means for selectively engaging
the gear ratios, and a control system including means for measuring deformation caused by torque in
the transmission system in at least one static component or assembly that is deformed due to torque in
the transmission system and means for controlling the torque in the transmission system,wherein the
control system is arranged to measure deformation and to adjust the torque in the transmission system
according to the measured deformation and a known relationship between the gear ratios, wherein the
known relationship is substantially linear and values corresponding to the measured deformation are
adjusted by a scaling factor.
2. The transmission system as claimed in claim 1, wherein the transmission system is arranged
such that selection of a new gear ratio takes place substantially instantaneously without substantial
power interruption.
3. A transmission system having a plurality of gear ratios, selector means for selectively engaging
the gear ratios, and a control system including means for measuring deformation caused by torque in
the transmission system in at least one static component or assembly that is deformed due to torque in
the transmission system and means for controlling the torque in the transmission system, wherein the
control system is arranged to measure deformation and to adjust the torque in the transmission system
according to the measured deformation and a known relationship between the gear ratios, wherein the
transmission system is arranged such that selection of a new gear ratio takes place almost
instantaneously without substantial power interruption.
4. The transmission system as claimed in claim 3, wherein the known relationship is substantially
linear and values corresponding to the measured deformation are adjusted by a scaling factor.
5. The transmission system as claimed in any one of the preceding claims, wherein the control
system is arranged to control the rate of change of torque in the transmission system in accordance with
the deformation measured.
6. The transmission system as claimed in any one of the preceding claims, wherein the means for
controlling torque in the transmission system has clutch means.
7. The transmission system as claimed in any one of the preceding claims, wherein the means for
controlling torque in the transmission system has means for controlling the speed of a drive source.
8. The transmission system as claimed in any one of the preceding claims, wherein the control
system has means for calculating the magnitude of torque in the transmission system.
9. A transmission system as claimed in any one of the preceding claims, wherein the control
system has estimating means for estimating torque in the transmission system when the selector means
engages an unengaged gear ratio.
10. The transmission system as claimed in any one of the preceding claims, having sensor means
for sensing the position of the selector means.
11. The transmission system as claimed in any one of the preceding claims, wherein the
transmission system has means for identifying fluctuations in the deformation measurements due to
factors other than drive line torque.
12. The transmission system as claimed in claim 11, wherein the control system is arranged to
record a plurality of readings and calculate the difference between the measurements, and to control the
torque to account for fluctuations in the deformation measurements.
13. The transmission system as claimed in any one of the preceding claims, wherein the control
system has at least one of means for measuring engine speed, means for measuring road speed or a
vehicle-mounted accelerometer.
14. The transmission system as claimed in any one of the preceding claims, wherein the means for
measuring deformation measures the amount of torsional deformation in the component or assembly.
15. The transmission system as claimed in any one of the preceding claims, wherein the means for
measuring deformation determines the direction of torque in the transmission system.
16. The transmission system as claimed in any one of the preceding claims, wherein the component
or assembly comprises at least one of a transmission system bearing, casing, support member,
mounting, or mounting bolts.
17. The transmission system as claimed in any one of the preceding claims, wherein the means for
measuring deformation has at least one load cell, and preferably a plurality of load cells.
18. The transmission system as claimed in any one of the preceding claims, wherein the means for
measuring deformation is mounted on a casing having a longitudinal axis and the casing is arranged
such that torque in the transmission system twistingly deforms the casing about the longitudinal axis.
19. The transmission system as claimed in any one of the preceding claims, wherein the means for
measuring deformation measures the amount of strain in the component or assembly.
20. The transmission system as claimed in claim 19, wherein the means for measuring deformation
comprises at least one strain gauge.
21. The transmission system as claimed in anyone of the preceding claims, having first and second
rotatable shafts, wherein the plurality of gear ratios is arranged to transfer drive between the first and
second shafts and has first and second gear wheels each rotatably mounted on the first shaft and having
drive formations formed thereon, the selector means comprises a selector assembly arranged to
selectively transmit torque between the first shaft and the first gear wheel and between the first shaft
and the second gear wheel, wherein the selector assembly comprises an actuator assembly and first and
second sets of engagement members that are moveable into and out of engagement with the first and
second gear wheels independently of each other, said selector assembly being arranged such that when
a driving force is transmitted, one of the first and second sets of engagement members drivingly
engages the engaged gear wheel, and the other set of engagement members is then in an unloaded
condition, wherein the actuator assembly is arranged to move the unloaded set of engagement members
into driving engagement with the unengaged gear wheel to effect a gear change.
22. The transmission system as claimed in claim 21, wherein the selector assembly is arranged such
that when a braking force is transmitted the first set of engagement members drivingly engages the
engaged gear wheel, and the second set of engagement members is in an unloaded condition, and when
a driving force is transmitted the second set of engagement members drivingly engages the engaged
gear wheel, and the first set of engagement members is then in an unloaded condition.
23. The transmission system as claimed in claim 21 or 22, wherein the actuator assembly is
arranged to bias the loaded set of engagement members towards the unengaged gear wheel without
disengaging the loaded set of engagement members from the engaged gear wheel.
24. A method for controlling torque in a transmission system having a plurality of gear ratios and
selector means for selectively engaging the gear ratios, comprising measuring the deformation caused
by torque in at least one component or assembly arranged to support or house rotatable components of
the transmission system, selecting an unengaged gear ratio, adjusting the torque in the transmission
system in accordance with the measured deformation and a known relationship between the gear ratios,
wherein the known relationship is substantially linear and adjusting values corresponding to the
measured deformation by a scaling factor.
25. The method as claimed in claim 24, comprising controlling the rate of change of torque.
26. The method as claimed in claim 24 or 25, comprising estimating the amount of torque in the
transmission system when an unengaged gear ratio will be engaged.
27. The method as claimed in any one of claims 24 to 26, comprising selecting a new gear ratio
substantially instantaneously without substantial power interruption.
28. A method for controlling torque in a transmission system having a plurality of gear ratios and
selector means for selectively engaging the gear ratios, comprising measuring the deformation caused
by torque in at least one component or assembly arranged to support or house rotatable components of
the transmission system, selecting an unengaged gear ratio, adjusting the torque in the transmission
system in accordance with the measured deformation and a known relationship between the gear ratios,
and selecting a new gear ratio substantially instantaneously without substantial power interruption.
29. The method as claimed in claim 28, comprising controlling the rate of change of torque.
30. The method as claimed in claim 28 or 29, comprising estimating the amount of torque in the
transmission system when an unengaged gear ratio will be engaged.
31. The method as claimed in any one of claims 28 to 30, wherein the known relationship is
substantially linear and adjusting values corresponding to the measured deformation by a scaling factor.
The present invention relates to a transmission system having a plurality of gear
ratios, selector means for selectively engaging the gear ratios, and a control system
including means for measuring deformation caused by torque in the transmission system
in at least one static component or assembly (50) that is deformed due to torque in the
transmission system and means for controlling the torque in the transmission system,
wherein the control system is arranged to measure deformation and to adjust the torque
in the transmission system according to the measured deformation and a known
relationship between the gear ratios, wherein the known relationship is substantially
linear and values corresponding to the measured deformation are adjusted by a scaling
factor. A method for controlling torque in a transmission system is also disclosed.

Documents:

2673-kolnp-2005-granted-abstract.pdf

2673-kolnp-2005-granted-assignment.pdf

2673-kolnp-2005-granted-claims.pdf

2673-kolnp-2005-granted-correspondence.pdf

2673-kolnp-2005-granted-description (complete).pdf

2673-kolnp-2005-granted-drawings.pdf

2673-kolnp-2005-granted-examination report.pdf

2673-kolnp-2005-granted-form 1.pdf

2673-kolnp-2005-granted-form 13.pdf

2673-kolnp-2005-granted-form 18.pdf

2673-kolnp-2005-granted-form 3.pdf

2673-kolnp-2005-granted-form 5.pdf

2673-kolnp-2005-granted-gpa.pdf

2673-kolnp-2005-granted-reply to examination report.pdf

2673-kolnp-2005-granted-specification.pdf


Patent Number 223853
Indian Patent Application Number 2673/KOLNP/2005
PG Journal Number 39/2008
Publication Date 26-Sep-2008
Grant Date 23-Sep-2008
Date of Filing 22-Dec-2005
Name of Patentee ZEROSHIFT LIMITED
Applicant Address 7 VERMONT PLACE, TONGWELL, MILTON KEYNES MK15 8JA
Inventors:
# Inventor's Name Inventor's Address
1 MARTIN, WILLIAM, WESLEY 22 GOODMAN GARDENS, WOUGHTON ON THE GREEN, MILTON KEYNES
PCT International Classification Number F16H 61/04, 59/16
PCT International Application Number PCT/GB2004/002955
PCT International Filing date 2004-07-08
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 0316004.1 2003-07-08 U.K.
2 0316403.5 2003-07-14 U.K.