1. Field of Invention
The invention relates to vehicle transmissions and particularly to direct shift 9 or DSG) transmissions that include a plurality of clutches which are alternatively engaged to convey torque from a primary motor to a differential gear via respective torque transfer paths.
2. Description of Related Art
Direct shift (or dual clutch) transmissions are well known in the automotive industry. European Patent application EP-1,541,898 discloses a dual clutch transmission for an agricultural tractor.
It is an object of the invention to provide a direct shift transmission with improved functionality.
According to the invention there is provided a vehicle transmission comprising first and second main torque transfer paths between a driven input and a differential gear, each main torque transfer path respectively comprising an in-line clutch, a synchromesh unit and a plurality of alternative torque transfer sub-paths being selectable by operation of the synchromesh unit, wherein the first main torque transfer path includes a continuously variable non-mechanical drive connection and the second main torque transfer path is mechanical throughout. Advantageously, the provision of a torque transfer path with a non-mechanical drive facilitates a standstill mode. In the preferred embodiment of the non-mechanical drive being hydrostatic and comprising a hydraulic pump and motor, a pure hydrostatic transmission stage can be provided.
In a hydrostatic transmission stage (first torque transfer path) the vehicle drive speed can be controlled by the angle of the pump (when of the swashplate type) wherein the vehicle can go forwards or backwards without any mechanical transmission change. This delivers a very safe mode in which the driver can reverse direction without operating a mechanical power shuttle and is ideally suited to low speed operations (<15 kph).
For higher speeds the transmission can transfer torque via the second torque transfer path. The torque transfer sub-paths selected by the synchromesh units offer a selection of gear ratios which can be augmented by appropriate operation of the continuously variable drive connection.
Although a hydrostatic drive connection is preferred, it is envisaged that this may be replaced with a continuously variable electric drive connection having an electric generator and motor.
It should be understood that the term ‘non-mechanical’ drive connection is intended to encompass means of transferring power from an input to an output without a continuous mechanical coupling therebetween. For example, the transfer of power may be hydraulic (using pressurised fluid) or electrical (using electrical power).
In a preferred embodiment the transmission further comprises first and second shafts each of which are hollow and form part of the first and second main torque transfer paths respectively, and a third shaft which is in a direct driving relationship with the differential gear and passes through the first and second shafts, each of the first and second shafts being connectable to the third shaft via said plurality of alternative torque transfer sub-paths.
The transmission may further comprise a fourth shaft which is parallel to, and in driving engagement with, the third shaft, each synchromesh unit being associated with a respective one of the first and second shafts and being moveable between a first position corresponding to a first torque transfer sub-path in which the associated first or second shaft is drivingly connected to the third shaft via the fourth shaft, a second position corresponding to a second torque transfer sub-path in which the associated first or second shaft is rendered integral with the first shaft, and a third position in which the associated first or second shaft is drivingly disconnected from the first shaft.
Preferably the transmission is a continuously variable power-split transmission further comprising an epicyclic module having first and second epicyclic inputs and one epicyclic output, the first epicyclic input being connected to said driven input, the non-mechanical drive connection being between the first and second epicyclic inputs, wherein the second main torque transfer path is via the epicyclic module. The epicyclic module preferably comprises first and second epicyclic outputs, the second main torque transfer path being via the first epicyclic output, the transmission further comprising a third main torque transfer path between the driven input and a differential gear, via the second epicyclic output, the third torque transfer path comprising a respective in-line clutch and sharing the synchromesh unit and plurality of alternative torque transfer sub-paths with said first main torque transfer path. In this embodiment, the transmission comprises three main torque transfer paths: one via the continuously variable drive connection, and two via the two epicyclic outputs. The shared synchromesh unit is driven via either the continuously variable drive connection or the second epicyclic output depending upon the position of the associated in-line clutches.
The vehicle can, therefore, start from a standstill using a first transmission stage wherein the transferred torque bypasses the epicyclic output, that is the non-mechanical route. When desired, perhaps at a given speed, the transmission may ‘up-shift’ upon command to a power-split stage in which the transferred torque is routed to the same synchromesh unit but via the epicyclic module.
The epicyclic module preferably comprises three compound planetary gear sets supported on a planet carrier, each planetary gear set engaging respective sun gears, a first sun gear being integral with a first epicyclic input shaft forming the first epicyclic input, a second and a third sun gear being integral with respective epicyclic output shafts forming the first and second epicyclic outputs. The two epicyclic output shafts are preferably mutually coaxial. Furthermore, the planet carrier may form said second epicyclic input.
Preferably, the in-line clutches of both the first and third torque transfer paths alternatively engage a common shaft.
The in-line clutches are preferably disposed upstream of the associated synchromesh unit within the respective main torque transfer path.
In a preferred embodiment the transmission further comprises a forward-reverse transmission module comprising an input shaft coupled to said driven shaft, an output shaft, first and second reverser clutches which are alternatively engageable to close respective forward and reverse drive paths between the input shaft and output shaft, wherein engagement of the first reverser clutch couples the input shaft directly to the output shaft, and engagement of the second reverser clutch couples the input shaft to the output shaft via first and second gear sets which each comprise a plurality of meshed gears, one of said gear sets comprising an odd number of gears and the other said gear set comprising an even number of gears.
There is also provided a method of controlling a transmission as described above, wherein each of said synchromesh units, the input-to-output speed ratio of said non-mechanical drive connection, and the in-line clutches are controllable by a control unit, the method comprising commanding selectively between a first mode in which torque is transferred via the first main torque transfer path, and a second mode in which torque is transferred via the second main torque transfer path, the in-line clutches of the first and second main torque transfer paths being alternately closed to select between the first and second modes.
Further advantages of the invention will become apparent from reading the following description of specific embodiments with the reference to the appended drawings in which:
The present invention is susceptible of embodiments of many different forms. While the drawings illustrate, and the specification describes, certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments.
With reference to
Driveshaft 22 is integral with an input shaft of the forward-reverse transmission module 12 and is also integral with an input side 28 of forward clutch 30 and first gear 32 in a first gear set 32, 34, 36 to be described in more detail below. Forward clutch 30 is closed to render driveshaft 22 integral with shaft 38 which forms a first epicyclic input.
Third gear 36 of the first gear set 32, 34, 36 is keyed to a shaft 40 which provides an input side to hydrostatic power branch 16 to be described below. A further gear 42 is keyed to shaft 40 and provides a first gear in a second gear set 42, 44. Gear 44 idles on shaft 38 and is integral with an input side 46 of reverse clutch 48. Closure of reverse clutch 48 completes a mechanical drive connection between driveshaft 22 and epicyclic first input 38 via the first gear train 32, 34, 36 and second gear train 42, 44.
Turning to the epicyclic module 14, first sun gear 50 is keyed to shaft 38 and drives a first set of planetary gears 52 supported by planet carrier 54. Second and third sun gears 56, 58 are each driven by respective planetary gear sets 60, 62 which are coupled to the same planet carrier 54. Second and third sun gears 56, 58 are integral with first and second epicyclic output shafts 64, 66 which are mutually coaxial.
The epicyclic module 14 in this example does not include a ring gear. However, it is envisaged that alternative epicyclic arrangements known in the art may be used instead without deviating from the invention.
Turning to the hydrostatic power branch 16, a variable displacement pump 68 is connected hydraulically to a fixed displacement pump 70 in a known manner. The pump 68 is driven by shaft 40 whilst the motor 70 drives output shaft 72 with integral gear 74 which itself is meshed with gear 76 which, in turn, is meshed with gear 78 being integral with planet carrier 54 which serves as a second epicyclic input. The variable displacement pump 68 may take may forms but is typically provided by an axial piston pump with a variable angle swashplate as in known continuously variable transmissions. The non-mechanical drive connection between pump 68 and motor 70 allows a continuous range of input to output speed ratios between input shaft 40 and output shaft 72 including a zero ratio in which the output speed is zero. The hydrostatic power branch 16 described is similar to that currently available on agricultural tractors branded VALTRA (registered trade mark) including a continuously variable transmission (CVT).
Although a hydrostatic drive connection is provided between shafts 40 and 72 it should be understood that other non-mechanical drive connections may be used instead such as those including an electric generator and an electric motor for example.
Together, the forward reverse transmission module 12, epicyclic module 14 and hydrostatic power branch 16 provide a, potentially standalone, CVT module having two output shafts 64, 66.
In the example shown in
Turning to the DSG module 18 torque is taken from one of shafts 64, 66, 80 via respective gear trains described below. In a first torque transfer path gear 82 is keyed to shaft 80 and meshed with gear 84 which is, in turn, meshed with gear 86 forming a gear train. Gear 86 idles on first synchromesh shaft 88 which itself is hollow and disposed coaxially with output shaft 90 coupled to differential gear 24. Furthermore, gear 86 is integral with an input side of first clutch C1.
Closure of clutch C1 renders gear 86 integral with first synchromesh shaft 88 which, in turn, is integral with first synchromesh gear 92 which forms part of first synchromesh unit 94.
First synchromesh unit 94 includes a coupling arrangement (not shown) which renders the driven synchromesh gear 92 with first synchromesh gear S1 or second synchromesh gear S2. Synchromesh arrangements are well known in the field of transmissions and the basic principle will not be described herein.
When first synchromesh gear S1 is engaged torque is transferred from first synchromesh shaft 88 to output shaft 90 via gears S1, 96, shaft 98 and gear train 100,102. Alternatively, when second synchromesh gear S2 is engaged torque is transferred from first synchromesh shaft 88 to output shaft 90 because second synchromesh gear S2 is integral with the latter.
In a second torque transfer path first epicyclic output shaft 64 is rendered integral with shaft 104 by closure of clutch C2. Meshed gears 106, 108 provide a drive connection between shaft 104 and second synchromesh shaft 110. Second synchromesh unit 112, similar to first synchromesh unit 94, includes a driven synchromesh gear 114 integral with second synchromesh shaft 110. In a similar manner to that described before, couplers (not shown) render the drive synchromesh gear 114 integral with either third synchromesh gear S3 or fourth synchromesh gear S4. By selective operation of second synchromesh unit 112, second synchromesh shaft 110 can be drivingly connected to output shaft 90 either directly (via gear S3) or indirectly (via gear S4, 116, shaft 98 and gears 100,102).
In a third torque transfer path second epicyclic output shaft 66 is coupled to input side of third clutch C3 via a pair of gears 18 and 120. Closure of clutch C3 provides a drive path between second epicyclic output 66 and first synchromesh shaft 88. The torque transfer sub-paths (to be described below) provided by first synchromesh unit 94 complete the torque transfer path to the output shaft 90 and thus differential gear 24.
The clutches involved, that is forward clutch 30, reverse clutch 48 and first, second, third clutch C1, C2, C3 are of the wet multi-disc type and are each hydraulically actuate to allow electro-hydraulic control from an electronic control unit (not shown). However it will be understood that other types of clutches can instead be utilised.
From reading the above description it will be become apparent that the transmission 10 provides three main torque transfer paths between the engine 20 and differential gear 24. In a first torque transfer path power is conveyed via the hydrostatic power branch 16, first clutch C1 and first synchromesh unit 94, thereby providing a hydrostatic drive path including an in-line non-mechanical drive connection. In a second torque transfer path power is conveyed via the power split arrangement of the epicyclic unit 14 and power branch 16, second clutch C2 and second synchromesh unit 112. In a third torque transfer path power is transmitted via the power split arrangement 14, 16, third clutch C3 and first synchromesh unit 94.
For each of the aforementioned torque transfer paths two torque transfer sub-paths are available and selectable by the associated synchromesh units 94, 112. This provides five practical paths to transmit torque from the engine 20 to differential unit 24. It should be appreciated that a sixth path via clutches C1 and S2 is possible but not preferred.
Also provided is a four-wheel drive clutch 122, the input side of which is driven by a pair of gears 124, 126 driven by output shaft 90. It should be understood that four-wheel drive clutch 122 permits selective engagement of a four-wheel drive mode in which the front wheels of the vehicle are also provided with power for additional traction.
In the following passages the various operational modes will be described with reference to the forward direction of travel. A separate description of the reverse mode will be given thereafter.
In a first transmission stage, or hydrostatic mode, neither the forward nor reverse clutches 30, 48 need be closed to deliver torque from the engine 20 to the differential gear 24. First clutch 01 is closed and first synchromesh gear S1 is engaged. The forward speed of the vehicle is controlled therefore by the engine output speed at driveshaft 22 and the variable ratio provided by hydrostatic power branch 16. Line 1 plotted on
When in transmission Stage 0 or 1 (see
Line 2 on
In transmission Stage 2 torque is transferred from the engine 20 to the differential 24 via the power split arrangement of epicyclic module 14 and power branch 16, third clutch C3 and first synchromesh gear S1. At constant engine revs, the drive speed is further increased by increasing the swashplate angle as illustrated by line 2 in
At (or near) maximum swashplate angle in transmission Stage 2, the input side and output side of second clutch C2 become equalised in terms of rotational speed. This point is represented by the intersection of lines 2 and 3 on
Further acceleration is enabled by a decrease in swashplate angle from maximum to minimum as represented by line 3 in
At (or near) minimum swashplate angle in transmission Stage 3 represented by the crossover of lines 3 and 4 in
An increase in transmission ratio in transmission Stage 4 is enabled by an increase in the swashplate angle from minimum to maximum as represented by line 4 in
At (or near) maximum pump angle in transmission Stage 4, the input and output sides of the second clutch C2 equalise in terms of speed. At this point, represented by the crossover of lines 4 and 5 in
It should be understood that
During deceleration, or a decrease in transmission ratio, the aforementioned sequence of clutch and synchromesh changes is reversed and the skilled person will understand that the unloaded synchromesh unit can engage the appropriate gear in anticipation of the next transmission stage change (down-shift).
In summary of the basic operation of the transmission shown in
Disposed at the front end of the transmission arrangement shown in
Moreover, by providing a constant drive connection between the driveshaft 22 and the hydrostatic branch 16, forward and reverse drive ratios are available at low speeds when both the forward and reverse clutches 30, 48 are open. Furthermore, the placement of the forward reverse transmission module 12 upstream of the epicyclic module 14 allows the latter to be reversed for reverse gears. In other words, without the reversing of the first epicyclic input 38 the changing from hydrostatic transmission stage (Stage 1) in reverse mode to the (reverse) second transmission stage (Stage 2) would be non-trivial.
When operating in the hydrostatic mode, or first transmission stage, the forward and reverse clutches 30, 48 can be open, in these modes both forward and reverse at low drive ratio is available and can be sensed by an appropriate electronic control unit (ECU) in real time. In order to prepare for any required up-shift in transmission stage, the ECU may pre-empt such a change by selectively engaging forward clutch 30 or reverse clutch 48 depending on the sensed direction of movement, indicated by (X) in
When under low load, determined by suitable pressure sensors in the hydrostatic power branch 16, the transmission 10 may operate in a ‘short-shifting mode’ wherein changes in transmission stage (as described above) are executed before the speed of the input and output sides of the incoming clutch are equalised. In other words, and with reference to
In one example, an ECU, having determined that the transmission is under low load and a high acceleration is commanded, may execute the up-shifts in transmission stage when the swashplate angle is at +/−50%. Advantageously, this avoids the need for the swashplate to reach maximum or minimum angle in order to up-shift.
The consequence is a transmission which behaves in a similar manner to known power-shift transmissions.
It should be understood that elements of the transmission illustrated in
In another arrangement not illustrated, the hydrostatic power branch 16 may be replaced with an electrostatic power branch comprising an electric generator and motor. Alternatively, the power branch may be replaced by a mechanical drive connection comprising one or more clutches as know in agricultural tractors in the VALTRA power shift range.
From reading the present disclosure, other modification will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the field of transmissions and component parts therefore and which may be used instead of or in addition to features already described herein.
Number | Date | Country | Kind |
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110968.6 | Jun 2011 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/060387 | 6/1/2012 | WO | 00 | 8/5/2014 |