Patent Application
20130053204
The invention relates to a gearbox arrangement which comprises a first gearbox with an adjoining range gearbox according to the preamble of claim 1.
The first gearbox is with advantage a dual-clutch gearbox. A dual-clutch gearbox comprises a first set of components substantially corresponding to the components in a first mechanical gearbox, and a second set of components substantially corresponding to the components in a second mechanical gearbox. The first set of components cover all the odd-numbered gears in the dual-clutch gearbox and the second set of components cover all the even-numbered gears. Switching between the two sets of components involves using clutch devices which make it possible to engage and disengage the respective sets of components. The fact that the two sets of components are used alternately makes it possible to effect stepped upward and downward gear changes in a dual-clutch gearbox without torque interrupt.
Many heavy vehicles often have a first gearbox connected to a so-called range gearbox. A range gearbox usually comprises a planetary gear which can provide each primary gear in the first gearbox with respective high and low transmission ratios. To operate the range gearbox, a driver can move an operating means, which may be fastened round a gear lever in the driving cab, to a position which indicates a desired gear position of the range gearbox. The driver moving the operating means to a desired position usually results in activation of an operating cylinder which is controlled by compressed air and which moves a ring gear of the range gearbox between the respective high and low transmission ratio positions. Alternatively, the gear change may be indicated by an automatic system. As the ring gear is connected in the low transmission ratio position to a stationary clutch cone and in the high transmission ratio position to a clutch cone on a rotating shaft, there has to be a torque interrupt during a gear change process in the range gearbox in order to synchronise the speed of the ring gear before it can be moved between the two positions.
The object of the present invention is to propose a gearbox arrangement which comprises a first gearbox with an adjoining range gearbox whereby gear changes can be effected without torque interrupt in at least the range gearbox.
This object is achieved with the gearbox of the kind mentioned in the introduction which is distinguished by the features indicated in the characterising part of claim 1. Changing gear between a low transmission ratio and a high transmission ratio in a range gearbox requires the provision of a torque interrupt in the range gearbox. According to the present invention, the first gearbox comprises an extra motion-transmitting connection which can transmit motion from at least one primary gear in the first gearbox to the output shaft without using the range gearbox. The primary gear in the first gearbox can thus provide an extra transmission ratio and the gearbox arrangement an extra gear. The extra gear is so dimensioned that it has a higher transmission ratio than the gear provided by the primary gear with a low transmission ratio in the range gearbox, and a lower transmission ratio than the primary gear with a high transmission ratio in the range gearbox. The extra gear thus becomes an intermediate gear during stepped upshifts and downshifts. Such an intermediate gear obviates the need for the range gearbox to switch directly between a low transmission ratio and a high transmission ratio. When the extra gear is activated, there is no load upon the range gearbox. In this unloaded state, the clutch element of the range gearbox can be moved to a desired position. When a gear change is to be made from this extra gear to a gear with high or low transmission ratio in the range gearbox, the clutch element can be moved beforehand to the desired position. The gear change process in the range gearbox can thus take place without torque interrupt. The first gearbox usually comprises several primary gears. Creating an extra gear for one or more of the primary gears in the first gearbox and giving them a suitable transmission ratio makes it possible to prevent a low transmission ratio in the range gearbox from being adjacent to a gear with a high transmission ratio in the range gearbox during a stepped upshift or downshift.
According to an embodiment of the present invention, the first gearbox comprises several gears each connectable to respective low and high transmission ratios of the range gearbox, and the gears are so dimensioned that all gears which have a low transmission ratio in the range gearbox have a lower transmission ratio than all gears which have a high transmission ratio in the range gearbox. In this case, gear changing in the range gearbox is only necessary between the highest gear which has a low transmission ratio in the range gearbox and the lowest gear which has a high transmission ratio in the range gearbox. In this case, creating an extra gear which has a transmission ratio between said gears is sufficient to prevent a gear with a low transmission ratio in the range gearbox from being directly adjacent to a gear with a high transmission ratio in the range gearbox. It is possible, however, that one or more gears which have a low transmission ratio in the range gearbox may have a higher transmission ratio than one or more gears which have a high transmission ratio in the range gearbox. In this case, it is necessary to create several extra intermediate gears to prevent a gear with a low transmission ratio in the range gearbox from being adjacent to a gear with a high transmission ratio in the range gearbox.
According to a preferred embodiment of the present invention, the first gearbox comprises several primary gears which are connectable to the extra motion-transmitting connection so that several extra gears are created, comprising at least two extra gears so dimensioned that they have a transmission ratio between a gear which has a low transmission ratio in the range gearbox and a gear which has a high transmission ratio in the range gearbox. Several extra intermediate gears are thus created to separate a gear with a low transmission ratio from a gear with a high transmission ratio in the range gearbox. This results in further time for gear change preparation in the range gearbox during a stepped gear change.
According to a preferred embodiment of the present invention, the range gearbox comprises a planetary gear with a clutch element which is movable between a low transmission ratio position and a high transmission ratio position. Such a clutch element may be a ring gear. In the low transmission ratio position the ring gear is usually coupled with a stationary clutch cone, and in the high transmission ratio position the ring gear is usually coupled with a clutch cone on a rotating shaft. For the ring gear to move between the two clutch positions, it has to be rotating at the same speed as the respective clutch cones. Such a synchronising process for the speed of the ring gear requires the provision of a torque interrupt in the range gearbox. According to the present invention, no torque interrupt need be provided in the gearbox arrangement when an extra gear is used as an intermediate gear while the ring gear is moved between the two clutch positions. The clutch element need not be a ring gear but may be a clutch element with substantially with any desired but functional configuration.
According to a preferred embodiment of the present invention, the extra motion-transmitting connection comprises an element which extends through the range gearbox to the output shaft. The range gearbox usually comprises a planetary gear comprising a sun wheel, planet wheels and a planet wheel carrier. A planet wheel carrier is usually provided with apertures. Such an element may therefore extend through at least one of the carrier's apertures and transmit torque to the output shaft. Alternatively, the extra motion-transmitting connection may have an element which has an extent beside the planetary gear and the range gearbox to the output shaft.
According to a preferred embodiment of the present invention, the first gearbox is a dual-clutch gearbox. Dual-clutch gearboxes comprise substantially two gearboxes connected in parallel which are used alternately during a stepped upshift or downshift. Alternating between the two parallel gearboxes makes possible a gear change process without torque interrupt. A gearbox arrangement which comprises a dual-clutch gearbox with an adjoining range gearbox according to the present invention may thus be used for stepped upshifts and downshifts entirely without torque interrupt. The dual-clutch gearbox may comprise a first input shaft engageable by means of a first clutch device, and a second input shaft engageable by means of a second clutch device. Such clutch devices and input shafts make it possible to engage and disengage quickly the two gearboxes connected in parallel.
According to an embodiment of the invention, the gearbox arrangement is so configured that a stepped gear change between two adjacent gears always involves the clutch devices effecting alternate engagement of said input shafts. This provides assurance that every step of the gear change can take place without torque interrupt. The dual-clutch gearbox comprises with advantage a first countershaft, a second countershaft, at least one primary gear which connects the first input shaft to the first countershaft, at least one primary gear which connects the first input shaft to the second countershaft, at least one primary gear which connects the second input shaft to the first countershaft, and at least one primary gear which connects the second input shaft to the second countershaft. The number of primary gears will in this case be at least four.
According to another embodiment of the invention, the dual-clutch gearbox comprises a mainshaft which is connected to the range gearbox, at least one gear which connects the first countershaft to the mainshaft and at least one gear which connects the second countershaft to the mainshaft. Said gears make it possible for the first countershaft and the second countershaft to be alternately connected to the mainshaft and consequently to the range gearbox.
Preferred embodiments of the invention are described below by way of examples with reference to the attached drawings, in which:
The dual-clutch gearbox 21 comprises a wall element 33 which divides the gearbox into a first space 34 substantially comprising the abovementioned components and a second space 35. The two countershafts s1, s2 extend from the first space 34 into the second space 35 through apertures in the wall element 33. The first countershaft s1 and the second countershaft s2 comprise in the second space 35 a further number of spur gears which are connectable to a mainshaft 36. The first countershaft s1 comprises two spur gears L1, H3 by which the first countershaft s1 can be connected to the mainshaft 36. The second countershaft s2 comprises likewise two spur gears R, H2, L2 by which the second countershaft s2 can be connected to the mainshaft 36. A fifth synchronising clutch 37 is adapted to connecting the first countershaft s1 to the mainshaft 36 by means of spur gear L1. The fifth synchronising clutch 37 is alternatively adapted to connecting the second countershaft s2 to the mainshaft 36 by means of spur gear R. Spur gear R effects rotation of the mainshaft 36 in an opposite direction and is therefore used for reverse gears. A sixth synchronising clutch 38 is adapted to connecting the second countershaft s2 to the mainshaft 36 by means of spur gear L2, H2. The spur gear transmission L2, H2 has here two designations, since it is used both when the range gearbox 22 has a high transmission ratio and a low transmission ratio. A seventh synchronising clutch 39 is adapted to connecting the first countershaft s1 to the mainshaft 36 by means of spur gear H3. The seventh synchronising clutch 39 is also adapted to connecting the first countershaft s1 to an extra shaft 40 by means of a spur gear H1.
The mainshaft 36 of the dual-clutch gearbox is connected via the range gearbox 22 to an output shaft 41 of the gearbox arrangement. The range gearbox 22 comprises a planetary gear 42 comprising in a conventional way a sun wheel, a number of planet wheels and a planet wheel carrier. Changing gear in the range gearbox 22 involves a clutch element in the form of a ring gear 43 being moved between a position LR which results in a low transmission ratio in the range gearbox 22 and a position HR which results in a high transmission ratio in the range gearbox 22. When the ring gear 43 is moved to the low transmission ratio position LR in
The seventh synchronising clutch 39 is also adapted to connecting the first countershaft s1 to the extra shaft 40 by means of a spur gear H1. The extra shaft 40 is rigidly connected to the output shaft 41 via a schematically depicted connecting element 44. The connecting element 44 extends in this case through at least one aperture of the planet wheel carrier. The extra shaft 40 therefore rotates always at the same speed as the output shaft 41. The transmission ratio provided by means of the shaft 40 and the connecting element 44 therefore corresponds to when the high transmission ratio in the range gearbox 22 is used. For this reason the spur gear connected to the shaft 40 is designated H1.
The clutch devices 24, 26 have the characteristic of being able alternately to engage and disengage the input shafts a1, a2 without torque interrupt. When the synchronising clutches 29-32, 37-39 are used to engage and disengage the primary spur gears I-VIII, a torque interrupt is required in order to synchronise the speed of the components concerned. When the ring gear 43 is used to switch the range gearbox 22 between the low transmission ratio position LR and the high transmission ratio position HR, the speed of the ring gear 43 has to be synchronised, which likewise requires a torque interrupt. Gear change operations with the ring gear 43 in the range gearbox 22 usually require a longer torque interrupt than gear change operations with the synchronising clutches 29-32, 37-39 in the dual-clutch gearbox 21.
Thereafter it is usually desired to engage gear 2. When this is initiated by the driver or by an automatic arrangement, the second synchronising clutch 30 is moved to a position in which it connects the second input shaft a2 to the first countershaft s1 by means of primary spur gear II. This takes place while gear 1 is still engaged. When this connection has been established, the clutch devices 24, 26 are activated so that the first input shaft a1 is disengaged while at the same time the second input shaft a2 is engaged and is therefore connected to the engine's driveshaft. As the clutch devices 24, 26 are used to change from gear 1 to gear 2, the change can take place without torque interrupt. Subsequent engagement of gears 3 and 4 is effected by the synchronising clutches 29, 30 successively activating primary spur gears III and IV. As the input shafts a1, a2 are used alternately, another spur gear can be engaged while the previous spur gear is still engaged. The clutch devices 24, 26 are used thereafter for the gear change so that it can take place without torque interrupt. A torque-transmitting path which comprises the first countershaft s1, spur gear L1 and the low transmission ratio position LR of the range gearbox 22 is used for all of gears 1-4.
When gear 5 is to be engaged, the synchronising clutch 31 is moved to a position in which it connects the first input shaft a1 to the second countershaft s1 by means of primary spur gear V. At the same time, the synchronising clutch 38 is moved to a position in which it connects the second countershaft s2 to the mainshaft 36 by means of spur gear L2. This is done while gear 4 is still engaged. The torque-transmitting path for gear 4 uses the first input shaft a1, whereas the torque-transmitting path for gear 5 uses the second input shaft a2. Here again it is likewise possible to use the clutch devices 24, 26 to effect the change between gears 4 and 5. A gear change without torque interrupt is thus likewise achieved. Thereafter a stepped upshift from gear 5 to gear 8 can take place in a similar way to the upshift from gear 1 to gear 4 except that in the gear range 5-8 the second countershaft s2 is used instead of the first countershaft s1.
In the gear range 1-8, the ring gear 43 is all the time in the low transmission ratio position LR in the range gearbox 22. When gear changes take place within the gear range 1-8, the gearbox arrangement works like a dual-clutch gearbox with eight gears, so gear changes within the gear range 1-8 can be effected without torque interrupt. Problems arise when the eight gears of the dual-clutch gearbox 21 are to be given a high transmission ratio in the range gearbox 22. The ring gear 43 then has to be moved to the high transmission ratio position HR in the range gearbox 22. This has to be preceded by the ring gear 43 being accelerated from motionless to a speed at which it can be connected to the clutch cone of the mainshaft 36. To avoid a torque interrupt when changing from gear 8 to gear 9, the synchronising clutch 39 is moved to the position in which it connects the first countershaft s1 to the extra shaft 40 by means of spur gear H1. The first countershaft s1 is thus connected to the output shaft 41 via spur gear H1, the extra shaft 40 and the connecting element 44. This can be done when gear 8 is engaged, therefore using the second countershaft 52 and the mainshaft 36. At the same time, the synchronising clutch 29 is moved to a position in which it connects the first countershaft s1 to the first input shaft a1 by means of primary spur gear I. When this has been achieved, the clutch devices 24, 26 can be used to effect the change between gears 8 and 9. The change between gear 8 and gear 9 can thus likewise effected without torque interrupt. Further stepped upshifts within the gear range 9-12 are effected by primary spur gears I-IV alternately connecting the first countershaft s1 to the first input shaft a1 and the second input shaft a2.
When gear changes are effected within the gear range 9-12, the range gearbox 22 is not used and there is therefore no load upon the ring gear 43. There is therefore plenty of time to move the ring gear 43 to the high transmission ratio position HR in the range gearbox 22. When a change takes place from gear 12 to gear 13, the ring gear 43 has therefore already been moved to the high transmission ratio position HR. The synchronising clutch 38 has also been moved to the position in which it connects the second countershaft s2 to the mainshaft 36 by means of spur gear H2. When this has been achieved, the change to gear 13 is effected by the clutch devices 24, 26 disengaging the second input shaft a2 and engaging the first input shaft a1. Thus a gear change without torque interrupt can likewise be effected between gears 12 and 13. Any further upward change within the gear range 13-20 is effected with the ring gear 43 in the high transmission ratio position HR in the range gearbox 22. When gear changes take place within this gear range 13-20, the gearbox arrangement works like a dual-clutch gearbox with eight gears, so gear changes within the gear range 13-20 can likewise be effected without torque interrupt. It may be noted here that when the highest gears 17-20 are used, which involves engagement of spur gear H3, the second countershaft s2 can be disengaged by putting the synchronising clutches 31, 32, 37, 38 into a neutral state. Such disengagement of the second countershaft s2 stops inter alia spur gear R which would otherwise cause relatively large losses by rotating in an opposite direction to the mainshaft 36. The disengagement of the second countershaft s2 may be done at any desired time when any of the highest gears 17-20 is used.
It may be noted that four gears R1-R4 are available for reversing the vehicle. In this case the input shafts a1, a2 are alternately connectable to the second countershaft s2 by means of the four spur gears V-VIII. The second countershaft s2 is in this case connected to the mainshaft 36 by means of spur gear R. During reversing, the range gearbox 22 is constantly in the low transmission ratio position LR, so no torque interrupt occurs when the reverse gears R1-R4 are shifted. In this case it is therefore spur gear R which results in reversing of the vehicle and spur gear L1 which results in forward movement with the lowest gears 1-4 disposed on different countershafts s1, 52. The clutch devices 24, 26 can therefore be used to switch between driving the vehicle forwards and reversing. This function is usable in situations where the vehicle becomes stuck and needs to be “rocked” free.
In this embodiment example, the eight primary spur gears I-VIII of the dual-clutch gearbox 21 are connectable to the range gearbox 22 when it is in the low transmission ratio position LR and in the high transmission ratio position HR. The primary spur gears I-VIII in the dual-clutch gearbox 21 are so dimensioned that all of the gears 13-20 which are reached with a high transmission ratio in the range gearbox 22 have a higher transmission ratio than all of the gears 1-8 which are reached with a low transmission ratio in the range gearbox 22. The ring gear 43 in the range gearbox 22 therefore need only be shifted in an intermediate gear range 9-12. The fact that the intermediate gear range 9-12 comprises four gears means that there is plenty of time to shift the range gearbox 22 between the low transmission ratio position LR and the high transmission ratio position HR.
The invention is not limited to the embodiment described above but may be varied freely within the scopes of the claims. The synchronising clutches 29-33, 37-39 depicted in
| Number | Date | Country | Kind |
|---|---|---|---|
| 1050324-1 | Apr 2010 | SE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/SE2011/050309 | 3/22/2011 | WO | 00 | 10/10/2012 |
