DESC:FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10 and rule 13]
“TWO-SPEED AUTOMATIC TRANSMISSION SYSTEM WITH
ELECTROMAGNETIC CLUTCH AND PLANETARY GEARS”
We, MTAEMTC PRIVATE LIMITED, an Indian Company, having a contact
address at KHASRA NO. 245, BAROTIWALA, HARIPUR ROAD, SOLAN,
HIMACHAL PRADESH- 174103 (INDIA).
The following specification particularly describes the invention and the
manner in which it is to be performed.
FIELD OF THE INVENTION
Embodiments of the present invention generally relate to the field of
vehicle transmission systems and more particularly to a two-speed automatic
transmission system with electromagnetic clutch and planetary gears.
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BACKGROUND OF THE INVENTION
In the field of automotive engineering, the constant drive for enhanced
efficiency and control in transmission systems has highlighted notable
shortcomings in conventional designs. These systems, predominantly
mechanical or hydraulic in nature, often compromise on fuel efficiency,
performance, and the crispness of gear changes. The dynamic nature of
driving conditions demands a transmission that can adapt swiftly and
seamlessly, maintaining an engine’s operation within its optimal power band.
Existing technologies, while innovative in their attempts to solve these
problems, have their own drawbacks. Automated manual transmissions
(AMTs) and dual-clutch transmissions (DCTs), for example, offer improved
shift times but tend to be mechanically complex and expensive. Their intricate
design requires precise control systems, adding to the overall cost and
potential maintenance issues. Continuously Variable Transmissions (CVTs),
another alternative, offer seamless gear ratios but can feel unnatural to drivers
due to the 'rubber band effect', and they also face durability concerns under
high torque scenarios.
The deficiencies of these systems often lie in their inability to combine
rapid, responsive gear changes with mechanical simplicity and cost
effectiveness. The complexity of DCTs, the perceptual disconnect in CVTs,
and the energy inefficiencies common to traditional automatic transmissions
leave a gap in the market for an improved solution.
Thus, there remains an unmet need for a Two-Speed Automatic
Transmission System with Electromagnetic Clutch and Planetary Gears, that
can transcend these issues. A novel system that enhances the driving
experience by ensuring quick and efficient gear transitions, while reducing the
mechanical complexity and maintenance needs, would be highly
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advantageous. This system should also effectively manage power transfer,
offer a tangible sense of direct engagement for the driver, and maintain
durability even under high stress conditions, thereby filling a void in current
transmission technology.
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OBJECT OF THE INVENTION
The primary objective of this invention is to develop a two-speed
automatic transmission system with an electromagnetic clutch and planetary
gears, ensuring secure and efficient torque transmission under high RPM and
torque conditions.
Another object of the invention is to engineer a system capable of
adeptly managing both high torque and RPM demands, thereby surpassing
the performance of conventional systems confined by these parameters.
Yet another object of the invention is to decrease the possibility of
failure under severe torque scenarios, thus improving the system's sturdiness
and reliability.
Yet another object of the invention is to streamline the assembly
process by allowing for a sideways configuration with gears, which reduces
the time and complexity involved in integrating the clutch into more extensive
systems.
Yet another object of the invention is to design a transmission system
with independent components, affording enhanced versatility and enabling
innovation in gear mechanisms without necessitating clutch assembly
alterations.
SUMMARY OF THE INVENTION
The present invention is described hereinafter by various embodiments.
This invention may, however, be embodied in many different forms and should
not be construed as limited to the embodiment set forth herein.
Embodiments of the present invention provide a two-speed automatic
transmission system with electromagnetic clutch and planetary gears for a
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vehicle. The automatic transmission system comprises a transmission housing
assembly fabricated from a high-strength material to house internal gearing
components; a gear set assembly housed within the transmission housing
assembly comprising a ring gear meshing with the ring gear and the sun gear
and a planetary carrier-2 supporting the plurality of planetary gears linked to a
power source and interacting with the gear set assembly further includes an
electromagnetic clutch assembly positioned within the transmission housing
assembly for facilitating the engagement and disengagement of the
transmission gears; and a motor assembly coupled to the transmission
housing assembly & the gear set assembly is configured to respond to RPM
or torque or vehicle speed-linked signals to facilitate gear shifts, thereby,
enabling seamless transition between different gear ratios, providing smooth
torque transfer and efficient power transmission.
In accordance with an embodiment of the present invention, the gear
set assembly is adaptable to accommodate different transmission ratios to suit
varying vehicle requirements.
In accordance with an embodiment of the present invention, the
planetary carrier-2 is manufactured from high-strength alloy steel, includes a
spline section with a length of 18 to 25 mm.
In accordance with an embodiment of the present invention, the
planetary carrier-2 also functions as an output shaft, providing flexibility in
torque transfer configurations.
In accordance with an embodiment of the present invention, the sun
gear is made from high-grade steel, with a major diameter of Ø20 to 50 mm.
In accordance with an embodiment of the present invention, the
planetary gears are manufactured from high-strength alloy steel with surface
treatments selected from case hardening or nitriding.
In accordance with an embodiment of the present invention, the system
is designed to handle a wide range of input torques, making it suitable for both
lightweight vehicles and high-torque applications.
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In accordance with an embodiment of the present invention, the
planetary carrier-1 is manufactured from hardened steel.
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In accordance with an embodiment of the present invention, the
electromagnetic clutch assembly operates within a voltage range of 12VDC to
96VDC and has a maximum current draw of 5 amps.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present
invention can be understood in detail, a more particular description of the
invention, briefly summarized above, may have been referred by
embodiments, some of which are illustrated in the appended drawings. It is to
be noted, however, that the appended drawings illustrate only typical
embodiments of this invention and are therefore not to be considered limiting
of its scope, for the invention may admit to other equally effective
embodiments. These and other features, benefits, and advantages of the
present invention will become apparent by reference to the following text
figure, with like reference numbers referring to like structures across the views,
wherein:
Figure 1A illustrates an outer perspective view of the two-speed
automatic transmission system with Electromagnetic Clutch and Planetary
Gears, in accordance with an embodiment of the present invention;
Figure 1B illustrates an outer perspective view of the two-speed
transmission system with motor, in accordance with an embodiment of the
present invention;
Figure 1C illustrates an exploded view of the Two-Speed Automatic
Transmission System, in accordance with an embodiment of the present
invention;
Figure 1D illustrates an illustrates a sectional view of the assembled
automatic transmission system, in accordance with an embodiment of the
present invention;
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Figures 2A-2B illustrate a front view and a side view of a transmission
housing, in accordance with an embodiment of the present invention;
Figures 3A-3B a front view and a side view of a ring gear, in accordance
with an embodiment of the present invention;
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Figures 4A-4B illustrate a side view and a front view of a planetary
carrier-2, in accordance with an embodiment of the present invention;
Figures 5A-5B illustrate a front view and a side sectional view of a sun
gear, in accordance with an embodiment of the present invention;
Figures 6A and 6B illustrate a front view and a side sectional view of a
planetary gear, in accordance with an embodiment of the present invention;
Figure 7 illustrates a front view of an input shaft, in accordance with an
embodiment of the present invention; and
Figures 8A and 8B illustrate a side view and a front view of a planetary
carrier-1, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
The present invention is described hereinafter by various embodiments
with reference to the accompanying drawing, wherein reference numerals
used in the accompanying drawing correspond to the like elements throughout
the description.
While the present invention is described herein by way of example using
embodiments and illustrative drawings, those skilled in the art will recognize
that the invention is not limited to the embodiments of drawing or drawings
described and are not intended to represent the scale of the various
components. Further, some components that may form a part of the invention
may not be illustrated in certain figures, for ease of illustration, and such
omissions do not limit the embodiments outlined in any way. It should be
understood that the drawings and detailed description thereto are not intended
to limit the invention to the particular form disclosed, but on the contrary, the
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invention is to cover all modifications, equivalents, and alternatives falling
within the scope of the present invention as defined by the appended claim.
As used throughout this description, the word "may" is used in a permissive
sense (i.e. meaning having the potential to), rather than the mandatory sense,
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(i.e. meaning must). Further, the words "a" or "an" mean "at least one” and the
word “plurality” means “one or more” unless otherwise mentioned.
Furthermore, the terminology and phraseology used herein is solely used for
descriptive purposes and should not be construed as limiting in scope.
Language such as "including," "comprising," "having," "containing," or
"involving," and variations thereof, is intended to be broad and encompass the
subject matter listed thereafter, equivalents, and additional subject matter not
recited, and is not intended to exclude other additives, components, integers
or steps. Likewise, the term "comprising" is considered synonymous with the
terms "including" or "containing" for applicable legal purposes.
Figure 1A illustrates an outer perspective view of the two-speed
automatic transmission system (100) with electromagnetic clutch and
planetary gears, in accordance with an embodiment of the present invention
(may be alternately referred as “the automatic transmission system (100)”).
Figure 1 provides a clear view of a transmission housing assembly (1) of the
automatic transmission system (100). This transmission housing assembly (1)
serves as the structural backbone that houses the gear set assembly (not
shown in figure 1) and is designed to endure the operational stresses imparted
during the vehicle's operation. The transmission housing assembly (1)
includes a transmission housing (1.1) fabricated from a high-strength material,
such as aluminum or steel alloy, designed to accommodate and protect the
internal gearing components effectively.
At the crux of the system's operational prowess is the electromagnetic
clutch assembly (which is not visible in Fig. 1 but is discussed in subsequent
figure 1C). This advanced mechanism, positioned within the transmission
housing, employs an electromagnetic actuator to facilitate the swift
engagement and disengagement of the transmission gears. The clutch is
designed to respond to RPM-linked signals, which allows for a highly
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responsive gear selection process, tailored to the varying demands of vehicle
acceleration and efficiency.
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Moving to Figure 1B, the two-speed automatic transmission system
(100) is depicted with the motor assembly (5) attached. The motor is coupled
to the transmission housing assembly (1) and is secured with robust bolts
(shown in fig. 1C), which are selected for their high tensile strength to
withstand the vibrational forces and torque stresses. The motor, an integral
component of the system (100), is meticulously engineered to synchronize
with the electromagnetic clutch, delivering precise control over the gear shifts.
This symbiosis between the motor and the transmission underpins the
system’s ability to cater to a wide range of vehicles, from lightweight bikes to
more demanding applications such as commercial electric vehicles, where
reliability and adaptability are paramount.
The motor assembly (5) may typically be made of high-performance
electrical steel and copper windings, to ensure efficient conversion of electrical
energy into mechanical energy. The incorporation of the motor highlights the
system's adaptability, demonstrating its capacity to seamlessly integrate with
various powertrain configurations.
In alternative embodiments, the automatic transmission system (100)
could be designed to accommodate motors of different power outputs to suit
specific vehicle requirements, including high-torque applications. Alternative
materials such as composites may be used for parts of the motor assembly (5)
to reduce weight without compromising strength.
After observing the external features of the two-speed automatic
transmission system (100) in Figures 1A and 1B, with and without the motor
assembly (5), now, referring to Figure 1C and 1D for an in-depth examination
of the gear set assembly's internal mechanisms and the interplay of its various
components.
In Figure 1C, illustrates an exploded view of the automatic transmission
system (100) that provides intricate details, highlighting the interplay of its
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various components within the gear set assembly (2), while Figure 1D
illustrates a sectional view of the assembled automatic transmission system
(100).
As shown in figure 1C and 1D, the transmission housing assembly (1)
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is
the robust outer shell that encapsulates and shields the intricate
components of the automatic transmission system (100). The transmission
housing (1.1) is typically cast from high-strength aluminum or steel alloys,
selected for their durability and ability to house and align the internal
components securely.
The transmission housing (1.1) is further illustrated in more detail, in
front view and side view shown in Figures 2A and 2B. As illustrated in Figure
2A, the transmission housing (1.1) features exemplary dimensions and
specifications to enable a skilled addressee to work the invention. The
threaded holes of M6 to 10 are provided to fix the gear set assembly (2) with
the transmission housing (1.1), & a guiding diameter of Ø140 to 160mm which
allows for easy fastening of the motor (6) to the transmission housing (1.1).
Returning to Figure 1C and 1D, the oil seal (1.2) is positioned to
maintain the integrity of the lubrication system, preventing contaminants from
infiltrating and oil from leaking out, the transmission housing (1.1) has hole of
diameter Ø26 to 52mm to facilitate the oil seal (1.2). The transmission
system’s efficiency is partly contingent on the quality of the ball bearing (1.3),
which facilitates smooth rotational movements with minimal friction There is
also a hole of diameter Ø32 to 52mm to facilitate the bearing to provide the
smooth rotation with the planetary carrier-2 (2.2). The breather assembly (1.4)
serves to equalize pressure within the housing and mitigate moisture
accumulation.
The gear set assembly (2) is the heart of the transmission, with the ring
gear (2.1) acting as the external boundary, interfacing with the transmission
housing (1.1) to form a stationary component. Made from heat-treated alloy
steel, the ring gear’s (2.1) durability ensures it can withstand the continuous
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interaction with the planetary gears (2.5). The ring gear is further detailed in
Fig. 3A and 3B.
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As can be seen in Figures 3A and 3B, the ring gear (2.1) features a
gear thickness of 10 to 15mm along with inner diameter & outer diameter to
facilitate the fitments with the mating parts.
Returning to figure 1C and 1D, the planetary carrier-2 (2.2), which may
double up as an output shaft, carries the planetary gears (2.5) and is
constructed to handle torque transfer with minimal flex. The sun gear (2.3) is
the central sprocket, often forged from high-grade steel, and requires precise
machining for interaction with the planetary gears (2.5) and ring gear (2.1).
One-way bearings (2.4), typically made of chrome steel, allow the sun gear
(2.3) to rotate freely in one direction and lock in the other, contributing to the
transmission’s two-speed functionality. The planetary gears (2.5), pivotal in
torque distribution, are likely manufactured through precision machining and
often are case-hardened for surface durability while retaining a tough core.
The input shaft (2.6) links the power source to the gear set, and its alignment
is crucial for efficient power transmission. The planetary carrier-1 (2.7)
supports the planetary gears (2.5) on the opposite end and is integral to the
gear set’s function. The oil seal (2.8) ensures lubrication within the gear set
without leakage. The ball bearings (2.9) facilitate the smooth operation of
rotating components. Bolts (2.10) secure the components, chosen for their
strength and resistance to loosening under vibration.
Exemplary embodiments disclosing exemplary dimensions each of the
planetary carrier-2 (2.2), the sun gear (2.3), the planetary gears (2.5) and the
input shaft (2.6) have been illustrated in the following figures explained below:
Figures 4A-4B illustrate a side view and a front view of the planetary
carrier-2 (2.2), in accordance with an embodiment of the present invention. As
shown in Figures 4A and 4B, the planetary carrier-2 (2.2) features precise
dimensions that are critical for its function. The side view (Figure 4A) shows
the overall length of 42 to 50mm.The planetary carrier-2 has a length of 18 to
25 mm in which transmission assembly (1.1) interfaces with the oil seal (1.2)
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& the ball bearing (1.3). It consists of a spline section with a length of 9 to
15mm. It further includes a central bore diameter of Ø8 to 15 facilitate to needle
bearing fitment in which the input shaft (2.6) arrests with this interface into the
planetary carrier-2 (2.2).
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Additionally, the planetary carrier-2 (2.2) is typically manufactured from
high-strength alloy steel, selected for its ability to endure high torque loads
without deformation. The component is generally machined to tight tolerances,
ensuring precise alignment and smooth operation within the transmission
system. The splined interface is designed to engage securely with the
planetary gears (2.5), distributing torque evenly. The carrier's body often
features additional reinforcement ribs to enhance structural integrity and
minimize flex under load. Surface treatments, such as nitriding or carburizing,
may be applied to the carrier to improve wear resistance and extend its service
life.
These dimensions are exemplary and illustrate the precision required
in manufacturing the planetary carrier-2 to meet the functional demands of the
transmission system.
Next, Figures 5A and 5B illustrate a front view and a side sectional view
of the sun gear (2.3), in accordance with an embodiment of the present
invention. As illustrated in Figures 5A and 5B, the sun gear (2.3) features
precise dimensions that are critical for its function.
The side sectional view (Figure 5B) provides further details, including
the inner diameter of Ø20 to 50mm to facilitate the one way bearing (2.4). The
central bore diameter of Ø8 to 15mm facilitates the needle bearing.
Again, the dimensions and construction details are exemplary and are
only meant to illustrate the precision required in manufacturing the sun gear to
meet the functional demands of the transmission system.
In that sense, the sun gear (2.3) is typically made from hardened steel,
chosen for its high strength and resistance to wear. The gear is manufactured
through precision machining processes, ensuring that the teeth are accurately
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formed for optimal meshing with the planetary gears (2.5). Heat treatment
processes such as carburizing or induction hardening may be applied to
enhance the surface hardness while maintaining a tough core, providing
durability and extended service life. The precise tolerances and surface finish
specifications ensure minimal friction and efficient power transmission within
the gear set.
Besides, Figures 6A and 6B illustrate a front view and a side sectional
view of the planetary gear (2.5), in accordance with an embodiment of the
present invention. As can be seen from the drawings, the planetary gear (2.5)
features precise dimensions critical for its function within the transmission
system. The front view (Figure 6A) shows the gear teeth profile, designed for
optimal meshing with the sun gear (2.3) and the ring gear (2.1).
The side view (Figure 6B) provides detailed measurements, including
the overall length of 10 to 15 mm.
Moreover, the planetary gears (2.5) are typically manufactured from
high-strength alloy steel, selected for its durability and ability to withstand high
torque loads. The gears undergo precision machining to ensure the accurate
formation of gear teeth and bore dimensions. Surface treatments, such as
case hardening or nitriding, are applied to the gears to improve wear
resistance and extend their operational life.
These dimensions and construction details are exemplary and illustrate
the precision required in manufacturing the planetary gears to meet the
functional demands of the transmission system.
Figure 7 illustrates a front view of the input shaft (2.6), in accordance
with an embodiment of the present invention. As illustrated in Figure 7, the
input shaft (2.6) features precise dimensions critical for its function within the
transmission system. The front view (Figure 7) shows the overall length of the
shaft at 50 to 100 mm, with multiple diameter sections along its length. The
shaft diameters are Ø20 mm to 40 mm, ensuring a precise fit with respect to
the ball bearing (2.9) & the one-way bearing (2.4) respectively.
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The shaft features a splined section designed to engage securely with
the motor assembly (6) and providing a robust interface for torque transfer.
The end section of the shaft has a diameter of Ø6 to 10, facilitating precise
alignment and smooth rotation within the needle bearings (2.11).
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The input shaft (2.6) is typically manufactured from high-strength alloy
steel, selected for its ability to withstand high torque loads, and provide reliable
power transmission. The shaft undergoes precision machining to ensure the
accurate formation of splines and diameters, maintaining tight tolerances
specified in the drawings. Surface treatments such as nitriding or carburizing
may be applied to enhance the surface hardness and wear resistance of the
shaft, extending its operational life. Any deviation to suit different applications
and power requirements are easily achievable without departing from the
scope of the present invention.
Furthermore, Figures 8A and 8B illustrate a section view and a front
view of the planetary carrier-1 (2.7), in accordance with an embodiment of the
present invention. As illustrated in Figures 8A and 8B, the planetary carrier-1
(2.7) features precise dimensions critical for its function within the transmission
system. The section view (Figure 8A) shows the diameters of Ø26 to 52 mm
& Ø32 to 52 mm which facilitate the oil seal (2.8) & the ball bearing (2.9) with
respect to the Input shaft (2.6) & diameter of Ø45 to 55 mm ensures the
planetary carrier-1 (2.7) fits snugly within the EM clutch assembly (3).
The front view (Figure 8B) provides further details, including a threaded
hole of M6 to 10 having a length of 10 to 15 mm at 3 places, as shown in the
section view (Figure 8A). This ensures secure attachment to the adjoining
components, providing stability and balance.
The planetary carrier-1 (2.7) is typically made from hardened steel,
chosen for its high strength and resistance to wear. The planetary carrier-1
(2.7) is manufactured through precision machining processes, ensuring the
accurate formation of critical dimensions and holes. The carrier's body often
features additional reinforcement ribs to enhance structural integrity and
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minimize flex under load. Surface treatments, such as nitriding or carburizing,
may be applied to improve wear resistance and extend its service life.
These dimensions and construction details are exemplary and illustrate
the precision required in manufacturing the planetary carrier-1 to meet the
functional demands of the transmission system.
In some embodiments, the gear set may incorporate helical gears for
quieter operation, or electronic control units may be implemented to adjust the
gear ratios dynamically. Materials like titanium or carbon fiber composites
could be considered for components like the planetary carriers (2.2, 2.7) for
their superior strength-to-weight ratios, albeit with cost considerations.
Returning to figures 1C and 1D, central to this automatic transmission
system (100) is the electromagnetic clutch assembly (3). Its function hinges
on the precise operation of the dry clutch mechanism, which is actuated by
RPM-linked signals or the alternative system using direct transmission RPM
sensing. The clutch’s components must exhibit exceptional wear resistance
and thermal stability, potentially utilizing advanced ceramics or composite
materials for the friction surfaces.
The motor assembly (5) is coupled to the transmission housing
assembly (1) and is secured with robust bolts (6). The motor assembly (5) is
intricately linked to the electromagnetic clutch (3), where it functions to actuate
the clutch mechanism. This component must be designed to respond swiftly
to RPM signals for agile gear transitions. Materials like high-grade electrical
steel, copper, and insulating composites are used for their electrical
performance and heat dissipation properties.
While the EM clutch (3) offers precise control over torque transmission
and facilitates smooth shifting, there are alternative clutch mechanisms that
may also be used in the present invention:
1. Centrifugal Clutch: This clutch type engages based on the rotational
speed of the input shaft, automatically engaging as it reaches a
predetermined RPM threshold. It offers a self-acting solution that
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eliminates the need for external control signals, making it suitable for
applications where simplicity and reliability are paramount. The
centrifugal clutch is seamlessly integrated into the planetary gear
assembly, adjacent to the Planetary Carrier-1, offering a streamlined
approach to clutch engagement in scenarios that demand less
complexity.
2. Hydraulic Clutch: Another alternative could be a hydraulic clutch
system, which uses fluid pressure to control the engagement and
disengagement of the clutch. This system can provide smooth
operation and is adaptable to a wide range of operating conditions. It
allows for variable control over the clutch engagement, offering a
balance between responsiveness and ease of use.
3. Electro-hydraulic Clutch: Combining elements of both EM and
hydraulic technologies, the electro-hydraulic clutch offers a hybrid
solution. It uses electrical signals to control a hydraulic mechanism that
actuates the clutch. This allows for precise control similar to the EM
clutch, with the added benefit of hydraulic smoothness and adaptability.
This system can be particularly effective in applications that require
both precise control and the ability to handle variable load conditions
seamlessly.
Each of these alternatives has its unique advantages and could serve
as a complement or substitute to the electromagnetic clutch (3), depending on
the specific requirements of the transmission system (100). Selection among
these options would hinge on factors such as the desired level of control,
simplicity, system integration, and operational demands of the application.
In the fabrication of the gear set assembly detailed in Figure 1C, the
manufacturing processes for components such as the gears include precision
machining or forging, followed by heat-treatment to ensure the requisite
hardness and resilience for sustained operation. The ball bearings, essential
for the fluid motion of rotating parts, are commonly produced from high-quality
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steel and finished with protective coatings to enhance their resistance to
degradation and corrosion.
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Considering alternatives, the gear components might employ advanced
lightweight materials such as titanium to reduce overall mass, or the
implementation of seals compatible with synthetic lubricants to improve
longevity. Such modular design principles afford straightforward substitution
of parts for regular maintenance or upgrade interventions, thereby potentially
prolonging the service life of the transmission system and simplifying the repair
process.
The collective assembly of the two-speed automatic transmission
system (100) embodies a seamless integration of elements, each playing a
crucial role in facilitating a refined driving experience. Centrally, the
electromagnetic clutch system synchronizes with the robust planetary gears,
shifting between gear ratios with marked efficiency. This integration is key to
achieving prompt vehicle acceleration and agile handling, fitting a broad range
of automotive applications from compact passenger vehicles to the more
demanding commercial vehicle sector.
The integration of a planetary gear set within the automatic
transmission system (100) embodies a distinctive and inventive concept.
Known for their compact size and high-density power transmission, planetary
gears provide an effective solution for space-conscious automotive design,
enabling a variety of gear ratios within a compact assembly. This gear
configuration is advantageous not only for its space efficiency but also for its
contribution to balanced torque distribution and potentially more economical
fuel usage, thereby lowering operating costs and minimizing the ecological
footprint of the vehicle. In the fabrication of the gear set assembly detailed in
Figure 1C, the manufacturing processes for components such as the gears
include precision machining or forging, followed by heat-treatment to ensure
the requisite hardness and resilience for sustained operation. The ball
bearings, essential for the fluid motion of rotating parts, are commonly
produced from high-quality steel and finished with protective coatings to
enhance their resistance to degradation and corrosion.
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Considering alternatives, the gear components might employ advanced
lightweight materials such as titanium to reduce overall mass, or the
implementation of seals compatible with synthetic lubricants to improve
longevity. Such modular design principles afford straightforward substitution
of parts for regular maintenance or upgrade interventions, thereby potentially
prolonging the service life of the transmission system and simplifying the repair
process.
The collective assembly of the two-speed automatic transmission
system (100) embodies a seamless integration of elements, each playing a
crucial role in facilitating a refined driving experience. Centrally, the
electromagnetic clutch system synchronizes with the robust planetary gears,
shifting between gear ratios with marked efficiency. This integration is key to
achieving prompt vehicle acceleration and agile handling, fitting a broad range
of automotive applications from compact passenger vehicles to the more
demanding commercial vehicle sector.
The integration of a planetary gear set within the transmission system
embodies a distinctive and inventive concept. Known for their compact size
and high-density power transmission, planetary gears provide an effective
solution for space-conscious automotive design, enabling a variety of gear
ratios within a compact assembly. This gear configuration is advantageous not
only for its space efficiency but also for its contribution to balanced torque
distribution and potentially more economical fuel usage, thereby lowering
operating costs and minimizing the ecological footprint of the vehicle.
Exemplary method of operation (Refer Fig. 1C and 1D):
An exemplary method of operation for the two-speed automatic
transmission system (100) with electromagnetic clutch and planetary gears
may work as follows: The process commences with the vehicle's engine
generating power that is conveyed to the input shaft (2.6). This rotational force
is then adeptly transferred to the sun gear (2.3), which occupies the central
position within the gear set assembly (2).
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Normally in 1st gear condition, the torque is transmitted from the motor (6) to
the input shaft (2.6). Following steps are involved in between 1st gear
engagement & torque transmission to the wheel:
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1. The Input shaft (2.6), the one-way bearing (2.4) & the sun gear (2.3)
engage and act like a single body, such that the entire torque is received from
the motor (6).
2. Then the torque is transferred from input shaft (2.6) via the one-way
bearing (2.4) & the sun gear (2.3) to the Planetary Carrier-2 (2.2).
3. The Planetary Carrier-2 (2.2) transmits the torque to the wheel with
the help of, say, a sprocket & chain/ belt.
2nd Gear Engagement Condition:
2nd gear engages when the RPM of motor (6) reaches the predefined
range, such as, but not limited to, predefined RPM or a predefined torque
value. In that condition, following are the steps involved:
1. One way bearing (2.4) starts over running on the input shaft (2.6) &
the sun gear (2.3) is isolated from the input shaft (2.6), so in this condition
torque/RPM does not transfer to the sun gear (2.3).
2. Instead, the Planetary Carrier-1 (2.7) gets engaged with the EM
clutch Assy (3) & transmits the RPM to the Planetary Carrier-2 (2.2) directly.
3. Planetary Carrier-2 (2.2) then transmits the RPM/torque to the wheel
with the help of, say, sprocket & chain/ belt & vehicle starts running in the 2nd
gear.
Throughout this operation, the transmission's integrity is maintained by
the robustness of the housing assembly (1), which contains all the moving
components securely. The system is designed to ensure optimal alignment
and smooth rotation, facilitated by dowel pins (2.10) and ball bearings (2.9),
all of which are tightly secured with bolts (2.11) made of durable materials
capable of withstanding the stresses of operation.
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Therefore, through its dynamic design and interaction of components,
the two-speed automatic transmission system (100) adeptly manages power
transfer, providing the necessary torque for acceleration and efficient speed
for cruising, while ensuring longevity and performance of the vehicle's
drivetrain.
Working example:
In practical applications, the two-speed automatic transmission system
(100) with an electromagnetic clutch demonstrates significant versatility and
adaptability across different vehicle requirements. The electromagnetic clutch
can be energized within a voltage range of 12VDC to 96VDC, depending on
the specific demands of the vehicle, with a maximum current draw of 5 amps.
This ensures efficient operation and responsive gear engagement. The
present invention exhibits a transmission ratio of 2.57, which can be fine-tuned
to lower ratios such as 2.3 or adjusted to higher ratios as needed, allowing for
flexible adaptation to various vehicle specifications and packaging constraints.
Furthermore, the torque capacity of the system is designed to handle a wide
range of input torques, from 10Nm to 50Nm. For more demanding
applications, the torque capacity can be increased up to 90Nm through
modifications in the internal mechanism and geometric adjustments, ensuring
robust performance under diverse operating conditions. This adaptability
highlights the system's capability to cater to a broad spectrum of automotive
applications, from lightweight vehicles to high-torque scenarios, enhancing
both its utility and appeal in the automotive industry.
The present invention of the two-speed automatic transmission system
(100) with an electromagnetic clutch and planetary gears offers several
advancements over conventional transmission systems:
Enhanced Efficiency in Gear Shifting: The incorporation of an
electromagnetic clutch allows for precise control of gear engagement,
providing a seamless and efficient shift between gears. This results in
improved vehicle performance, particularly in the context of acceleration and
fuel economy.
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Versatility Across Vehicle Types: Designed to accommodate a wide
range of automotive applications, from compact cars to commercial vehicles,
this system's adaptability is a testament to its innovative approach. This
versatility ensures broad market applicability and the potential for widespread
adoption.
Reduced Mechanical Complexity: By utilizing a planetary gear set and
electromagnetic clutch, the invention simplifies the transmission system.
Fewer moving parts mean there's a reduced chance of mechanical failure,
thereby increasing reliability and reducing maintenance requirements.
Space-Saving Design: The compact arrangement of the planetary
gears allows for a smaller transmission footprint, which is particularly
advantageous in modern vehicles where space is at a premium. This design
efficiency does not compromise on power or performance, making it a
preferred choice for efficient vehicle design.
Improved Torque Distribution: The planetary gear configuration
inherently provides balanced torque distribution, which contributes to better
handling and stability of the vehicle. This feature is especially beneficial under
varying load conditions, ensuring consistent performance.
Cost-Effective Manufacturing: The ability to use less stringent
dimensional control for component manufacturing without compromising on
performance leads to reduced production costs. This cost-effectiveness can
be a significant advantage in competitive automotive markets.
Longevity and Durability: The materials and manufacturing methods
suggested for the components, like heat-treated alloy steels and protective
finishes for bearings, ensure a long operational life for the transmission
system, further adding to its economic and practical appeal.
By addressing and overcoming the limitations of traditional transmission
systems, this invention sets a new standard for performance, reliability, and
efficiency in automotive transmission technology.
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The different implementations provided above are not limiting and are
only illustrative examples of the different scope of the present subject matter.
Other implementations apparent to a person skilled in the art are also included
within the scope of the present subject matter.
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Various modifications to these embodiments are apparent to those
skilled in the art from the description and the accompanying drawings. The
principles associated with the various embodiments described herein may be
applied to other embodiments. Therefore, the description is not intended to be
limited to the embodiments shown along with the accompanying drawings but
is to be providing broadest scope of consistent with the principles and the
novel and inventive features disclosed or suggested herein. Accordingly, the
invention is anticipated to hold on to all other such alternatives, modifications,
and variations that fall within the scope of the present invention and the
appended claims. ,CLAIMS:We Claim
1. A two-speed automatic transmission system with electromagnetic clutch
and planetary gears for a vehicle, the automatic transmission system
(100) comprising:
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a transmission housing assembly (1) fabricated from a high-strength
material to house internal gearing components;
a gear set assembly (2) housed within the transmission housing
assembly (1), the gear set assembly (2) comprising:
a ring gear (2.1),
a sun gear (2.3),
a plurality of planetary gears (2.5) meshing with the ring gear
(2.1) and the sun gear (2.3),
a planetary carrier-1 (2.7) and a planetary carrier-2 (2.2)
supporting the plurality of planetary gears (2.5);
an input shaft (2.6) linked to a power source and interacting with
the gear set assembly (2);
an electromagnetic clutch assembly (3) positioned within the
transmission housing assembly (1) for facilitating the engagement and
disengagement of the transmission gears; and
a motor assembly (5) coupled to the transmission housing assembly
(1) for controlling the electromagnetic clutch assembly (3).
2. The automatic transmission system (100) as claimed in claim 1, wherein
the electromagnetic clutch assembly (3) is configured to respond to RPM
or torque or vehicle speed-linked signals to facilitate gear shifts, thereby,
enabling seamless transition between different gear ratios, providing
smooth torque transfer and efficient power transmission.
3. The automatic transmission system (100) as claimed in claim 1, wherein
the gear set assembly (2) is adaptable to accommodate different
transmission ratios to suit varying vehicle requirements.
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4. The automatic transmission system (100) as claimed in claim 1, wherein
the planetary carrier-2 (2.2) is manufactured from high-strength alloy
steel, and includes a spline section with a length of 9 to 15 mm.
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5. The automatic transmission system (100) as claimed in claim 1, wherein
the planetary carrier-2 (2.2) also functions as an output shaft, providing
flexibility in torque transfer configurations.
6. The automatic transmission system (100) as claimed in claim 1, wherein
the sun gear (2.3) is made from high-grade steel, with a major diameter
of Ø20 to 50 mm and gear thickness ranging from 10 to 15 mm.
7. The automatic transmission system (100) as claimed in claim 1, wherein
the planetary gears (2.5) have a gear thickness of 10 to 15 mm and are
manufactured from high-strength alloy steel with surface treatments
selected from case hardening or nitriding.
8. The automatic transmission system (100) as claimed in claim 1, wherein
the system is designed to handle a wide range of input torques, making it
suitable for both lightweight vehicles and high-torque applications.
9. The automatic transmission system (100) as claimed in claim 1, wherein
the planetary carrier-1 (2.7) includes a threaded hole of M6 to 10 within a
length of 10 to 15 mm at 3 places and is manufactured from hardened
steel.
10. The automatic transmission system (100) as claimed in claim 1, wherein
the electromagnetic clutch assembly (3) operates within a voltage range
of 12VDC to 96VDC and has a maximum current draw of 5 amps.
Dated this the 6th Day of September 2024