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Integrated design of the transmission fork actuator
The transmission system plays a crucial role in the overall performance of a vehicle. As environmental and fuel efficiency standards become more stringent, the transmission must also evolve to meet these demands. This includes being lighter and more compact in design. Reducing the weight and number of components not only improves fuel economy but also supports the broader goal of environmental sustainability. By analyzing the shifting fork actuator, an innovative integrated mechanism can be developed that enhances functionality while maintaining a compact structure, aligning with future vehicle requirements.
**Transmission Body Structure**
As a vital component of the vehicle’s powertrain, the transmission is responsible for transferring engine torque and speed through gear ratio changes, enabling the vehicle to move. The transmission body is typically divided into four main functions: power transmission, gear selection and shifting operation, gear selection and shifting execution, and housing connection. Among these, the actuator is the most critical part, serving as the link between the operating mechanism and power output, especially during gear shifts.
**1. Traditional Fork Actuator**
In traditional designs, each shift fork operates independently, often requiring multiple synchronizers, shift forks, and fork shafts. This leads to a bulky and heavy structure, increasing the size and weight of the transmission housing. As shown in Figure 1, the one-to-one relationship between fork and fork shaft results in a higher number of parts, which negatively impacts fuel efficiency and environmental goals. Therefore, there is a need to integrate functions, reduce weight, and minimize the number of components.
**2. Integrated Fork Actuator**
Integrating the self-locking and interlocking functions of the wave groove (as seen in Figure 2) creates a more compact and efficient design. In this configuration, three fork assemblies are combined onto a single fork shaft, reducing the number of components and compressing the overall geometry. However, it's essential to ensure that the integrated actuator still performs all necessary functions, such as self-locking and interlocking.
The interlocking block assembly ensures that the forks remain locked in place when in their initial position or when engaged with a gear. The wave groove and steel ball system provides the self-locking function, while the interlocking block prevents unintended gear shifts. As shown in Figure 3, the axial movement of the wave groove relative to the fixed steel ball generates a spring-loaded locking effect.
Figure 4 illustrates the shifting action, where the interlocking block rotates around the fork shaft, allowing the selected gear pin to drive the corresponding fork. At the same time, the interlocking block prevents other forks from moving, ensuring proper interlocking. Similar mechanisms are observed in Figure 5, where the interlocking block prevents simultaneous shifts, enhancing reliability and control.
**3. Verification of the Integrated Fork Actuator**
To validate the performance of the integrated actuator, it was installed on a commercial vehicle platform by SAIC for a 50,000 km durability test under harsh road conditions. The system performed flawlessly, with no issues such as gear misshifts. Compared to traditional independent systems, the integrated design reduced the transmission’s weight and volume by 15%, making it more aligned with green and eco-friendly vehicle trends.
**Conclusion**
This paper explores the integration of mechanical functions in the transmission actuator, drawing inspiration from electronic circuit design principles. By analyzing and integrating functional components, the transmission can be made smaller and lighter, meeting the growing demand for sustainable and efficient vehicles. The key innovation lies in using mechanical integration to achieve functional efficiency, offering a new approach to forward design and product development. This not only enriches design methodologies but also fosters greater autonomy and creativity in engineering solutions.