CHANGE SPEED GEAR TRAINS

Abstract: An automatic gearbox for an automobile or truck comprises one or two layshafts (14, 16) with interleaved plate type clutches (20, 22, 24) for ratio selection. The gearbox provides primary and secondary stages of ratio selection, each having at least two selectable ratios whereby a minimum of four ratios are available. In at least one of those stages, two selectable ratios are provided by two mainshaft/layshaft constant mesh gear pairs (60/58, 36/56) and associated clutches so that a single stage can provide three, four or more ratios, and thus six, eight or more ratios overall.

Description: CHANGE SPEED GEAR TRAINS This invention relates to change speed gear trains, particularly but not exclusively to such gear trains for use in the mass market for highway vehicles , including automobiles and trucks . Presently available gear trains for highway vehicles include gearboxes of the manual shift and the power shift kind. Manual shift gearboxes tend to be of the single layshaft kind with plate type input clutches. Power shift gearboxes are mainly of the epicyclic kind with torque converter input . Both are well established and have their merits , the merit of the former bein its simplicity and reliability and low cost , the merit of the latter being its smooth operating characteristics . "--v Equally however , both such gearboxes are subject - to significant limitations . The single layshaft manual shift gearbox is not readily adapted for power shifting. The epicyclic power shift gearbox is also subject to significant limitations including complexity , servicing difficulties , need for a torque converter , original cost , and limitations in the number of ratios available. This latter aspect precludes its use in all but relatively lightweight trucks , and automobiles . Neither gearbox provides an output shaft which is very conveniently placed for a front wheel drive where the gearbox mounts directly on the front-located engine. Multi-layshaft gear trains of the kind employing , multiple plater-interleaved clutches have been proposed in -many different layouts and designs. Most of these have been either for industrial usage or heavy duty vehicle. transmissions of the kind employed in shuttle type vehicles of the crawler kind , or front end loaders. In our prior European patent EP 0 012 022 B we have described a four-la shaft gearbox for buses and other public service vehicles. For such heavy duty applications the design constraints imposed by the mass road vehicle market are either not applicable or are much less stringent . These requirements include a paramount need for compactness, a multiplicity of ratios ( particularly for trucks ) , the availability of power shift . Relative simplicity of construction and ease of servicing with attendant minimal manufacturing and servicing cost , and fuel efficiency. So far as multiple ratios and power shifting are concerned , many previously _proposed multi-layshaft gearboxes may be able to meet these requirements to some extent , but in most cases these are very cumbersome and heavy and relatively expensive transmissions which are ruled out by the stringent space and economic factors imposed by highway vehicle design. In other cases , the number of available ratios is increased by the provision of added-on output stages whereby , for example , a basically four-ratio gear train is converted to an eight speed transmission ( four low and four high ) . However , such an arrangement is basically unsuitable for use in vehicle transmissions for the truck and automobile market since the output stage is not integrated into the transmission as a whole and , for example , the clutch of such an add-on output stage is required to take the full transmission output torque , which in the case of a truck trans- mission may well be seven times the maximum engine torque . As a result , the clutch has to be of the dog type ( possibly with synchronisation ) which is a great disadvantage so far as power shift is concerned, or else the clutch has to be of relatively large diameter which is also very undesirable for space economy reasons. An object of the present invention is to provide a change speed gear train and a transmission and highway vehicle incorporating same offering improvements in relation to one or more of the factors identified above , or generally. - 4 - According to the invention there is provided a change speed gear train together with a highway vehicle transmission and a highway vehicle incorporating same , as defined in the accompanying claims. In this specification and the claims , the expression " highway vehicle " means a vehicle such as a truck or automobile , which is intended for use primarily on highways or roads and which has a gear train providing at least four forward transmission ratios, and which is capable of sustained operation at the usual operating speeds of highway vehicles. The expression is intended to cover general purpose vehicles which fall within the above definition , but which by virtue of , for example , a four wheel drive , are also capable of operation over rough terrain. In embodiments described below a change speed gear train comprises a central shaft assembly having change speed gears rotatable about a common axis. One or two layshafts are grouped around the central shaft and parallel thereto. The , or each , layshaft has layshaft gears in constant mesh with the gears on the central shaft assembly. Selectively actuatable clutch means is provided to effect torque changes . The assembly of the central shaft and the layshaft and their associated gears provide primary and secondary stages of torque variation . Each of the stages includes at least two selectable torque paths. The stages are arranged in series ( so that the torque resulting from one stage necessarily passes through the other stage ) whereby a minimum of four selectable torque paths providing a graded sequence of torque changes are provided between drive input and drive output gears of the gear train - said drive input and drive output gears being located on the shaft assembly constituted by the central shaft and the layshaft. One of said primary and secondary stages of torque variation is provided by at least two independently actuatable multiple interleaved plate type clutches and associated constant mesh change speed gear pairs. One gear of each of the pairs is on the same layshaft and the other is on the central shaft . Each clutch is associated with its own one of said change speed gear pairs. The clutches are independently actuatable to cause torque to be transmitted through the respective pair of change speed gears . This provides two torque paths for said one stage of torque variation . In the embodiment this arrangement enables two , three or more transmission ratios to be obtained conveniently from just one of the stages of torque variation , whereby a relatively large number of transmission ratios can be obtained conveniently and economically . Three torque paths can be obtained by merely providing a direct drive clutch between the mainshaft gears of the two gear pairs . Four ratios could be obtained by adding a further gear pair and an associated clutch. In the embodiment , the gear train provides a graded sequence of transmission ratios as required by highway vehicles to meet varying road and load conditions. The clutches in the embodiment are all of the multiple plate kind actuated by fluid pressure actuators under the control of automatic ratio changing equipment which senses vehicle/transmission parameters and changes ratios by varying the fluid pressure supplied to the relevant clutches. Power shifting , being a refinement of automatic ratio changing , provides that the timing of the clutch actuation is such that the disengagement of one clutch with regard to the engagement of the next clutch is timed to provide substantially no interruption of power flow. The gear train is arranged so that at least one stage of torque increase follows each clutch means , whereby the latter is not required to transmit the full gear train output torque. In many cases , the clutch means are mounted on the layshafts . The lubrication of the clutch plates is provided by a pressurised lubricant feed via suitable ducts , some of which extend length¬ wise of the layshafts. This arrangement enables retardation of the transmission to be provided by partial engagement of an additional transmission ratio not in use for transmission purposes . In the embodiments , where the gearbox width is to be minimised , then a single layshaft arrangement is preferred . Where gearbox length is to be minimised , two layshafts are preferred. The embodiments provide a particularly convenient arrangement for use in a front wheel drive automobile. With either one or two layshafts , the final drive output from the gear train can be conveniently arranged at the same end as the input , but offset from it. In this way , where the vehicle-has a front-mounted engine , the drive output from the gear train to the input of the differential drive unit connected to .the front wheels is conveniently located at a reasonably central position between the front ground wheels. This avoids the need to provide a special countershaft for the purpose. The invention also provides a gear train comprising any novel combination or sub-combination of the features disclosed herein. Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which : Fig. 1 shows a partly-sectioned view of a change speed gear train according to the invention ; Fig. 2 shows an end elevation view on arrow II in Fig. 1 ; Fig. 3 shows , separated from the gear train , the second of the two layshafts thereof ; Fig. 4 shows a schematic diagram of the gear train of Figs. 1 to 3 ; Figs. 5 and 6 shows , in views similar to those of Figs. 1 and 3 , a second embodiment of the invention ; Fig. 7 shows a schematic diagram of the embodiment of Figs. 5 and 6 ; Figs. 8 and 9 show- sectional views through a third embodiment , Fig.8 showing the gear train proper and Fig. 9 showing one of the two layshafts ; Fig. 10 shows a schematic diagram of the embodiment of Figs. 8 and 9 ; Fig. 11 shows a schematic diagram of a modification of the embodiment of Figs. 8 to 10 ; Fig. 12 shows a schematic diagram of a two layshaft gear train with coaxial input and output arrangements ; Fig. 13 shows a schematic diagram of a single layshaft gear train with coaxial input and output shafts ; Fig. 14 shows an axial section through a single layshaft gear train with various optional drive output arrangements indicated ; Fig. 15 shows a schematic diagram of the embodiment of Fig. 14 ; and Figs. 16 and 17 show schematic diagrams of modifications- of the embodiment of Figs. 14 and 15. In the embodiment of Figs. 1 to 4 , a gear train 10 comprises a central shaft assembly 12 , and two layshafts 14 , 16 , arranged to drive a differential drive unit 18 of a transmission of a front wheel drive/front engine automobile. Layshafts 14 , 16 have double clutch assemblies 20 , 22 and central shaft 12 has an end clutch 24 whereby transmission ratios are selected . The gear train is located in a housing or gearbox 26 containing an oil bath for the gears and the multiple interleaved plates of the clutch assemblies. Not shown in Figs. 1 to 4 are systems for providing oil feed to the clutch plates and fluid pressure control ( hydraulic or pneumatic ) to the actuators of the clutches to effect ratio changes in sequence and under automatic control. Drive input to the gear train is through a resilient coupling device 28 to a splined input shaft 30 extending lengthwise of main shaft 12 and coupled at its remote end to the housing 32 of mainshaft clutch 24 , and hence to the radially outer set of clutch plates dogged to the housing . The radially inner set of clutch plates are dogged to a tubular mainshaft portion 34 carrying mainshaft out¬ put gears 36 , 38 . Housing 32 of mainshaft clutch 24 is fixed to a main- shaft input,gear 40 which is in constant mesh with an input gear 42 of primary layshaft 14. Primary layshaft output gears 44 , 46 mesh with the mainshaft output gears 36 , 38 respectively . Primary,layshaft clutch 20 enables layshaft gears 44 or 46 to be drivably coupled to the layshaft input gear 42 through the layshaft inner shaft portion 48 which is connected to the housing 50 of layshaft 14 and hence to the radially outer set of interleaved clutch plates dogged thereto. The corresponding radially inner sets of clutch plates are dogged to layshaft tubular outer shaft portions 52 and 54 , and hence coupled to the layshaft output gears 44 and 46 respectively. Secondary layshaft 16 is of similar construction to primary layshaft 14 . Its input gears 56 and 58 are in constant mesh with , respectively , mainshaft output gear 36 and a further mainshaft gear 60 forming an integral part of a cluster gear with gears 36 , 38 . The output gear 62 of secondary layshaft 16 is coupled via layshaft clutch 22 to layshaft gears 56 or 58. Output gear 62 meshes with the input gear 64 of differential drive unit 18. In use , mainshaft clutch 24 is actuatable to cause torque to pass either direct from input shaft 30 to the cluster gear 36 , 38 , 60 , or else to pass to the cluster gear via primary layshaft 14 ( which itself enables layshaft clutch 20 to cause the drive to pass via the layshaft gears 44 or 46 ) . Hence there are effectively three ratios or torque paths provided by this first stage of torque variation . Secondary layshaft 16 provides a secondary stage of torque variation . It offers two torque paths between the mainshaft output gear cluster 36 , 38 , 60 and the layshaft output gear 62 , the torque passing either via layshaft gear 56 or gear -58 according to appropriate actuation of double clutch assembly 22, the latter being connected to output gear 62 in the same way that clutch 20 is connected to its input gear 42. Thus , the transmission 10 provides six transmission ratios overall in the very compact structure shown in Figs. 5 and 6. In the embodiment of Figs. 5 , 6 and 7 the arrangement is generally similar to that of Figs. 1 to 4 in that the gear train 70 comprises two layshafts 72 , 74 driving a front wheel drive unit 76 . However , the mainshaft input clutch 78 ( corresponding to clutch 24 in Figs. 1 to 4 ) is located at the drive input end of the gear train and primary layshaft 72 comprises a single multi-plate clutch 80 having its radially outer set of clutch plates connected to the layshaft output gear 82 and its radially inner set of plates connected via the layshaft inner shaft 84 to the layshaft input gear 86 , Secondary layshaft 74 is constructed in a manner similar to that of secondary layshaft 16 in Figs. 1 to 4, but has an additional torque input via a layshaft inner shaft 88 and an associated input gear 90 . The main shaft 92 has output gears 94 , 96 meshing with the secondary layshaft input gears 98, 100 respectively -; In addition a main shaft end clutch 102 of the multiple plate kind has its radially inner set of plates dogged to a tubular shaft carrying a third mainshaft output gear 104 in constant mesh with gear 90 on layshaft 74. In use , six ratios are provided in the two torque variation stages provided by the layshaft 72 and 74 . Two ratios being associated with the former and three with the latter , the third ratio of the secondary layshaft being due to the provision of mainshaft end clutch 102 . The gear train 80 operates in a similar manner to . that of Figs. 1 to 4 , the six ratios being controlled automatically . It is to be noted that this embodiment is slightly longer in the axial direction than that of Fig. 1. In the embodiment of Figs. 8,9, and- 10 there is shown another two-layshaft gear train 200 adapted for front wheel drive but which provides twelve transmission ratios instead of six. The basic layout is similar to that of Figs. 1 to 4 , but end clutches 202 , 204 are provided on the primary and secondary layshafts 206 , 208 and the input clutch 210 of mainshaft 212 is located at the input end of the gear train . Layshaft clutches 214 and 216 correspond to clutch 22 of Figs. 1 to 4 with the addition of a layshaft inner shaft interconnecting the housing ( and hence the outer set of clutch plates ) of the double clutch and the inner- set of .clutch plates on the end clutches 203 , 204 . The input gear 218 of mainshaft- 2T2 meshes with input gear 220 of primary layshaft 206. The mainshaft out¬ put cluster gear comprises gears 222 , 224 and 226 - 1 3 meshing with ( on the primary layshaft 206 ) output gears 228 and 230 , and end clutch gear 232 . On secondary layshaft 208 , the mainshaft output gears mesh with end clutch gear 234 and input gears 236 , 238 . The secondary layshaft final output gear 240 meshes with a differential drive ' unit , as described above. Figs. 8 and 9 show details of the construction and arrangement of the clutches of the gear train which are applicable also to other embodiments. Mainshaft input clutch 210 has its radially inner set of interleaved clutch plates 242 dogged to the input shaft 244 which is driven via a resilient coupling 246 . The corresponding outer set of plates 242 is dogged to the clutch housing 248 and directly coupled to the mainshaft input gear 218 through a tubular shaft 250. Other input clutches in this specification are similarly constructed. Layshaft clutches 202 , 204 have inner sets of plates 252 directly dogged to the layshaft inner shaft portions, and outer sets of plates 252 dogged via the clutch housing 254 to the layshaft end clutch gears 232 , 234. The structure of the double clutch assemblies 214 , 216 is likewise representative of the other embodiments . As shown , the layshaft inner shaft portion 256 is connected via a radial web 258 to an annular clutch housing 260 to which the two sets of radially outer clutch plates 262 are dogged , the corresponding inner set being dogged to an annular sleeve directly connected to the relevant layshaft gear 236 , 238 etc.. In this embodiment , layshaft 206 provides four torque paths between the mainshaft input gear 218 and the mainshaft output cluster gear 222 , 224 , 226 . The secondary layshaft 208 provides three transmission ratios between the main shaft cluster - gear and the gear train output pinion 208 , whereby the total number of ratios available is twelve. In the embodiment of Fig. 11 , the general structure and arrangement is as described above but with the omission of the layshaft end clutches 202 , 204 and their associated constant mesh gears and the layshaft inner shaft portions connecting them to the double clutches 214 , 216 . Thus , this embodiment provides a primary stage of torque variation having three paths or ratios and a secondary stage providing two , whereby the total number of paths or ratios available is six. In the embodiment of Fig. 12 central shaft 230 has an input clutch 232 acting between an input gear 234 and a central cluster gear 236 , 238 , 240 . A central shaft output clutch 242 acts between cluster gear 240 and final output gear 244. Primary layshaft 246 has a double clutch assembly 248 serving to selectively interconnect layshaft input gear 250 with layshaft output gears 252 and 254 , these latter three gears meshing respectively with the central shaft gears 234 , 238 and 240. This provides three torque- paths or ratios in the primary stage of the gearbox. Secondary layshaft 256 comprises double clutch 258 and layshaft input gears 260 , 262 and layshaft output gear 264 , whereby three torque paths are available in the secondary stage of the gearbox. Thus , nine ratios overall are available , three more than would be the case if the drive output were taken from the secondary layshaft output gear 264 to ( for example ) a front wheel drive arrangement . The gear train of Fig. 12 is suitable for truck applications , for example , where the transmission layout is the traditional front engine/ front gearbox with a propeller shaft driving the rear wheels. The embodiments described above have all been two- layshaft gear trains . The embodiments of Figs. 13 to 17 are all single layshaft gear trains . Turning now to the embodiment of Fig. 13 , it will be noted that this is a single layshaft gear train with coaxial input and output . Input clutch 270 acts between mainshaft input gear 272 and mainshaft output cluster gear 274 , 276 . Layshaft 278 comprises a primary portion having gears 278 and 280 meshing with mainshaft gears 272, 274 respectively , a layshaft clutch 282 serving to drivably interconnect these layshaft gears . A secondary portion -of layshaft 278 comprises a dual clutch 284 and layshaft gears 286 , 288 meshing respectively with mainshaft gears 276 and 290 , the latter pair being drivably interconnectable by a second mainshaft clutch 292. Six transmission ratios overall are provided by virtue of three torque paths, from mainshaft input gear 272 to cluster 274 , 276 , and two torque paths between the cluster gear and the gear train output gear 290. Fig.- 13 also shows in dotted lines alternative output arrangements at each end of layshaft 278 , output gear 294 providing an offset output at the non-drive input end , and output gear 296 providing the front wheel drive configuration. The single and double clutches in this embodiment are constructed substantially as described above in the previous embodiments. With reference to the schematic diagrams , such as Fig. 13 in this application generally , it must be understood that the diameters of the pinions indicated are not necessarily drawn to scale and for questions of drive ratio and the like reference must be made to the assembly drawings , such as Figs. 8 and 9 . It will be appreciated , with reference to Fig. 13 , that modification of the drive output arrangements by virtue of the use of the gears 294 or 296 will reduce the number of available transmission ratios to four since the direct drive torque path between gears 276 and 290 is then not available. Turning now to the embodiment of Figs. 14 and 15 , this is a single layshaft six ratio front wheel drive configuration gear train employing individual clutches on the layshaft instead of double clutches β Input clutch 400 acts between mainshaft input gear 402 and mainshaft cluster gear 404 , 406 . On the layshaft 408 , the primary or input clutch 410 is operable to transmit drive between layshaft gears 412 and 414 meshing with the mainshaft gears 402 , 404 , thereby providing two torque paths in the primary stage of the gear train. The secondary stage of the gear train comprises three clutches 416 , 418 and 420 , the latter being on the mainshaft and the former two on the layshaft . These three clutches are of the multi-plate interleaved kind and serve to selectively transmit torque from the mainshaft to the inner shaft portion 422 of the layshaft which has an output gear 424 - connected to a front wheel drive in the manner described above. An optional output at the opposite end 426 may also be provided where a straight through but offset drive arrangement is required. In Fig. 14 , this output is indicated by the drive flange 428 • . ' This embodiment operates in a substantially similar way to that of the preceding embodiment. End clutch 420 can be partially engaged in addition to the clutch engaged at any given time for transmission purposes ' to provide a retarder . The end clutch 420 can be conveniently supplied with coolant such as oil under pressure ..- -.- In the embodiments of Figs. 16 and 17 , two of the clutch means have been combined into a double clutch assembly similar to that described above in connection with preceding embodiments . In Fig. 16 , clutches 416 and 418 have been combined into a double clutch 440 . In Fig. 17 end clutch 420 and clutch 418 have been combined into a double clutch 442 , with corresponding modification of the shaft arrangements . In the above embodiments , the principal advantages include the common feature of two directly-clutchable torque paths available from one or both of the two stages of torque variation , whereby relatively large numbers of transmission ratios are available from a very compact assembly .- This compactness is enhanced by the use of the double clutch assemblies . Moreover the gear trains described all offer the facility for automatic control and power shifting in a compact format suitable for the mass highway vehicle market and without the requirement for a torque converter and its associated expense and fuel inefficiency . Other advantages of the transmissions described will be apparent from the discussion in the preamble of this specification. Although details of. the automatic control system have not been shown in the drawings , such can be readily provided by means merely of fluid pressure conduits to " the actuators of the individual clutch assemblies.

Claims: - 1 9 - CLAIMS : 1. A change speed gear train for a highway vehicle comprising : a central shaft having torque change gears rotatable about a common axis ; one or more layshafts rotatable about respective axes parallel to the axis of the central shaft and having layshaft input and output gears in constant mesh with said central shaft gears together with selectively actuatable clutch means to effect said torque changes ; said assembly of the central shaft and the layshaft and their associated gears providing primary and secondary stages of—torque_ variation , each of said stages including . at least two selectable torque paths , and said stages being arranged in series whereby a minimum of four selectable torque paths providing a graded sequence of torque changes are provided between drive input and drive output gears of the gear train located on the shaft assembly constituted by the central shaft and the layshaft ; characterised in that one of said stages of torque variation is provided by at least two independently actuatable multiple interleaved plate type clutches and associated constant mesh change speed gear pairs , one gear of each of said pairs being on the same layshaft and the other on the central shaft , and each clutch being associated with its own one of said change speed gear pairs , and the clutches being independently actuatable to cause torque to be transmitted through the respective pair of change speed gears , whereby two of the torque paths provided by said one stage of torque variation are determined by the torque changes provided by the gears of said gear pairs . 2. A gear train according to claim 1 characterised in that said central shaft change speed gears comprise central shaft input and output gears with clutch means located between them , the gear train comprising two layshafts including a primary layshaft to transmit drive between said central shaft input and output gears, and a secondary layshaft having secondary layshaft input gears in constant mesh with said central shaft output gears , together with associated clutch means to enable drive to be selectively transmitted to said drive output gear of the gear train on said secondary layshaft. K - A gear train according to claim 2 characterised in that said central shaft clutch means acting between the central shaft input and output gears is located at the end of the gear train remote from the drive input thereto . 4. A gear train according to claim 1 characterised in that a single layshaft and its associated layshaft gears and clutch means provides both said primary and secondary stages of torque variation , at least two pairs of gears being provided on- the central shaft with clutch means between the gears of each pair to permit variation of the torque path through the gear train. 5. A gear train according ' to any one of the preceding claims characterised in that a gear train output gear located on said secondary layshaft or on said unique layshaft is positioned at the same end of the gear train as the drive input thereto so as to be suitable to be coupled to a differential drive assembly of a front wheel drive road vehicle. 6. A gear train according to any one of claim 1 to 4 characterised in that a gear train output gear located on said secondary layshaft or on said unique layshaft is positioned at the opposite end of the gear train from the drive input thereto so as to be suitable to couple through a fore/aft propeller shaft to a rear wheel drive assembly ,said secondary layshaft or said unique layshaft being offset downwardly ( in the working attitude of the apparatus ) from the central shaft , ' thereby reducing the requirement for housing said propeller shaft in a road vehicle body structure. 7. A gear train according to any one of the preceding claims characterised in that said two independently actuatable clutches associated with said same layshaft comprise a double multiple iaterleaved plate type clutch assembly mounted on said same layshaft and located between the associated layshaft gears thereon. 8. A gear train according to claim 7 characterised .in that said layshaft associated with the double clutch assembly comprises at least one outer tubular shaft and at least one inner shaft extending through said outer- shaft , said double clutch assembly comprising inner and outer sets of interleaved clutch plates , said inner shaft being coupled to said outer set or sets of clutch plates and said outer tubular shaft or shafts being coupled to said inner clutch plates. 9. A highway vehicle characterised by a drive transmission comprising a gear train according toany one of the preceding claims together with automatic or semi-automatic control equipment to effect ratio changes.

Inventors: TAILBY RAYMOND ALFRED, WINDSOR-SMITH CLAUDE PETER, TAILBY, RAYMOND, ALFRED, WINDSOR-SMITH, CLAUDE, PETER
Applicants: TAILBY RAYMOND A, WINDSOR SMITH CLAUDE P, TAILBY, RAYMOND, ALFRED, WINDSOR-SMITH, CLAUDE, PETER
Application year: 1985
Main classification: F16H3
IPC codes: F16H3