Key design factors and solutions for gearbox speed design

    In the past few years, due to the need to reduce fuel consumption and optimize power, how to improve the efficiency of vehicle transmissions has become an important development trend in automotive design. There are two driving forces behind this trend: first, in places with high oil prices, such as China and India, the main driving force is the customer's operating costs, because fuel costs are a crucial factor in the total purchase cost of a vehicle; second, in markets where oil prices are at the world average, such as the United States, government encouragement and requirements are the main driving force for improving efficiency.

    Vehicle manufacturers realize that improvements in transmissions and drivetrains are the most effective means of improving fuel efficiency. This improvement can be achieved by optimizing predetermined speed shifts and shift points for each gear, taking into account the vehicle's load status. In order to achieve the desired efficiency, manufacturers have placed higher demands on the performance, flexibility and reliability of the sensors used in the drivetrain.

    Speed ​​sensors detect wheel speed data that is transmitted to the controller so that it can optimize gear shifting. These sensors must meet the necessary performance parameters set by the manufacturer, taking into account the operating speed range, temperature range, sensor electronic characteristics, output signal type and overall accuracy. Flexibility in sensor construction is also very important to transmission system designers. Since every transmission design is different, flexibility in sensor cables, connectors, housing length and diameter, and electrical interfaces allows designers to integrate sensors into the transmission system according to the location required for the specific design.

Challenges faced by speed sensors for transmissions to improve reliability and reduce procurement costs:
• Fluids and debris in the vehicle penetrate the sensor
• Vibration levels affect sensor integrity and accuracy
• Tight air gap tolerances will damage the sensor element

    Honeywell Sensing & Control's speed sensors for transmissions use Hall-effect magnetic sensing technology to provide an accurate digital signal that allows the controller to identify the shift point for each gear. Our product line is rich in varieties, including sensors with different electrical and performance characteristics to meet the different product specifications of manufacturers. We also provide custom sensors, adjusting the physical characteristics of the above sensors according to customer requirements to best meet the manufacturer's design requirements. In addition, we provide test samples to ensure good performance before the sensor is officially put into production. As part of the design process, Honeywell uses finite element analysis to simulate the magnetic field effects and environmental stresses that can affect sensor performance to help develop an optimal target wheel and sensor structure. This will minimize application problems encountered in the future design process. The product line series products have an IP66, IP67 or IP69K protection level to prevent sensor leakage, and can withstand 30G shock and 20G vibration environments to ensure high-precision performance.

     Honeywell has a professional technical support team with many years of global experience in designing speed sensors for vehicle transmissions. Honeywell's design team is currently working hard to develop a new generation of speed sensors that will have a higher level of customization and higher air gap flexibility.
Honeywell sincerely invites you to work with our global technical support team at the beginning of your design to better understand your application and find the most valuable transmission speed sensor for your design, taking into account factors such as quality, flexibility, price and delivery time.