Products Description
The transmission pneumatic control system is a core device that realizes automatic gear shifting of vehicle transmissions through compressed air drive. It mainly consists of pneumatic actuators (cylinders, pistons), control components (solenoid valves, ECUs), and auxiliary devices (air storage tanks, filters). Its working principle is: after the driver sends a gear shifting command (via handle or electronic signal), the ECU processes the signal and controls the solenoid valve to guide compressed air into the specified cylinder chamber. The piston moves linearly under air pressure, driving the shift fork to engage the gear set, thereby completing high-low gear switching (especially for auxiliary boxes of heavy-duty transmissions). It replaces traditional manual mechanical operation, significantly optimizing shifting efficiency and driver comfort.
Product features & advantages
Lightweight operation: The shifting force is only 1/10 of that of traditional mechanical systems (≤16N for mainstream models), greatly reducing driver fatigue during long-distance or frequent shifting.
High reliability: Pneumatic components have a simple structure, strong resistance to vibration and harsh environments (such as dust, humidity), and the failure rate is 30% lower than that of hydraulic systems.
Excellent economy: By optimizing shifting logic, it can reduce fuel consumption by 5%-10% (verified by ZF TraXon system tests). The manufacturing cost is only 1/5 of that of AMT automatic transmissions, suitable for cost-sensitive commercial vehicle markets.
Strong compatibility: It can be adapted to 5-18 speed manual transmissions, and can be quickly integrated into existing vehicle models through modular design (e.g., compatible with Fast, Qijiang gearbox series).
Intelligent upgrade potential: The electronic-pneumatic integrated version (with ECU) can be connected to vehicle GPS and sensors to realize predictive shifting (e.g., automatically adjusting gears according to road conditions such as slopes), further improving safety.
Application scope
Heavy-duty trucks: Mainly used in long-distance logistics trucks (e.g., Dongfeng Tianlong, FAW Jiefang J7) and heavy-duty transport vehicles, adapting to frequent high-low gear switching under heavy loads.
Engineering vehicles: Suitable for construction machinery such as dump trucks, concrete mixers, and mining vehicles, which need to switch gears frequently in complex working conditions (e.g., steep slopes, muddy roads).
Racing cars: Equipped in sequential transmissions of racing cars (e.g., FSAE racing cars) to achieve clutch-free shifting, shortening the shifting time to milliseconds and improving racing performance.
New energy commercial vehicles: Low-voltage pneumatic versions are developed for electric trucks and hybrid vehicles, matching the vehicle's electric control system to reduce energy consumption.
Basic parameters
| Parameter | Typical Value Range |
|---|---|
| Working air pressure | 0.6-0.8 MPa |
| Shifting response time | 0.8-1.5 seconds (electronic-pneumatic type) |
| Adaptable transmission gears | 5-18 speeds |
| Working temperature | -40°C to +80°C |
| Air consumption per shift | ≤0.3 L (standard atmospheric pressure) |
| Weight of core components | 3-5 kg (cylinder + control valve) |
| Protection grade |
IP6K9K (dustproof and high-pressure water resistance) |
FAQs
1. Product Introduction
The transmission pneumatic control system uses compressed air for automatic gear shifts, consisting of pneumatic actuators (cylinders, pistons), controls (solenoid valves, ECUs) and auxiliaries (air tanks, filters). When the driver sends a shift command, the ECU triggers the solenoid valve to direct air into the cylinder-pushing the piston to move the shift fork and engage gears. It replaces manual shifting for smoother operation.
2. Product Features & Advantages
Easy to operate: Shifting force is 1/10 of traditional systems (≤16N), reducing driver fatigue.
Durable: Simple structure, resistant to vibration/dust/moisture; 30% lower failure rate than hydraulic systems.
Cost-effective: Cuts fuel use by 5%-10% and costs 1/5 of AMT transmissions.
Versatile: Fits 5-18 speed manual transmissions (Fast, Qijiang, etc.) and retrofits easily.
Smart-ready: ECU-equipped versions connect to GPS/sensors for predictive shifting.
3. Application Scope
Heavy-duty trucks: Dongfeng Tianlong, FAW Jiefang J7-for frequent high-low shifts with heavy loads.
Engineering vehicles: Dump trucks, mixers-adapts to rough terrain.
Racing cars: Enables clutchless, millisecond shifts for better performance.
New energy trucks: Low-voltage versions match electric/hybrid systems.
4. Basic Parameters
Note: Check product manual for brand/model variations. |
|---|
5. FAQs
Q: Air leak?
A: Check connections/seals-replace damaged parts. Replace cylinder if it leaks.
Q: Maintenance needed?
A: Clean valve/filter every 50,000km; check pressure/sensors every 100,000km.
Q: Retrofit to manual transmission?
A: Yes-confirm transmission model/dimensions first.
Q: Cold weather impact?
A: No-use low-temp oil and anti-freeze air dryer.
Q: Mechanical vs electronic?
A: Mechanical (cheaper, physical links); electronic (ECU, predictive shifting).
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