Methods and systems for improving the operation of automatic transmissions for motor vehicles
BACKGROUND OF THE INVENTION 
     The methods and apparatus of the present invention are directed to modification and improvement of automatic transmissions for automotive vehicles of the type installed by the original equipment manufacturers. It is particularly directed to the improvement and modification of automotive transmissions known as &#34;440-s&#34;. 
     The &#34;heart&#34; of an automatic transmission is the valve body. Among other things, the valve body receives input signals in the form of hydraulic pressures to control the shifting pattern and timing of an automatic transmission. A more detailed discussion of the operation and importance of the valve body in an automatic transmission system for automobiles may be found with reference to U.S. Pat. No. 4,449,426, issued to the present inventor on May 22, 1984. 
     Automatic transmissions installed by original equipment manufacturers are calibrated to provide gear shifts to accommodate the comfort of the driver and passengers. However, the original shifting pattern is generally inefficient from a mechanical point of view and tends to shorten the useful life of the original transmission. Correcting and modifying an original automatic transmission through structural modification of the valve body, is complicated, laborious and expensive. 
     It is the object of the present invention to correct and modify deficiencies of automatic transmission installed by original equipment manufacturers without making any substantial structural modifications to the valve body itself. The corrections and modifications provided by the methods and systems of the present invention are directed to the employment of fluid mechanics which modify regulation or output signals of the original valve body to operate the sub-systems of the automatic transmission to overcome inherent drawbacks therein. Other objects and advantages of the method and systems of the present invention will become apparent to those skilled in the art from the following discussion. 
     SUMMARY OF THE INVENTION 
     The methods and systems of the present invention are adapted to employ fluid mechanics for modifying and correcting the operation of an automatic transmission installed by the original equipment manufacturer without making any substantial structural modifications to the valve body. The methods and systems of the present invention are particularly useful in connection with automatic transmissions commonly referred to in the trade as &#34;440-s&#34;. In one aspect of the present invention, the clearance stroke of a servo-piston is reduced to increase the engagement stroke for more gradual engagement over a longer period of time. In conjunction with the reduction of the clearance stroke, a spring system is installed to assure that the pressure applied to the servo-piston more closely matches the actual pressure for engagement over the increased engagement time period to control the engagement stroke. 
     In further aspects of the invention, valve means are employed together with a feed orifice to provide a rapid threshold fluid pressure applied to the servo-piston in conjunction with the reduced clearance stroke to more quickly commence a reverse engagement stroke. Similarly, valve means and orifice feed cooperate in conjunction with drive engagement. The valve system does not merely provide &#34;on/off&#34; fluid flow, but it coordinates the pressure rise in the overall system to perform several different functions, including providing full flow to the 1-2 band to prevent engagement delay in response to an increase in line pressure. 
     In other aspects of the invention, downshift of gears is primarily controlled by fluid volume within the system and corresponding adjustments to the feed hole size, thereby avoiding dependency on complicated regulating valves included in the original equipment. The system employs fluidic accumulation for regulation in proportion to fluid flow friction and line pressure, instead of in proportion to modulated pressure (or throttle valve). The higher total tension of springs installed in accordance with the method of the present invention shortens the engagement time at higher motor RPM&#39;s and tends to eliminate slides and bumps during gear shifts. 
     In a further aspect of the invention, the total overall quantity of fluid flow required to operate the different sub-systems of an automative transmission is significantly reduced as compared to the quantity of fluid required for operation of an automatic transmission installed by the original equipment manufacturer. The use of a lesser overall volume of fluid to operate the automatic transmission advantageously tends to reduce or eliminate lockup converter failure by assuring that sufficient fluid will be available for providing the necessary oil to the converter front, and generally reduces sudden line pressure drops by assuring that the transmission pump is operating below its maximum pumping capacity. 
     The methods and systems of the present invention advantageously correct and modify known disadvantages in the operation of automatic transmissions installed by original equipment manufacturers by modifying pre-existing input and output signals. No substantial structural modifications to the valve body itself are required to result in the operational improvements and functional advantages provided by the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 of the drawings is a graph illustrating uncorrected reverse gear engagement of an automatic transmission; 
     FIG. 2 is a graph showing reverse gear engagement as corrected in accordance with the present invention; 
     FIGS. 3A-3E are schematic drawings illustrating the corrected reverse engagement shown by FIG. 2; 
     FIG. 4 illustrates a graph showing uncorrected drive (forward) engagement; 
     FIG. 5 illustrates a graph showing corrected drive (forward) engagement in accordance with the present invention; and 
     FIGS. 6A-6E schematically illustrate servo-boost valve operation during forward engagement in accordance with the present invention. 
    
    
     DESCRIPTION OF THE BEST MODES FOR CARRYING OUT THE INVENTION 
     The methods and systems of the present invention for correcting and modifying automatic transmissions for automotive vehicles will now be discussed with reference to FIGS. 1-5 of the drawing. A publication entitled &#34;TRANSGO® 440 Training And Parts: Complete Repair Method&#34; which provides specific examples of corrections made in accordance with the method and systems of the present invention is expressly incorporated by reference into the present specification. 
     As previously noted herein, the valve body of an automatic transmission constitutes the primary element for controlling the gear shift of an automatic transmission. The valve body is a complicated mechanical structure, and adjustments and corrections of the mode and manner of gear shifts in an automatic transmission by structural adjustments to the valve body itself is complicated, time consuming and expensive. It is therefore desirable to &#34;design around&#34; the valve body without making any substantial structural adjustments thereto when modification or correction of the shifting pattern of the automatic transmission is desired. 
     FIG. 1 of the drawing illustrates uncorrected engagement into reverse gear in an automatic transmission of the type installed by an original equipment manufacturer. As will be understood by those familiar with the art, reverse engagement of the transmission occurs through the movement of a reverse servo-apply piston driven by transmission fluid introduced through a feed or control orifice defined in a separator plate. The first phase of piston movement is referred to as the clearance stroke which is essentially free play or free movement of the piston before the transmission band engages a drum. Thereafter, further movement of the piston results in engagement, which continues until sufficient fluid pressure is established to complete the gear shift. As is evident from FIG. 1 of the drawing, the angle of engagement (the ratio of piston movement to time) is relatively steep and abrupt, and often results in a bump or noticeable slide because the torque-absorbing portion of the engagement stroke occurs too rapidly. Moreover, the large clearance distance over which the piston must travel requires that the feed or control orifice defined in the separator plate be correspondingly large to accommodate the flow of a sufficiently large quantity of transmission fluid to avoid time delays in reverse engagement. 
     In accordance with the methods and systems of the present invention, the clearance travel of the reverse servo-apply piston is significantly reduced, as illustrated by FIG. 2 of the drawing. As a result of the reduced clearance travel, the engagement movement of the piston occurs over a longer period of time. Accordingly, the angle of engagement (the ratio of piston movement to time) is less than that of the original transmission (as illustrated by FIG. 1) resulting in a smoother engagement phase since the fluid pressure applied is increased more gradually over a larger time period. Thus, although the total time for a complete piston movement through clearance and engagement is approximately the same in FIGS. 1 and 2, the vast majority of travel time of the piston movement in FIG. 2 occurs during the engagement phase, and not during the clearance phase. 
     The reduction of the piston movement during clearance, and the resultant decrease in the engagement angle, (the ratio of applied pressure to piston distance travelled during engagement) is accomplished in several different ways. In the first instance, adjustments are made to an engagement pin carried by the reverse servo-apply piston so that engagement commences after a shorter distance of piston travel. Resilient means, preferably a series of compression springs opposing the movement of the piston and calibrated to match the pressure required for engagement, are installed in place of pre-existing springs. The springs provide improved control of piston movement during engagement to assure a smooth engagement. A servo-boost valve is provided to permit fluid to be applied to the servo-piston until a predetermined engagement fluid pressure is attained. Thereafter, the servo-boost valve automatically closes and all further fluid flow occurs through the control orifice in the separator plate. In this manner, an immediate increase in system pressure occurs during the reduced clearance phase to quickly commence the engagement phase, but final engagement is controlled by fluid feed through the control orifice in the separator plate to result in a more gradual and smoother final engagement. Since the clearance distance to be travelled by the piston has been significantly reduced, the size of the orifice and flow rate of the transmission fluid therethrough can be correspondingly reduced, thereby enabling the system to operate using a smaller overall quantity of transmission fluid, which further enhances the smooth and gradual engagement by permitting more precise control over the fluid pressure applied to the servo piston. The reduction in the quantity of transmission fluid needed for operation of the system advantageously tends to eliminate abrupt pressure drops in the system as a result of demands on the transmission pump in excess of the pump capacity, since the lesser pressure required to operate the system assures that the pump is operating below its maximum capacity. 
     FIG. 3 of the drawing illustrates a schematic diagram of a system in accordance with the present invention resulting in the reduced clearance stroke and the reduced applied pressure/time ratio illustrated by FIG. 2. FIG. 3A is an exploded view of the structural components employed in connection with the reverse engagement operation of the present invention. A cushion spring 2 and plurality of washers are mounted around an engagement pin 8 driven by a reverse servo-piston 6. A plurality of adjustment shims 9 are mounted around the engagement pin between the washers 4 and a shoulder 11 defined by the engagement pin. A plurality of return springs 10 are mounted proximate to the forward end 12 of the engagement pin, and exert a resilient force against the direction of movement of the reverse servo-piston. The engagement pin is not affixed to the piston head, and in operation, the cushion spring engages the piston head and the washers, the washers then engaging the return springs and/or the adjustment shims. 
     FIG. 3B is an exploded view of a reverse servo-boost valve 13 including a valve body comprising a shank 14, a spool 16, and a head 18. The valve body defines a spring pocket 20 for accommodating therein an outer spring 22 and an inner spring 24 received within the outer spring. 
     FIG. 3C is a schematic view of reverse engagement illustrating transmission fluid flow. As illustrated in the drawing, the servo-valve 13 is open and permits fluid to flow through it. Fluid flows through the valve into the reverse servo-piston 6, and is met by the resistance of the return springs 10 opposing downward movement of the piston. When a predetermined threshold pressure (e.g., 14 p.s.i.) is established in the line 26 between the valve and the piston 6, the valve is automatically closed and all further fluid flow occurs exclusively through a control orifice 28 once a check ball 30 has been seated. Fluid flow through the control orifice 28 corresponds to the commencement of the engagement stroke of the reverse servo-piston. This fluid flow, together with the opposed force of the return springs 10 on the reverse servo-piston 6, controls the speed of movement of the servo-piston during the reverse engagement phase to assure gradual and smooth increases in applied fluid pressure to result in smooth engagement. In the event that further engine torque/power is applied, the reverse servo-booster valve 13 senses the pressure increase and again opens to allow rapid application of transmission fluid from the transmission pump and through the valve 13, bypassing the control orifice 28, to provide increased fluid pressure and flow to the reverse servo-piston 6 to prevent the slipping of the reverse band. 
     FIGS. 3D and 3E schematically illustrate the position of the reverse servo-valve 13 when the valve is closed (and all fluid flow is channelled through the control orifice 28) and when the valve is open (thereby channelling fluid flow through the valve 13 and by-passing the control orifice 28), respectively. 
     FIGS. 4 and 5 of the drawing illustrate graphs similar to those of FIGS. 1 and 2 respectively, showing uncorrected and corrected drive engagement. As is apparent from FIG. 4, the clearance distance of the piston stroke is relatively long, and the engagement angle, representing the ratio of system pressure buildup to time, is relatively steep. 
     FIG. 5 illustrates the pressure/application time ratio for drive engagement of the automatic transmission illustrated by FIG. 4, as corrected and modified in accordance with the method and system of the present invention. Although the overall time required for total drive engagement for the corrected transmission is substantially identical to the total time for drive engagement of the uncorrected transmission, it is apparent that the engagement phase of the piston travel is substantially longer for the corrected transmission than for the uncorrected transmission. Accordingly, the ratio of pressure application/time (or distance travelled by the piston during the engagement stroke) is substantially less for the corrected transmission, thereby resulting in a smoother, more continuous drive engagement. The longer pressure application period during the overall drive engagement procedure is attained by adjusting the position of an engagement pin carried by a forward servo-piston to expedite the commencement of the forward engagement stroke. A servo-boost valve is provided to supplement fluid pressure applied to the servo-piston through control orifices to control the overall rate of fluid pressure applied to the servo-piston. Unlike the factory installed transmission which provides only an &#34;on/off&#34; type valve to supplement orifice fluid flow, the valve provided by the present invention controls the supplemental fluid flow to more precisely compensate for pressure changes in the system during drive engagement. Preferably, the valve is dimensioned to provide a second control orifice in its fully opened position. As illustrated by the sequence of FIGS. 6A-6E, the position of the valve controls the rate of fluid flow through the valve. As shown in the drawings, the valve 32 includes shank 34, a spool 36, and a head 38, each of which has a different outer dimension. The shank portion is employed to completely block fluid flow in the closed position of the valve, the spool portion is employed for maximum fluid flow through the valve, and the head portion is employed for intermediate fluid flow through the valve. 
     The size of a control orifice 40 is reduced to reduce the quantity and flow of transmission fluid through the orifice, thereby enhancing the gradual and continuous increase in line pressure during the extended drive engagement phase. Resilient means may be provided to oppose the movement of the servo-piston to counteract the force of the transmission fluid to match the actual pressure required for drive engagement, further enhancing the gradual pressure increase in the system. The net result of the modification provided by the method and system of the present invention, similar to that provided for the reverse engagement, is an overall engagement stroke of a servo-piston which is completed within the same time period as that of the original uncorrected transmission, but which results in a smoother, more continuous and efficient shift. 
     In a further aspect of the present invention, the servo-boost valve of the type described above, is employed to coordinate the pressure rise system to perform several different functions. For example, during no load (idle or high vacuum), the servo-boost valve remains closed and the servo-piston is fed directly through the control orifice of the separator plate. If a driver moves the gear shift lever of the automatic transmission to drive and applies throttle by depressing the accelerator pedal before the transmission drive band is applied, the increase in line pressure opens the servo-boost valve and immediately feeds full fluid flow to the band to prevent delay in drive engagement. 
     The servo-boost valve also avoids dangerous pressure drops during downshift. For example, to prevent rough downshift during the operation of an air conditioned vehicle, the calibration of the control orifice is raised to 88 pounds. To prevent bang if the drive happens to apply throttle during the coast 3-2 downshift, the servo-boost valve is wide open between 88-135 pounds. At 135 pounds, the valve resizes the flow to control the speed of the 1-2 band applied during 4-2 and 3-2 kickdown. Therefore, the valve function is coordinated with changes in the valve body, the servo, and the channel plate, to control shift feel and avoid dangerous pressure drops in the system. 
     As discussed herein, a significant feature of the method and systems discussed herein is a reduction of approximately 40-50% in volume of the transmission fluid necessary for the operation of the transmission in conjunction with a corresponding reduction in the size of the control orifice. The reduction in volume of transmission fluid brings the system within the safe limits of pump capacity and tends to significantly reduce abrupt drops in line pressure resulting from pressure demands of the operating system which exceed the capacity of the pump. As discussed herein, reduction of total fluid volume and corresponding reduction in control orifice size, in operative association with a servo-boost regulating valve, results in both improved reverse engagement and improved drive engagement. Corresponding considerations must also be made with respect to downshift. Adjustments to the exhaust ports for transmission fluid during downshift must be adjusted in proportion to the adjusted control orifice in the separator plate and the reduced overall volume of transmission fluid present in the operating system. For example, if the original volume of transmission fluid required for a 4-2 downshift is 9 cubic inches, the reduced volume for a similar downshift in the modified system is approximately 4 cubic inches. Similarly, a 3-2 downshift requiring approximately 5 cubic inches of transmission fluid in the original system, requires only approximately 2.6 cubic inches of fluid in the modified system. As a result of the reduced volume of transmission fluid required for downshifts in the modified system, it is possible to control the time and the feel of the downshift while staying safely below the capacity of transmission fluid to be delivered by the pump to maintain enough line pressure to keep the 2nd (or input) clutch from slipping. As a result, the downshift is primarily controlled by the volume of transmission fluid within the system, and the size of the control orifice. During downshift operations, particularly during a 4-2 or a 3-2 kickdown, the servo-boost valve is operating in conjunction with the control orifice size to regulate the flow rate of transmission fluid to enhance a smooth and gradual downshift operation and avoid any abrupt changes in line pressure. 
     In a further aspect of the present invention, the pre-existing modulator system, which controls an accumulator valve to control the gear shift, is disconnected from the modulator system. The accumulator valve is placed in direct communication with the control orifice through which the transmission fluid flows. In this manner, better adjustment may be made to the accumulator valve through the fluid flowing through the control orifice. Accordingly, the overall system is rendered more flexible and easier to correct or modify by a mechanic who is required to only adjust the size of the orifice to control or modify the shift. It is not necessary to remove the valve body itself since the adjustments may be made externally from the valve body. 
     The reduced volume of transmission fluid necessary for both upshifts and downshifts result in a further advantage to the overall system by eliminating or reducing lockup converter failure. As known to those skilled in the art, and as more fully discussed in the aforementioned TRANSGO® publication, lockup converter failure occurs when the demand for transmission fluid in the system exceeds the capacity of the pump. As a result, insufficient fluid is provided to the converter front, thereby resulting in the accidental glazing of the lockup plate which ultimately results in the development of a shudder. This problem is avoided in accordance with the method of the present invention since the reduction in the volume of oil necessary to effect an upshift or downshift is reduced well below the maximum pump capacity, thereby assuring that the pump retains the capability of providing adequate front oil pressure to the converter at all times during operation of the system. 
     Other modifications and advantages of the methods and system disclosed herein falling within the scope of the present invention will become apparent to those skilled in the art. Accordingly, the discussion of the best modes of the invention made in the present specification and the attached Appendix A have been intended to be illustrative but not restrictive of the scope of the invention, that scope being defined by the following claims and all equivalents thereto.