Multi-gear gearbox structure for lock ring type synchronizer conical surface composite texture optimization

Abstract

The invention provides a locking ring type synchronizer conical surface composite texture optimized multi-gear gearbox structure. The locking ring type synchronizer conical surface composite texture optimized multi-gear gearbox structure is characterized in that a gearbox is composed of a shell, an input shaft assembly, an output shaft assembly, a gear transmission mechanism, a synchronous gear shifting mechanism and a lubricating and cooling system. The shell is designed by integrating light-weight aluminum alloy and nano ceramic radiating fins, the input / output shaft improves the transmission stability through a high-precision bearing and an overload protection structure, the gear transmission mechanism optimizes the efficiency through a modification straight gear and a planetary gear train, and the synchronous gear shifting mechanism is connected with an electronic sensor through a composite texture lock ring. According to the gearbox, the problems that a traditional gearbox is insufficient in heat dissipation, large in gear shifting impact, low in lubricating efficiency and the like are solved, transmission efficiency is improved, and the gearbox is suitable for high-end equipment such as new energy automobiles and heavy machinery.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle gearbox, in particular to a lock ring type synchronizer cone surface composite texture optimized multi-gear gearbox structure. BACKGROUND

[0002] At present, as the core component of power transmission, the performance of gearbox directly affects the operation efficiency and reliability of equipment, but the traditional gearbox has many problems and technical bottlenecks in practical application. In the aspect of shell structure, the strength and lightweight of part of the gearbox shell are difficult to balance, and the contradiction is prominent, which not only limits the equipment installation space, but also increases the energy consumption; the shafting assembly is prone to vibration and noise due to insufficient precision; the transmission efficiency of gear transmission mechanism needs to be improved, and the energy loss is significant at high speed and heavy load, which affects the power output performance; the synchronous shifting mechanism has the problems of poor shifting smoothness, slow response speed, long synchronization time and large impact, which seriously affects the driving experience; the lubrication and heat dissipation system cannot accurately meet the needs of each component under different working conditions, and local overheating and poor lubrication often occur, thereby reducing the service life and reliability of the gearbox. For example, the synchronizer of part of the traditional automobile gearbox is seriously worn when frequent shifting, and the heat dissipation is not timely, which leads to high oil temperature, affecting the vehicle power performance and driving experience; the oil temperature of a certain type of automobile gearbox exceeds 120℃ after continuous shifting, and the annual wear of the synchronizer cone surface is 0.3mm, which seriously shortens the service life. Therefore, it is urgent to optimize and improve each component of the gearbox to improve the overall performance.

[0003] In the prior art, the synchronizer disclosed in Chinese patent CN103486794A does not solve the problem of cone surface heat dissipation, and the lubrication system of CN105673232A lacks intelligent temperature control function. With the development of new energy vehicles and heavy machinery, the traditional gearbox cannot meet the needs in terms of transmission efficiency, shifting smoothness, reliability and the like. Therefore, it is urgent to optimize and improve each component of the gearbox to improve the overall performance.

[0004] In view of the above problems, the present application provides a lock ring type synchronizer cone surface composite texture optimized multi-gear gearbox structure.

[0005] To solve the above technical problems, the present application proposes the following technical scheme: a lock ring type synchronizer cone surface composite texture optimized multi-gear gearbox structure, characterized in that: the equipment is composed of a shell part, an input shaft assembly part, an output shaft assembly part, a gear transmission mechanism part, a synchronous shifting mechanism part and a lubrication and heat dissipation system part, the shell part is composed of a high-strength aluminum alloy shell, a heat dissipation fin, a cooling water channel and a mounting interface, the input shaft assembly part is composed of an input shaft, a positioning shaft journal, an angular contact ball bearing and a torque limiter, the output shaft assembly part is composed of an output shaft, an output gear, a double-row cylindrical roller bearing, a thrust ball bearing and a double-lip oil seal, the gear transmission mechanism part is composed of a straight-tooth cylindrical gear and a planetary gear mechanism, the synchronous shifting mechanism part is composed of a lock ring type synchronizer, a shifting yoke and an electronic sensor, and the lubrication and heat dissipation system part is composed of a gear oil pump, a temperature control valve group, a radiator and an oil channel.

[0006] Further, as a preferred, the shell part is composed of a high-strength aluminum alloy shell, a heat dissipation fin, a cooling water channel and a mounting interface. The aluminum alloy shell is made of A356-T6 alloy vacuum die casting, the shell bottom is provided with a positioning through hole connected to the base through a bolt, the shell wall thickness is optimized to 4-6mm through finite element analysis, the outside is uniformly distributed with trapezoidal heat dissipation fins, the fin surface is sprayed with 0.1mm thick nano ceramic heat dissipation coating. The shell is integrated with a serpentine cooling water channel, the water channel is communicated with the external radiator through a quick connector, and a standardized mounting interface is provided on the shell bottom, so as to realize high strength, light weight and high efficiency of the shell.

[0007] Further, as a preferred, the input shaft assembly part is composed of an input shaft, a positioning shaft journal, an angular contact ball bearing and a torque limiter. The input shaft is made of 40CrNiMoA alloy steel forging, the shaft journal bottom is provided with a connecting through hole connected to the base through a bolt, one end of the input shaft is connected with the torque limiter through a involute spline, and the other end of the input shaft is connected with the shell through a pre-tightened 70000 type angular contact ball bearing, so as to realize high-precision rotation and overload protection of the input shaft.

[0008] Further, as a preferred, the output shaft assembly part is composed of an output shaft, an output gear, a double-row cylindrical roller bearing, a thrust ball bearing and a double-lip oil seal. The output shaft is made of 20CrMnTi carburizing and quenching, the output gear is connected with the output shaft through interference fit, the gear end face is provided with an axial positioning check ring, the output shaft is supported by a NUP200 series double-row cylindrical roller bearing and a 51000 series thrust ball bearing, the bearing lubrication adopts oil mist lubrication, and lithium-based lubricating grease is applied to the double-lip skeleton oil seal lip, so as to realize high-precision rotation and overload protection of the input shaft.

[0009] Further, as preferred, the gear transmission mechanism part is composed of straight-tooth cylindrical gear, planetary gear mechanism. The gear material is selected as 20CrMnTiH, the planetary gear mechanism is composed of sun gear, planet gear, planet carrier and ring gear, the sun gear is connected with the input shaft by spline, the ring gear is fixed with the housing, the planet carrier is connected with the output shaft, the planet gear bearing adopts needle bearing, so that the stable operation of the gear transmission mechanism part is realized.

[0010] Further, as preferred, the synchronous gear shifting mechanism part is composed of lock ring type synchronizer, gear shifting fork, electronic sensor. The cone surface of the lock ring type synchronizer adopts composite texture structure, the auxiliary texture is micro-pit array, the cone surface is laser cladded with 0.1mm thick ceramic coating, the gear shifting fork is connected with the engagement sleeve through fork groove, the electronic sensor adopts Hall type and is installed on the fork shaft, so that the gear shifting position and speed are monitored in real time.

[0011] Further, as preferred, the lubrication and heat dissipation system part is composed of gear oil pump, temperature control valve group, radiator, oil channel. The gear oil pump is variable vane pump, the oil pump motor is controlled by ECU, the displacement is adjusted according to oil temperature and rotating speed. The temperature control valve group contains main valve and bypass valve, the opening temperature of the main valve is 85℃, the full opening temperature is 95℃, the opening temperature of the bypass valve is 70℃, the radiator adopts plate-fin structure, the oil channel is divided into main oil channel and branch oil channel, paper filter is installed inside, so that the effective heat dissipation of the whole gearbox system is realized. BRIEF DESCRIPTION OF DRAWINGS

[0012] Figure 1 Assembly schematic diagram of gearbox

[0013] Figure 2 Assembly schematic diagram of input shaft assembly and output shaft assembly

[0014] Figure 3 Assembly schematic diagram of synchronous gear shifter

[0015] Figure 4 Principle diagram of lubrication and heat dissipation system part

[0016] In the figure: 1, the shell part, 1-1, aluminum alloy shell, 1-2, heat dissipation fin, 1-3, cooling water channel, 1-4, mounting interface; 2, input shaft assembly part, 2-1, input shaft, 2-2, locating journal, 2-3, angular contact ball bearing, 2-4, torque limiter; 3, output shaft assembly part, 3-1, output shaft, 3-2, output gear, 3-3, double-row cylindrical roller bearing, 3-4, thrust ball bearing, 3-5, double-lip oil seal; 4, gear transmission mechanism part, 4-1, helical cylindrical gear, 4-2, sun gear, 4-3, planet gear, 4-4, planet carrier, 4-5, ring gear; 5, synchronous shifting mechanism part, 5-1, coupling sleeve, 5-2, stamped outer ring needle bearing, 5-3, spring, 5-4, shift gear one, 5-5, shift gear one, 5-6, synchronizer ring one, 5-7, synchronizer ring two, 5-8, ring block, 5-9, positioning pin, 5-10, shift fork, 5-11, shift fork, 5-12, electronic sensor, 6, lubrication and heat dissipation system part, 6-1, gear oil pump, 6-2, temperature control valve group, 6-3, radiator, 6-4, oil channel. DETAILED DESCRIPTION

[0017] The present application provides a lock ring type synchronizer cone surface composite texture optimized multi-gear gearbox structure, in order to make the purpose, technical scheme and advantages of the present application more clear and clear, the present application will be described in detail below with the help of the accompanying drawings in specific examples. It should be understood that the described examples are only part of the embodiments of the present application, but not all the embodiments. Based on the embodiments of the present application, other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0018] The present application provides a technical scheme: the present application mainly consists of six parts, respectively, the shell part, the input shaft assembly part, the output shaft assembly part, the gear transmission mechanism part, the synchronous shifting mechanism part and the lubrication and heat dissipation system part. Because the present application is a composite structure, the installation sequence from inside to outside is adopted. First, place the aluminum alloy shell (1-1) on the assembly workbench, check whether there is a blowhole, crack and other defects on the surface of the shell. Use high pressure water gun to clean the inside of the shell, remove the casting residual sand particles, then blow dry with compressed air, then evenly spray nano ceramic heat dissipation coating on the surface of the heat dissipation fin (1-2) outside the shell, the spraying pressure is 0.4 MPa, the coating thickness is controlled at 0.1 mm, after spraying, put it into the oven to make the surface solidify. The inlet and outlet of the cooling water channel (1-3) are connected with the external radiator through the quick connector, the joint sealing adopts fluorine rubber O ring, and the O ring is ensured not to be twisted and deformed during installation, finally the positioning pin and bolt are installed at the mounting interface (1-4) at the bottom of the shell, to ensure that the mounting interface is tightly connected with the equipment base.

[0019] The input shaft assembly part is composed of input shaft (2-1), positioning journal (2-2), angular contact ball bearing (2-3), torque limiter (2-4), first, the positioning journal (2-2) of the input shaft (2-1) is detected in precision, the cylindricity error is measured by using roundness gauge, which should be ≤0.002mm, then the inner ring of the angular contact ball bearing (2-3) is heated to 120℃, and kept for 30 minutes, then it is sleeved in the bearing mounting part of the input shaft, after the bearing is cooled, the spring scale is used to measure the bearing pre-tightening force, the pre-tightening force is controlled in the range of 80-120N by adjusting the gasket thickness of the bearing end cover, then the torque limiter is installed in the spline end of the input shaft and fixed by bolts, finally the input shaft assembly is assembled into the bearing hole of the shell, and the bearing outer ring is ensured to be in interference fit with the shell hole.

[0020] The output shaft assembly part is composed of output shaft (3-1), output gear (3-2), double-row cylindrical roller bearing (3-3), thrust ball bearing (3-4), double-lip oil seal (3-5), first, the output gear (3-2) of the output shaft (3-1) is heated to 200℃, and kept for 1 hour, then it is quickly sleeved in the interference fit part of the output shaft, the radial roundness runout of the gear is monitored by using the dial gauge, which should be ≤0.03mm, then after the gear is cooled, the axial positioning retainer ring is installed, then the double-row cylindrical roller bearing (3-3) and the thrust ball bearing (3-4) are respectively pressed into the corresponding parts of the output shaft, the special pressing sleeve is used when the bearing is installed, to avoid directly knocking the bearing outer ring, the output shaft assembly is assembled into the shell, the bearing clearance is adjusted, and finally the double-lip oil seal (3-5) is installed, lithium-based lubricating grease is applied on the lip when the oil seal is installed, to ensure that the lip is tightly fitted with the surface of the output shaft.

[0021] The gear transmission mechanism part is composed of spur cylindrical gear (4-1) and planetary gear mechanism, first, the planetary gear mechanism is installed, the gear ring (4-5) is fixed on the shell by bolts, then the planetary gear (4-3) is installed on the planetary gear shaft of the planet carrier (4-4), the planetary gear shaft and the planet carrier are in transition fit, the planetary gear bearing adopts needle bearing, and appropriate amount of lubricating oil is injected when installing, then the sun gear (4-2) is connected with the spline of the input shaft, then the planet carrier is connected with the output shaft by bolts, then the spur cylindrical gear (4-1) is installed, and the gear and the shaft are in interference fit.

[0022] The synchronous gear shifting mechanism part is composed of a combination sleeve (5-1), a stamping outer ring needle bearing (5-1), a spring (5-3), a gear shift gear (5-4), a gear shift gear (5-5), a synchronous ring (5-6), a synchronous ring (5-7), a ring block (5-8), a positioning pin (5-9), a gear shift cage (5-10), a gear shift fork (5-11), and an electronic sensor (5-12). First, the combination sleeve (5-1), the stamping outer ring needle bearing (5-2), the spring (5-3), the gear shift gear (5-4), the gear shift gear (5-5), the synchronous ring (5-6), the synchronous ring (5-7), the ring block (5-8), the positioning pin (5-9), and the gear shift cage (5-10) are assembled into a lock ring type synchronizer. Then, the lock ring is installed in the tapered surface matching part of the combination sleeve (5-1). The matching gap between the lock ring and the combination sleeve is checked. The gap in the circumferential direction should be uniform. Then, the gear shift fork (5-11) is inserted into the fork groove of the combination sleeve. Then, the fork shaft is installed in the fork shaft hole of the housing. The fork shaft and the hole are matched in clearance fit. Then, the electronic sensor (5-12) is installed to ensure that the sensor can accurately sense the position change of the fork shaft. Finally, the sensor wire harness is connected. The wire harness connector needs to be waterproof to prevent oil and water from entering.

[0023] The lubrication and heat dissipation system part is composed of a gear oil pump (6-1), a temperature control valve group (6-2), a radiator (6-3), and an oil gallery (6-4). The gear oil pump (6-1) is fixed on the oil pump mounting seat of the housing by bolts. The oil pump inlet is connected to the oil pan of the housing by an oil suction pipe. A filter screen is installed at the end of the oil suction pipe. Then, the temperature control valve group (6-2) is installed. The main valve and the bypass valve are connected to the oil gallery through a flange. The flange gasket is made of oil-resistant rubber. Then, the radiator (6-3) is installed at the front end of the vehicle and connected to the cooling water channel of the housing through the cooling liquid pipeline. The pipeline joint is fixed by a clamp. Finally, the oil gallery (6-4) is installed.

[0024] During operation, first, the transmission is fixed and connected to the power source and the transmission device. Lubricating oil is injected to the upper limit of the oil scale. After starting, the gear oil pump maintains the oil gallery pressure at 0.2-0.4 MPa. The temperature control valve adjusts the cooling intensity according to the oil temperature, so that the oil temperature is stabilized at 80-95℃. During gear shifting, the gear shift fork pushes the combination sleeve to contact the lock ring to complete the meshing of the synchronous gear. The electronic sensor monitors the signal in real time and controls intelligently. The power is transmitted to the output shaft through the planetary gear train and the helical gear. The lubrication system circulates oil to each part. The heat dissipation system dissipates heat through heat exchange of the cooling liquid.

[0025] Although embodiments of the present application have been shown and described, it would be appreciated by those of ordinary skill in the art that changes, modifications, substitutions and variations can be made to the embodiments without departing from the principles and spirit of the application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A lock ring type synchronizer cone face compound texture optimized multi-gear transmission structure, characterized in that: The equipment is composed of a shell part, an input shaft assembly part, an output shaft assembly part, a gear transmission mechanism part, a synchronous gear shifting mechanism part and a lubrication and heat dissipation system part, the shell part is composed of a high-strength aluminum alloy shell, heat dissipation fins, cooling water channels and mounting interfaces, the input shaft assembly part is composed of an input shaft, a positioning shaft journal, an angular contact ball bearing and a torque limiter, the output shaft assembly part is composed of an output shaft, an output gear, double-row cylindrical roller bearings, thrust ball bearings and double-lip oil seals, the gear transmission mechanism part is composed of straight-tooth cylindrical gears and planetary gear mechanisms, the synchronous gear shifting mechanism part is composed of a lock ring type synchronizer, a gear shifting yoke and electronic sensors, and the lubrication and heat dissipation system part is composed of a gear oil pump, a temperature control valve group, a radiator and oil channels.

2. A lock ring type synchronizer cone composite texture optimized multi- speed gearbox structure according to claim 1, characterized in that, The shell part is composed of a high-strength aluminum alloy shell, heat dissipation fins, cooling water channels and mounting interfaces. The aluminum alloy shell is made of A356-T6 alloy through vacuum die casting, the bottom of the shell is provided with a positioning through hole connected to the base through bolts, the shell wall thickness is optimized to 4-6 mm through finite element analysis, the outside is uniformly distributed with trapezoidal heat dissipation fins, the fin surface is sprayed with 0.1 mm thick nano ceramic heat dissipation coating. The shell is internally integrated with a serpentine cooling water channel, the water channel is communicated with the external radiator through a quick connector, and the bottom of the shell is provided with standardized mounting interfaces, so that the shell has high strength, light weight and high heat dissipation efficiency.

3. A lock ring type synchronizer cone composite texture optimized multi- speed gearbox structure according to claim 1, characterized in that The input shaft assembly part is composed of an input shaft, a positioning shaft journal, an angular contact ball bearing and a torque limiter. The input shaft is made of 40CrNiMoA alloy steel through forging, the bottom of the shaft journal is provided with a connecting through hole connected to the base through bolts, one end of the input shaft is connected to the torque limiter through an involute spline, and the other end of the input shaft is connected to the shell through a pre-tightened 70000 type angular contact ball bearing, so that the input shaft has high-precision rotation and overload protection.

4. A lock ring type synchronizer cone composite texture optimized multi- speed gearbox structure according to claim 1, characterized in that: The output shaft assembly part is composed of an output shaft, an output gear, double-row cylindrical roller bearings, thrust ball bearings and double-lip oil seals. The output shaft is made of 20CrMnTi carburizing and quenching, the output gear is connected to the output shaft through interference fit, the gear end face is provided with an axial positioning retainer, the output shaft is supported by NUP200 series double-row cylindrical roller bearings and 51000 series thrust ball bearings, the bearing lubrication adopts oil mist lubrication, and lithium-based lubricating grease is applied to the double-lip oil seal lip, so that the input shaft has high-precision rotation and overload protection.

5. A lock ring type synchronizer cone composite texture optimized multi- speed gearbox structure according to claim 1, characterized in that: The gear transmission mechanism part is composed of straight-tooth cylindrical gears and planetary gear mechanisms. The gear material is selected from 20CrMnTiH, the planetary gear mechanism is composed of a sun gear, planet gears, a planet carrier and a ring gear, the sun gear is connected to the input shaft through a spline, the ring gear is fixed to the shell, the planet carrier is connected to the output shaft, and the planet gear bearing adopts needle bearings, so that the gear transmission mechanism part operates stably.

6. A lock ring type synchronizer cone composite texture optimized multi- speed gearbox structure according to claim 1, characterized by: The synchronous gear shifting mechanism part is composed of a lock ring type synchronizer, a gear shifting fork and an electronic sensor. The cone surface of the lock ring type synchronizer adopts a composite texture structure, the auxiliary texture is a micro-pit array, the cone surface is laser cladded with a 0.1mm thick ceramic coating, the gear shifting fork is connected with the engaging sleeve through a fork groove, and the electronic sensor adopts a Hall type and is installed on the fork shaft to monitor the gear shifting position and speed in real time.

7. A lock ring type synchronizer cone composite texture optimized multi- speed gearbox structure according to claim 1 characterized in that: The lubrication and heat dissipation system part is composed of a gear oil pump, a temperature control valve group, a radiator and an oil channel. The gear oil pump is a variable vane pump, the oil pump motor is controlled by an ECU, and the displacement is adjusted according to the oil temperature and rotating speed. The temperature control valve group comprises a main valve and a bypass valve, the opening temperature of the main valve is 85℃, the full opening temperature is 95℃, the opening temperature of the bypass valve is 70℃, the radiator adopts a plate-fin type structure, and the oil channel is divided into a main oil channel and a branch oil channel and internally provided with a paper filter element, so as to realize effective heat dissipation of the whole gearbox system.

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