Software and hardware matching method for synchronization system

Abstract

This invention discloses a hardware and software matching method for a synchronization system, comprising the following steps: 1) learning the position of the shift fork synchronization point, the synchronizer slider force, and the synchronization capacity of the synchronization system during self-learning; 2) calculating the required speed difference to be synchronized based on the collected input and output shaft speeds when shifting gears is required; 3) calculating the required shifting force based on the speed difference, the required synchronization time, and the synchronization capacity of the self-learned synchronization system; 4) when the calculated required shifting force is less than the slider force of the target gear synchronizer, only the target gear synchronizer is activated; when the calculated required shifting force is greater than or equal to the slider force of the target gear synchronizer, multiple synchronizers are activated together to eliminate the speed difference. This invention has the advantages of simple structure, more compact layout, and the ability to eliminate speed differences.

Description

Technical Field

[0001] This invention relates to the field of automotive transmission technology, and more specifically to a hardware and software matching method for a synchronization system. Background Technology

[0002] The synchronization system used in current passenger car automatic transmissions is structurally identical to that of manual transmissions, namely one of the common locking ring inertial synchronization devices. Its structure includes synchronizer sleeves, synchronizer hubs, gear ring assemblies, and gear rings. The main features are: relying on the friction between the gear ring and the gear ring to quickly synchronize the circumferential speed of the synchronizer sleeve and the gear ring assemblies. At the same time, the gear ring and synchronizer sleeve are designed with locking angles to ensure synchronization is completed, while the locking angle structure of the gear ring ensures that the synchronizer sleeve can smoothly engage with the gear ring assemblies. Finally, the torque is transmitted through the design of the reverse cone angles of the synchronizer sleeve and the gear ring.

[0003] This type of locking ring inertial synchronization device was developed and optimized based on manual transmissions, and the design considerations do not fully meet the usage requirements of automatic transmissions. This is mainly manifested in varying degrees of noise during low-speed gear shifts. Furthermore, due to the interaction between the synchronizer sleeve splines, the gear ring splines, and the external splines of the gear ring, the existing synchronization device has a relatively high probability of failure during the gear ring shifting stage.

[0004] Moreover, due to factors such as manufacturing process, space constraints, and cost control, this classic lock-ring type inertial synchronization device generally suffers from the following problems:

[0005] 1. Noise is easily generated when the synchronizer sleeve contacts the external spline of the gear ring.

[0006] 2. Noise is easily generated when the synchronizer sleeve separates from the external spline of the gear ring.

[0007] 3. Noise is easily generated when the synchronizer sleeve contacts the gear ring.

[0008] 4. During the synchronization process, gear shifting often becomes stuck or jammed.

[0009] 5. The grooves for the synchronizer to mate with the gear ring require precise machining, which increases costs.

[0010] 6. The boss that mates with the gear ring and synchronizer requires precise control, which increases costs.

[0011] 7. The locking face angle of the synchronizer sleeve needs to be precisely machined, which increases costs.

[0012] 8. The length of the inverted conical surface of the synchronizer sleeve needs to be precisely machined, which increases the cost.

[0013] 9. The external spline of the gear ring, the approach clearance, etc. occupy the axial space of the synchronization system, making the structure not compact enough.

[0014] 10. Excessive free travel after the gear sleeve passes through the gear ring and before contacting the gear causes secondary impact, tooth breakage, and other phenomena.

[0015] Based on the principles of design optimization and cost control, and with consumers' increasing demands for overall vehicle driving comfort and safety, it is urgent to design a hardware and software matching scheme for a synchronization system that meets the usage conditions and shifting action characteristics of automatic transmissions. Summary of the Invention

[0016] This invention provides a hardware and software matching method for a synchronization system that is simple in structure, has a more compact layout, and can eliminate speed differences.

[0017] To achieve the above objectives, the present invention adopts the following technical solution:

[0018] A hardware / software matching method for a synchronization system, the synchronization system including a shift fork assembly, a synchronizer assembly, a gear ring assembly, and a gear assembly, wherein the shift fork assembly is connected to the synchronizer assembly, the synchronizer assembly mates with the gear ring assembly, the gear ring assembly does not have external splines, and the gear ring assembly mates with the gear assembly by setting a gear ring conical surface, the hardware / software matching method includes the following steps:

[0019] 1) During self-learning, learn the position of the shift fork synchronization point, the synchronizer slider force, and the synchronization capacity of the synchronization system;

[0020] 2) When gear shifting is required, calculate the speed difference that needs to be synchronized based on the collected input shaft and output shaft speeds;

[0021] 3) Calculate the shifting force to be applied based on the speed difference, the required synchronization time, and the synchronization capacity of the self-learning synchronization system;

[0022] 4) When the calculated shift force is less than the slider force of the target gear synchronizer, only the synchronizer of the target gear is activated; when the calculated shift force is greater than or equal to the slider force of the target gear synchronizer, multiple synchronizers are activated together to eliminate the speed difference.

[0023] 5) When the input shaft and output shaft speeds are not synchronized, control the shifting force of a single synchronizer to be less than the slider force, so that the shift fork is kept at the synchronization point, and ensure that the synchronizing sleeve always applies axial force to the slider, so that the gear ring assembly generates friction torque.

[0024] 6) Once the input shaft and output shaft speeds are synchronized, increase the shifting force for the target gear and move the shift fork away from the synchronized position;

[0025] 7) The synchronizer sleeve overcomes the slider force and passes through the gear ring to engage with the gear;

[0026] 8) The synchronization point position, synchronizer slider force, and synchronization capacity during the output process are used to correct the basic hardware characteristics of the synchronization system.

[0027] In this invention, no external spline structure is provided on the gear ring assembly. This is because the function of the external spline on the gear ring is to cooperate with the conical surface of the gear ring to ensure that the synchronizer sleeve does not pass through the gear ring during synchronization, thus playing a locking role, and to apply a synchronizing force to eliminate the speed difference during synchronization, thus playing a synchronizing role. However, in this invention, a matching software solution is used to replace the locking function of the external spline on the gear ring, and the sliders of the target gear synchronizer and other gear synchronizers are used to replace the synchronizing function of the external spline on the gear ring.

[0028] After the external spline structure of the gear ring assembly is eliminated, the pre-synchronization and synchronization of the synchronization system are both achieved by the synchronizer's slider. Therefore, the approach clearance that must exist due to the external spline of the gear ring can be eliminated, making the axial space of the synchronization system more compact. At the same time, due to the elimination of the external spline of the gear ring, the axial space it occupies is freed up, which can be used for the arrangement of the synchronizer assembly, making the axial space arrangement of the synchronization system more compact.

[0029] After the external spline structure is eliminated in the gear ring assembly, since the pre-synchronization and synchronization of the synchronization system are both achieved by the synchronizer's slider, the synchronizer sleeve and the gear ring assembly are not directly connected. Therefore, the secondary idle stroke before the sleeve contacts the gear after passing through the gear ring is no longer limited by the gap between the gear ring's external spline and the gear. The synchronizer sleeve can be designed to be closer to the gear, and the secondary idle stroke in the prior art can be shortened or even eliminated through structural design.

[0030] The present invention compares the prior art as follows:

[0031] 1. Existing toothed rings have external splines, which can easily generate noise when the synchronizer sleeve contacts the external splines of the toothed ring; however, the toothed ring assembly of the present invention does not have external splines, thereby eliminating this noise.

[0032] 2. Existing toothed rings have external splines, which can easily generate noise when the synchronizer sleeve separates from the external splines of the toothed ring; however, the toothed ring assembly of the present invention does not have external splines, thereby eliminating this noise.

[0033] 3. Existing synchronizer gear sleeves are prone to noise when they come into contact with the gear ring because there is an impact between the gear sleeve and the external spline of the gear ring when they come into contact; however, the gear ring assembly of the present invention does not have external splines, thereby eliminating this noise.

[0034] 4. In the synchronization process of existing technologies, the phenomenon of shifting jamming and jamming often occurs because the synchronizer sleeve squeezes the external spline of the gear ring; however, the gear ring assembly of the present invention does not need to be provided with external splines, and only applies axial force through the slider, thereby avoiding this problem.

[0035] 5. In existing technologies, the grooves for the synchronizer and gear ring to mate require precise machining because the synchronization spline and the gear ring's external spline must fit within a certain circumferential range, increasing costs. However, the gear ring assembly of this invention does not have external splines, allowing the grooves on the synchronizer assembly that mate with the gear ring assembly to use either standard tolerances or unspecified tolerances; this saves costs and reduces quality risks.

[0036] 6. In existing technologies, the bosses that mate with the synchronizer on the gear ring require precise control because the synchronization spline and the gear ring's external spline must fit within a certain circumferential range, increasing costs. However, the gear ring assembly of this invention does not have external splines, allowing the bosses on the gear ring assembly that mate with the synchronizer assembly to use either standard tolerances or unspecified tolerances; this saves costs and reduces quality risks.

[0037] 7. In existing technologies, the locking surface angle of the synchronizer sleeve requires precise machining because the locking surface of the synchronizer sleeve needs to precisely mate with the external spline locking surface of the gear ring to achieve synchronization and locking functions, thus increasing costs. However, the gear ring assembly of this invention does not require external splines, allowing the locking surface angle of the synchronizer sleeve to use either general tolerances or unspecified tolerances; this saves costs and reduces quality risks.

[0038] 8. In existing synchronizer sleeves, the length of the inverted conical surface needs to be precisely machined because the external spline of the gear ring needs to be aligned through the synchronizer assembly, increasing costs. The gear ring assembly of this invention does not require an external spline, thus saving costs and reducing quality risks.

[0039] 9. Existing toothed rings with external splines and proximity clearances occupy axial space in the synchronization system, resulting in a less compact structure. In contrast, the toothed ring of this invention does not require external splines, thus saving axial arrangement space.

[0040] 10. In existing technologies, the toothed sleeve has excessive free travel after passing through the toothed ring and before contacting the gear, causing secondary impacts and tooth breakage. However, the toothed ring assembly of the present invention does not have external splines, thus avoiding the limitations imposed by the external splines of the toothed ring; the synchronizer toothed sleeve can be designed to be closer to the gear, and the secondary free travel in the prior art can be shortened or even eliminated through structural design.

[0041] Furthermore, the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system in step 1) need to be learned multiple times during the transmission's self-learning process after it is taken off the production line, and then corrected by the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system fed back in step 8).

[0042] Furthermore, the synchronizer slider force is obtained by combining the synchronizer individual slider force data with the slope of the shift fork position change during transmission self-learning for closed-loop learning; the synchronization point position is identified by the characteristic that the shift fork position remains stationary during synchronization, combined with the change in the speed curve; the synchronization capacity is calculated based on theoretical calculations, individual test results of the gear ring assembly, and the synchronization force, synchronization time, and speed difference during transmission self-learning.

[0043] Furthermore, the feature is that the shift fork assembly has a position magnet that works in conjunction with a Hall sensor, and the position signal of the shift fork is transmitted to the TCU through signal processing, thereby obtaining simulated shift fork position information.

[0044] Furthermore, the synchronization point position, synchronizer slider force, and synchronization capacity correction of the synchronization system, supplemented by the feedback in step 8), can be provided for each gear shift action when the vehicle is in use; or it can be provided only after a gear shift action is performed under specific working conditions.

[0045] Furthermore, the specific operating conditions include downshifting, upshifting, and shifting at a frequency of 10 times / min, with the number of shifts reaching 1,000, 10,000, 20,000, and 100,000 times. The specific number depends on the characteristics of the friction materials and lubricating oil used in the synchronization system. These characteristics can be determined through individual tests of the synchronization system and used as a reference for software strategies.

[0046] Furthermore, the action of multiple synchronizers working together to eliminate speed differences refers to the following situation:

[0047] If the required shift time is 400ms or the speed difference to be eliminated is 2600rpm, and the synchronization capacity of the target gear synchronizer alone cannot meet the software requirements, multiple gear synchronizers need to be activated to eliminate the speed difference together.

[0048] Furthermore, before the speed difference is eliminated, the shift fork is controlled by software to make the shifting force less than the slider force of the shift synchronizer, so that the synchronization system involved in the synchronization remains stationary in the synchronized position. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the synchronization system structure of the present invention.

[0050] Figure 2 This is a cross-sectional view of the synchronization system of the present invention.

[0051] Figure 3 This is a cross-sectional view of a synchronization system based on existing technology.

[0052] Figure 4This is a schematic diagram of the structure of the shift fork assembly described in this invention.

[0053] Figure 5 This is a schematic diagram of the synchronizer assembly described in this invention.

[0054] Figure 6 This is an enlarged schematic diagram of a synchronizer component in the prior art.

[0055] Figure 7 This is a schematic diagram of the toothed ring assembly described in this invention.

[0056] Figure 8 This is a schematic diagram of the gear assembly described in this invention.

[0057] Figure 9 This is the main control flowchart of the synchronization system of the present invention. Detailed Implementation

[0058] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0059] like Figures 1 to 9 As shown, the hardware and software matching method of the synchronization system includes a shift fork assembly 1, a synchronizer assembly 2, a gear ring assembly 3, and a gear assembly 4. The shift fork assembly 1 is connected to the synchronizer assembly 2. Preferably, the shift fork assembly 1 and the synchronizer assembly 2 are connected together through a clearance fit between the shift fork foot 12 and the gear sleeve shift fork groove 21. The shift fork assembly 1 is equipped with a position magnet 11, which cooperates with a Hall sensor on the transmission housing. The position signal of the shift fork is transmitted to the TCU through signal processing to form a simulated position, so as to control the state of the synchronization system as accurately as possible.

[0060] Synchronizer assembly 2 cooperates with gear ring assembly 3. Gear ring assembly 3 does not have external splines. Gear ring assembly 3 has a gear ring cone surface 33 that cooperates with gear assembly 4. Gear assembly 4 has a gear cone surface 42 that cooperates with gear ring cone surface 33. In this invention, no external spline structure is provided at the outer circle 32 of gear ring assembly 3. During the synchronization of gear shifting, shift fork assembly 1 is controlled by the control system to move in the gear-shifting direction, which drives synchronizer slider 22 of synchronizer assembly 2 to move in the same direction. This causes synchronizer slider 22 to contact the protrusion 31 of gear ring assembly 3, pushing gear ring cone surface 33 and gear cone surface 42 to engage and generate frictional torque to eliminate speed difference. During this process, the control system executes corresponding software strategies by recognizing shift fork position, speed difference, etc., so that when speed difference is not eliminated during synchronization, synchronizer sleeve will not pass through gear ring, thus playing a locking role. At the same time, the software calculates and identifies whether multiple gears need to participate in the synchronization process simultaneously.

[0061] like Figure 2 , Figure 3In the prior art, the outer circle of the gear ring assembly 3 has a gear ring external spline 32′ with a thickness of △3; while the synchronizer assembly 2 needs to maintain a certain gap △2 with the gear ring assembly 3; the gear ring assembly 3 and the gear assembly 4 need to maintain a certain gap, which results in the tooth tip 23 of the synchronizer assembly 2 having a free stroke △4 after passing through the gear ring; in the prior art, the gap △2, the thickness △3, and the free stroke △4 together constitute the gap △1′ between the tooth tip 23 of the tooth ring and the tooth tip 41 of the gear ring on the gear assembly 4. The gear ring assembly 3 of the present invention does not have an external spline 32′, but only a smooth outer circle 32. Therefore, the synchronizer assembly 2 does not need to maintain a certain gap △2 with the gear ring assembly 3; and there is no spline thickness △3. Although a certain gap △4 still needs to be maintained between the gear ring assembly 3 and the gear assembly 4, it is no longer related to the gap △1 between the tooth tips 23 of the tooth sleeve and the tooth tips 41 of the gear ring on the gear assembly 4. That is, △1 is no longer affected by the gear ring assembly 3 in the structural design and can be designed to be as close to zero as possible; thus, the synchronization system can be arranged more compactly in the axial direction.

[0062] See Figures 1-9 The hardware and software matching method includes the following steps:

[0063] 1) During offline self-learning, the synchronizer slider force, shift fork synchronization point position, and synchronization capacity of the synchronization system are learned. During individual synchronizer testing, the synchronizer slider force is tested, and the collected data is used as basic characteristic input for software parameter reference. Then, combined with the slope of the shift fork position change during synchronization, closed-loop learning is performed to finally determine the synchronizer slider force in the transmission assembly state. During shift fork synchronization point self-learning, the input shaft speed changes drastically during synchronization. Simultaneously, when the shift fork driving force is less than the synchronizer slider force, the shift fork remains stationary due to the support force of the gear ring. At this time, the shift fork synchronization point position can be identified through the position signal given by position magnet 11.

[0064] The synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system in step 1) need to be learned multiple times during the automatic learning of the transmission after it is taken off the production line, and then corrected by the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system fed back in step 8).

[0065] Preferably, the synchronizer slider force is obtained by combining the synchronizer individual slider force data with the slope of the shift fork position change during transmission self-learning for closed-loop learning; the synchronization point position is identified by the characteristic that the shift fork position remains stationary during synchronization, combined with the change in the speed curve; the synchronization capacity is calculated based on theoretical calculations, the test results of the gear ring assembly 3 individual units, and the synchronization force, synchronization time, and speed difference during transmission self-learning.

[0066] During the individual test of the gear ring assembly, the synchronization capacity of each gear was tested, and the data was collected and combined with theoretical calculations as the basic characteristic input to the software parameters for reference. Then, the synchronization capacity of the synchronization system under the state of the transmission assembly was calculated by combining the synchronization time, speed difference and shift fork driving force during the transmission self-learning.

[0067] Preferably, the shift fork assembly 1 has a position magnet 11 that works in conjunction with a Hall sensor to transmit the position signal of the shift fork to the TCU through signal processing, thereby obtaining simulated shift fork position information.

[0068] 2) When the TCU detects that a gear shift is required, it calculates the speed difference that needs to be synchronized based on the collected input shaft and output shaft speeds and the transmission ratio between the target gear and the current gear.

[0069] 3) Calculate the shifting force to be applied based on the speed difference, the required synchronization time, and the synchronization capacity of the self-learning synchronization system.

[0070] 4) When the calculated shift force is less than the slider force of the target gear synchronizer, only the shift fork of the target gear needs to be activated to drive the slider of the target gear synchronizer to apply a synchronizing force to the gear ring, thereby achieving synchronization. When the calculated shift force is greater than or equal to the slider force of the target gear synchronizer, if only the target gear synchronizer is activated, synchronization timeout will occur. In this case, multiple synchronizers need to be activated together to eliminate the speed difference and meet the synchronization time requirements.

[0071] Preferably, the action of multiple synchronizers working together to eliminate speed difference refers to the following situation:

[0072] If the required shift time is 400ms or the speed difference to be eliminated is 2600rpm, and the synchronization capacity of the target gear synchronizer alone cannot meet the software requirements, multiple gear synchronizers need to be activated to eliminate the speed difference together.

[0073] Preferably, before the speed difference is eliminated, the shift fork is controlled by software to make the shifting force less than the slider force of the shift synchronizer, so that the synchronization system involved in the synchronization remains stationary in the synchronized position.

[0074] 5) When the input and output shaft speeds are not synchronized, i.e., before the speed difference is eliminated, the shifting force on a single synchronizer is controlled to be less than the slider force, keeping the shift fork at the synchronization point, and thus keeping the synchronizer at the synchronization point position. This ensures that the synchronizing sleeve continuously applies an axial force to the slider, causing the gear ring assembly to generate a frictional torque. In other words, it ensures that the tip 23 of the synchronizing sleeve continuously applies an axial force to the synchronizer slider 22, keeping the gear ring cone surface 33 engaged with the gear cone surface 42 to generate a frictional torque.

[0075] 6) When the input shaft and output shaft speeds are synchronized, increase the shifting force of the target gear, the shift fork assembly 1 leaves the synchronized position, and the other gear shift forks involved in the synchronization return to the neutral position.

[0076] 7) The synchronizer sleeve overcomes the slider force and passes through the gap △1 between the tooth tip 23 of the sleeve and the tooth tip 41 of the gear ring on the gear assembly 4, and engages with the gear assembly 4.

[0077] 8) The synchronization point position, synchronizer slider force, and synchronization capacity during the output process are used to correct the basic hardware characteristics of the synchronization system. This action is not required to be performed every time. Its main purpose is to take into account the capacity decay of the synchronization system under extreme conditions or after multiple operations in a short period of time, as well as fatigue decay after long-term use, which requires correction of the basic hardware characteristics of the synchronization system. The timing of its execution can be during the use of the whole vehicle, with feedback of the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system for each gear shift; or it can be feedback of the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system only after a gear shift is performed under specific operating conditions. Furthermore, the specific operating conditions include power downshifting, power upshifting, and gear shifting at a frequency of 10 times / min, with the number of gear shifts reaching 1,000, 10,000, 20,000, and 100,000 times. The specific number depends on the friction materials and lubricating oil characteristics used in the synchronization system. This characteristic can be determined in individual tests of the synchronization system and used as a reference for software strategies.

[0078] The hardware and software matching scheme of this synchronization system avoids the noise problem that is easy to be generated when the synchronizer sleeve tooth tip 23 contacts the outer spline 32′ of the gear ring due to the smooth outer circle 32 structure of the gear ring assembly 3; it also avoids the noise problem that is easy to be generated when the synchronizer sleeve tooth tip 23 separates from the outer spline 32′ of the gear ring; it also avoids the impact noise that may exist when the sleeve tooth tip 23 contacts the gear ring tooth tip 41 and the outer spline 32′ of the gear ring and the synchronizer assembly 2; since the synchronizer assembly 2 only needs to overcome the slider force to move during the entire synchronization process, it also avoids the shifting jamming and jamming problem caused by the synchronizer sleeve tooth tip 23 squeezing the outer spline 32′ of the gear ring.

[0079] In the prior art, the engagement between the synchronizer sleeve tooth tip 23 and the outer spline 32′ of the gear ring must be within a certain axial range, requiring positional accuracy of the protrusion 31 and the outer spline 32′ of the outer gear ring, precise thickness requirements for the protrusion 31, and positional accuracy and precise thickness requirements for the synchronizer groove 24 that engages with the protrusion 31. However, the gear ring assembly 3 of the present invention has a smooth outer circle 32, which allows the thickness of the groove 24 and the protrusion 31 to use either general tolerances or undefined tolerances, while eliminating the corresponding positional accuracy requirements. This can save costs and reduce quality risks.

[0080] In existing synchronizer gear sleeves, the locking surface angle of the tooth tip 23 requires precise machining because the locking surface of the tooth tip 23 needs to precisely mate with the locking surface of the outer spline 32′ of the gear ring to achieve synchronization and locking functions, thus increasing costs. However, the gear ring assembly 3 of this invention has a smooth outer circle 32, allowing the locking surface angle of the tooth tip 23 to use either general tolerances or unspecified tolerances, saving costs and reducing quality risks.

[0081] In existing synchronizer sleeves, the length of the conical surface 25 requires precise machining, and a conical clearance angle 26 is provided because the synchronizer assembly 2 is used to align the outer spline 32′ of the gear ring, increasing costs. However, the gear ring assembly 3 of this invention has a smooth outer circle structure, eliminating the need for alignment by the synchronizer assembly 2. Therefore, the length of the conical surface 25 of the synchronizer sleeve does not require precise machining, and the conical clearance angle 26 can be omitted or not precisely machined, thereby saving costs and reducing quality risks.

[0082] In the prior art, the gap △1′ between the tooth tip 23 of the gear sleeve and the tooth tip 41 of the gear ring on the gear assembly 4

[0083] The synchronization system is composed of the gap △2 between the synchronizer assembly 2 and the gear ring assembly 3, the thickness △3 of the outer spline 32′ of the gear ring, and the gap △4 between the gear ring assembly 3 and the gear assembly 4. In this invention, the gap △1 between the tooth tip 23 of the gear sleeve and the tooth tip 41 of the gear ring on the gear assembly 4 is independent of △2, △3, and △4; it is only necessary to ensure that △1 is greater than 0 when the synchronizer is at the synchronized position. Therefore, the synchronization system of this invention can be arranged in a more compact axial space. Compared to the 39mm axial arrangement space required by the prior art, this invention can be arranged in a 33mm axial space. Furthermore, because △1 can be designed to be as small as possible, the secondary impact and tooth breakage phenomena caused by excessive free travel of the gear sleeve after passing through the gear ring and before contacting the gear in the prior art can be eliminated.

[0084] Finally, it should be noted that the above-described embodiments are merely preferred embodiments of the present invention used to illustrate the technical solutions of the present invention, and are not intended to limit them, much less limit the scope of protection of the present invention; although the invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to depart from the scope of protection of the claims.

Claims

1. A hardware and software matching method for a synchronization system, the synchronization system comprising a shift fork assembly (1), a synchronizer assembly (2), a gear ring assembly (3), and a gear assembly (4), wherein the shift fork assembly (1) is connected to the synchronizer assembly (2), and the synchronizer assembly (2) cooperates with the gear ring assembly (3), characterized in that, The gear ring assembly (3) does not have an external spline. The gear ring assembly (3) is fitted with the gear assembly (4) by setting a gear ring cone surface (33). The hardware and software matching method includes the following steps: 1) During self-learning, learn the position of the shift fork synchronization point, the synchronizer slider force, and the synchronization capacity of the synchronization system; 2) When gear shifting is required, calculate the speed difference that needs to be synchronized based on the collected input shaft and output shaft speeds; 3) Calculate the shifting force to be applied based on the speed difference, the required synchronization time, and the synchronization capacity of the self-learning synchronization system; 4) When the calculated shift force is less than the slider force of the target gear synchronizer, only the synchronizer of the target gear is activated; when the calculated shift force is greater than or equal to the slider force of the target gear synchronizer, multiple synchronizers are activated together to eliminate the speed difference. 5) When the input shaft and output shaft speeds are not synchronized, control the shifting force of a single synchronizer to be less than the slider force, so that the shift fork is kept at the synchronization point, and ensure that the synchronizing sleeve always applies axial force to the slider, so that the gear ring assembly generates friction torque. 6) Once the input shaft and output shaft speeds are synchronized, increase the shifting force for the target gear and move the shift fork away from the synchronized position; 7) The synchronizer sleeve overcomes the slider force and passes through the gear ring to engage with the gear; 8) The synchronization point position, synchronizer slider force, and synchronization capacity during the output process are used to correct the basic hardware characteristics of the synchronization system.

2. The hardware and software matching method for a synchronization system according to claim 1, characterized in that: The synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system in step 1) need to be learned multiple times during the transmission's off-line self-learning process, and then supplemented by the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system feedback in step 8).

3. The hardware and software matching method for a synchronization system according to claim 2, characterized in that: The synchronizer slider force is obtained by combining the individual synchronizer slider force data with the slope of the shift fork position change during the transmission self-learning process for closed-loop learning. The synchronization point position is identified by the characteristic that the shift fork position remains stationary during synchronization, combined with the change in the speed curve; the synchronization capacity is calculated based on theoretical calculations, the test results of the gear ring assembly (3) unit, and the synchronization force, synchronization time, and speed difference during the transmission self-learning process.

4. The hardware and software matching method for a synchronization system according to claim 3, characterized in that... The shift fork assembly (1) has a position magnet (11) that works with a Hall sensor to transmit the position signal of the shift fork to the TCU through signal processing, thereby obtaining simulated shift fork position information.

5. The hardware and software matching method for a synchronization system according to claim 2, characterized in that: The aforementioned feedback of synchronization point position, synchronizer slider force, and synchronization capacity correction of the synchronization system in step 8) means that during vehicle use, the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system are fed back for each gear shift.

6. The hardware and software matching method for the synchronization system according to claim 2, characterized in that: The synchronization point position, synchronizer slider force, and synchronization capacity correction of the synchronization system, supplemented by step 8), means that the synchronization point position, synchronizer slider force, and synchronization capacity of the synchronization system are only fed back after the shifting action is performed under specific working conditions. Specific working conditions include power downshifting, power upshifting, and when the shifting action is performed at a frequency of 10 times / min, the number of shifting actions reaches 1,000, 10,000, 20,000, and 100,000 times.

7. The hardware and software matching method for a synchronization system according to claim 1, characterized in that: Before the speed difference is eliminated, the shift fork is controlled by software to make the shifting force less than the slider force of the shift synchronizer, so that the synchronization system involved in the synchronization remains stationary in the synchronized position.

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