Asymmetric Synchronizer Teeth Reduce Blocker Release Load
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Solution Overview
Problem
Existing synchronizers in transmissions face high blocker release loads, wear issues, and transmission drag losses due to traditional 45-degree angled teeth, which compromise robustness and shift quality.
Innovation Solution
The synchronizer features asymmetric, shallow angle sleeve and blocker teeth with distinct angular configurations (e.g., 40-degree and 50-degree angles) and advanced indexing teeth to reduce blocker release loads and enhance wear resistance, allowing for improved shift quality and reduced drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional 45-degree angled teeth are used on sleeve and blocker ring, then the teeth are robust to wear, but the blocker release load is relatively high
Solution Approach 1:
The patent applies asymmetry by configuring the sleeve teeth with different angles on opposite sides (first angle and second angle where first angle ≠ second angle). This asymmetric tooth geometry allows optimization of both wear resistance and blocker release load by distributing contact stresses more effectively during engagement and disengagement phases.
Solution Approach 2:
The patent changes the geometric parameters of the teeth by using shallow angles (e.g., 20-40 degrees) instead of the traditional 45 degrees. This parameter modification reduces the blocker release load while maintaining adequate wear resistance through the asymmetric configuration that optimizes contact patterns.
2Force
If the surface angles of teeth are reduced relative to longitudinal axis, then the blocker release load is reduced, but the teeth have narrow cross-sections that are not robust to wear
Solution Approach 1:
The asymmetric tooth design allows each side of the tooth to have optimized geometry: one side can have a shallower angle to reduce blocker release load while the other side maintains a steeper angle for wear resistance. This resolves the contradiction by allowing different functional requirements to be met on different surfaces of the same tooth.
Solution Approach 2:
Different regions of the tooth (different sides) are given different angular properties tailored to their specific functional requirements. The first side is optimized for reducing release load while the second side is optimized for wear resistance, allowing local optimization of properties throughout the tooth structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively reduces blocker release loads, enhances cold shift quality, and minimizes transmission drag losses, resulting in a more robust and efficient synchronizer for both upshifts and downshifts.
Implementation Method 1
Engagement of these two surfaces is a clutching action which causes the second component to be speed synchronized with the blocker ring and sleeve
Data Source
AI summary
A synchronizer for a transmission of a motor vehicle is provided. The synchronizer includes a sleeve and a blocker ring. The sleeve includes sleeve spline teeth and advanced sleeve spline teeth. The blocker ring includes blocker spline teeth. The sleeve spline teeth and blocker spline teeth are each asymmetrical and have a blunt tip, a first angled side, and a second angled side. The first and second angled sides have different angular relationships to a longitudinal axis of the teeth.