Synchronizer Dog Ring Recess Layout for Uniform Torque Transfer
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Solution Overview
Problem
Existing transmission devices face challenges in achieving uniform torque transfer during gear shifting due to non-uniform load distribution and shape deviations in dog rings with fewer recesses, leading to inefficiencies in torque transfer and increased weight and stress in welding seams.
Innovation Solution
A transmission device with a first rotating member featuring a combination of first and second recesses, where the total number exceeds the number of protrusions on the synchronizing ring, arranged symmetrically and uniformly to enhance torque transfer uniformity, reducing weight and improving load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a dog ring has fewer recesses (e.g., three recesses), then the device complexity is reduced and manufacturing is easier, but the torque transfer uniformity deteriorates and load distribution becomes non-uniform
Solution Approach 1:
The dog ring is segmented into multiple recesses (at least three, preferably four or more) distributed around its circumference. Each recess receives a protrusion from the synchronizing ring, creating multiple discrete torque transfer points that collectively provide uniform torque distribution while maintaining structural simplicity
Solution Approach 2:
The recesses are strategically positioned at specific circumferential locations around the dog ring to optimize load distribution. By placing recesses at evenly spaced intervals (e.g., 120 degrees apart for three recesses, or 90 degrees for four recesses), the local torque transfer quality is improved at each contact point, resulting in overall uniform torque transfer
2Weight of moving object
If a dog ring has fewer recesses, then the weight is reduced and manufacturing is simpler, but the welding seam load distribution deteriorates
Solution Approach 1:
The welding seam between the dog ring and gear wheel is segmented into multiple sections corresponding to the recess locations. By distributing recesses and their associated welding seams around the circumference, the total welding length is reduced compared to a solid ring design, lowering weight while improving load distribution across multiple smaller welding zones
Solution Approach 2:
The welding seams are positioned at specific locations corresponding to the recesses, creating localized high-strength zones where torque is transferred. This concentrates welding effort at critical load points rather than requiring continuous welding around the entire circumference, improving both weight efficiency and load distribution
3Manufacturing precision
If a dog ring has fewer recesses, then manufacturing precision requirements are reduced, but the torque transfer efficiency deteriorates due to shape deviations
Solution Approach 1:
The torque transfer function is segmented into multiple discrete recess-protrusion interfaces rather than relying on a single continuous contact surface. This segmentation means that minor manufacturing deviations at one interface do not compromise the entire torque transfer system, as other interfaces can compensate, thereby maintaining high torque transfer efficiency with relaxed precision requirements
Solution Approach 2:
Each recess is designed with specific local geometric features (such as tapered walls or rounded corners) that facilitate reliable engagement with protrusions. These localized quality enhancements at each recess ensure consistent torque transfer at each contact point, maintaining overall efficiency even with moderate manufacturing tolerances
Data Source
AI summary
A transmission device includes a first rotating member and a ring for synchronizing the first rotating member and a second rotating member relative to each other. The first rotating member is provided with a plurality of first recesses for receiving a plurality of protrusions provided on the synchronizing ring. The first rotating member has one said first recess for each of said protrusions. The first rotating member is provided with one or more second recesses making the total number of first and second recesses exceeding the number of said protrusions.