Dual Clutch Synchronization Unit Axial Length Reduction
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Solution Overview
Problem
Existing synchronization units for positive dual clutches in gearwheel mechanisms have a significant axial overall length, which can hinder their application in space-constrained environments such as vehicles.
Innovation Solution
The synchronization unit features axially indented synchronizer rings and a sleeve carrier with complementary axial cutouts and projections, allowing the synchronizer rings to nest inside the sleeve carrier, reducing the axial overall length. Additionally, the synchronizer rings have external toothing sections only over a reduced circumferential length, simplifying production, and the selector sleeve has a complementary internal toothing system to prevent positive connection in neutral positions, reducing tilting moments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional synchronization units are used with complete circumferential toothing, then reliable torque transmission is achieved, but the axial overall length increases and production complexity increases
Solution Approach 1:
The synchronizer ring is nested axially inside the sleeve carrier through axial indentations and complementary cutouts/projections. This nesting arrangement allows the synchronizer ring to be positioned within the axial space of the sleeve carrier, significantly reducing the axial overall length of the synchronization unit while maintaining functional integrity for torque transmission
2Ease of manufacture
If complete circumferential toothing is provided on synchronizer rings, then reliable engagement is achieved, but manufacturing complexity and material usage increase
Solution Approach 1:
Instead of providing toothing over the entire circumference of the synchronizer ring, the invention applies toothing only to specific axial sections where engagement is required. This localized toothing approach reduces manufacturing complexity and material usage while maintaining sufficient engagement reliability for the synchronization function
3Ease of operation
If the selector sleeve has continuous internal toothing, then positive connection is ensured, but tilting moments increase in neutral positions
Solution Approach 1:
The internal toothing of the selector sleeve is segmented into discrete sections rather than being continuous. This segmentation allows the selector sleeve to engage positively with the synchronizer ring when needed, while providing gaps in neutral positions that reduce tilting moments and facilitate smoother operation
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
This design achieves a reduced axial overall length, simplifies production, and enhances mobility and guide length between components, thereby improving the synchronization unit's efficiency and adaptability in gearwheel mechanisms of vehicles.
Implementation Method 1
a multiple disk assembly, which is pressed together by corresponding axial pressure loading of the respective synchronizer ring and can thus transmit a torque, frictionally, to the clutch gear
Implementation Method 2
The pressure piece has a compression spring which acts on the ball segment in a corresponding circumferential groove of the selector sleeve
Data Source
AI summary
A synchronization unit for a positive dual clutch. The synchronization unit has a sleeve carrier that is axially and rotationally fixed to an output shaft and a shifting sleeve that is rotationally fixed and axially displaceable relative to the sleeve carrier. The synchronization rings of a synchronization clutch on the sleeve carrier side and the sleeve carrier comprise axially interlocked circumferential segments.