Friction Ring with Differential Conical Angles
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Solution Overview
Problem
Existing synchronizer rings in variable ratio gear transmissions face challenges in achieving a balance between efficiency and shifting comfort due to the conflict between conical angles, leading to self-locking effects that impair shifting performance and increase complexity, cost, and weight.
Innovation Solution
A friction ring with a conical inner surface and outer installation surface having different angles, along with a restraining device and security features, allows for precise axial positioning and secure installation, preventing self-locking and enhancing shifting comfort while maintaining high efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If small conical angles are used in the friction pairing, then efficiency is improved with high synchronization torques despite lower actuation forces, but self-locking effect occurs which impairs shifting comfort
Solution Approach 1:
The synchronizing device is divided into multiple independent friction pairings (first, second, third friction pairings) with different conical angles. Each friction pairing can engage independently, allowing the system to distribute the synchronization torque across multiple surfaces with optimized angles, avoiding self-locking while maintaining high efficiency.
Solution Approach 2:
Different friction pairings have different local conical angles optimized for their specific functions. The first friction pairing has a smaller conical angle for high torque generation, while the second and third friction pairings have larger conical angles to prevent self-locking and facilitate smooth engagement, creating local optimization throughout the system.
2Power
If multiple conical synchronizing devices with multiple friction surfaces are developed, then performance and torque capacities are increased, but complexity, costs and weight increase
Solution Approach 1:
Multiple friction pairings are merged into a single integrated synchronizing device structure. The first, second, and third friction pairings share common components such as the cone shell and friction rings, allowing multiple friction surfaces to be combined in a compact arrangement that increases torque capacity without proportionally increasing overall device complexity.
Solution Approach 2:
The cone shell and friction rings serve multiple functions simultaneously. The cone shell provides structural support while also forming conical surfaces for multiple friction pairings. The friction rings engage with multiple cone shells in sequence, allowing a single component to participate in multiple synchronization stages, reducing the total number of parts needed.
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 solution simplifies the installation and positioning of the friction ring, reduces self-locking issues, and achieves high shifting performance with reduced complexity and weight, thereby improving shifting comfort and efficiency.
Implementation Method 1
The synchronization is achieved in this respect by friction between the corresponding friction partners
Data Source
AI summary
The invention relates to a friction ring (1) for a synchronizing unit (2) of a variable ratio gear transmission. The friction ring (1) comprises a conical friction body having an inner friction surface and an outer installation surface which each bound the friction ring body in a radial peripheral direction extending perpendicular to an axial friction ring axis (4). The friction ring body comprises a projection (9) for restraining a movement of the friction ring (1) relative to a synchronizer ring (7) substantially along the friction axis in operation in the synchronizing unit (2).