Gearbox Synchronizer Ring Spring Layout for Vibration Damping
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Solution Overview
Problem
Existing synchronization units for manual transmissions face challenges in minimizing vibrations and noise at high speeds, which lead to undesirable noise development and component damage, while also requiring a compact structure and low cost.
Innovation Solution
The synchronization unit incorporates ring springs coupled with the synchronous ring and pressure piece to center the synchronous rings, preventing unwanted movements and vibrations, and uses U-shaped pressure pieces with radial grooves and coupling elements to ensure reliable coupling and centering, thereby reducing vibrations and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the structure of synchronization units is simplified to reduce cost, then manufacturing cost decreases, but vibrations and noise increase at high speeds
Solution Approach 1:
The pressure piece is divided into multiple independent pressure elements arranged around the synchronous ring. Each pressure element can independently apply force to center the synchronous ring, providing effective vibration damping without requiring a complex overall structure. This segmentation allows cost-effective manufacturing while maintaining performance.
Solution Approach 2:
The invention changes the structural parameters of the pressure piece by introducing multiple pressure elements with specific geometric configurations (radii, spacing, engagement depth). These parameter optimizations enable effective centering and vibration reduction using simple, inexpensive components.
2Ease of manufacture
If the structure of synchronization units is simplified to reduce cost, then manufacturing cost decreases, but reliability deteriorates due to component damage from vibrations
Solution Approach 1:
By segmenting the pressure piece into multiple pressure elements, the system achieves effective centering and vibration damping that protects components from damage. This segmented approach provides reliable protection against vibration-induced failures while keeping each individual pressure element simple and inexpensive to manufacture.
3Device complexity
If the structure of synchronization units is simplified, then device complexity decreases, but space requirement increases due to larger components needed for vibration control
Solution Approach 1:
The pressure elements serve multiple functions simultaneously: they center the synchronous ring, dampen vibrations, and maintain proper spacing. This multi-functionality allows compact design without requiring additional specialized components for vibration control, thus reducing overall space requirements while maintaining simplicity.
Solution Approach 2:
The pressure elements are positioned within the existing structural space of the synchronization unit, utilizing the available radial and axial dimensions efficiently. The pressure elements nest within the space between the pressure piece body and the synchronous ring, achieving vibration control without increasing overall component dimensions.
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 effectively prevents vibrations and noise, maintains a compact structure, and is constructed inexpensively, ensuring reliable operation and low drag moments.
Implementation Method 1
ring springs coupled with the synchronous ring and pressure piece to center the synchronous rings
Implementation Method 2
friction cone section with a radial inside frictional area on, which can work together with a friction section of the first coupling body in the sense of speed synchronization
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A synchronization unit (10) for a manual transmission is described, comprising a first synchronization ring (18), a second synchronization ring (22), at least one pressure piece (40), and two ring springs (52, 54). The first synchronization ring (18) and the second synchronization ring (22) each have a friction cone section (28, 32) and a locking tooth section (36, 38). One of the ring springs (52, 54) is arranged on a radial outer side of the friction cone section (28) of the first synchronization ring (18), and the other ring spring (52, 54) is arranged on a radial outer side of the friction cone section (32) of the second synchronization ring (22). Furthermore, the two ring springs (52, 54) are coupled axially by means of the pressure piece (40).