Index Torque Measurement for Synchronizer Engagement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current transmission systems face inefficiencies in measuring index torque for synchronizers, which affects smooth gear transitions and fuel economy, as existing methods do not effectively compare index torque to drag torque.
Innovation Solution
An index torque measurement system comprising a blocker ring, a source of index torque, and a measurement system that calculates and measures the force required to overcome the index torque, allowing for the design optimization of synchronizer engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If index torque measurement is implemented for synchronizer design optimization, then smooth gear transition and transmission efficiency are improved, but measurement complexity and device requirements increase
Solution Approach 1:
A measurement sleeve is introduced as an intermediary component between the synchronizer sleeve and the measurement system. This mediator translates the complex torque measurement task into measurable linear displacement, simplifying the overall measurement system while maintaining measurement accuracy for index torque characterization.
Solution Approach 2:
The patent replaces direct mechanical torque measurement with a mechanical-to-linear displacement conversion system. By using the measurement sleeve and block mechanism to convert rotational torque effects into linear motion that can be measured by displacement sensors, the system avoids complex direct torque measurement apparatus.
2Ease of operation
If varying index torque is applied to allow smooth indexing, then blocker ring teeth engagement with synchronizer sleeve teeth is improved, but control system complexity increases
Solution Approach 1:
The system employs dynamic index torque application where the torque varies during the indexing process. The measurement system captures this varying torque profile, allowing the synchronizer design to optimize for smooth engagement by understanding how torque changes throughout the indexing sequence, rather than requiring complex real-time control.
Solution Approach 2:
The measurement system performs preliminary characterization of index torque under varying conditions before actual operation. This advance understanding of torque requirements allows for optimized synchronizer design that achieves smooth indexing without requiring complex active control systems during operation.
3Manufacturing precision
If force measurement to overcome index torque is implemented, then synchronizer engagement performance is verified, but measurement precision requirements increase
Solution Approach 1:
The measurement sleeve is nested within the synchronizer sleeve, and the block is nested within the measurement sleeve. This nested arrangement allows the measurement system to be integrated into the existing synchronizer structure, using the synchronizer's own components as part of the measurement apparatus, thereby reducing the need for external high-precision measurement equipment.
Solution Approach 2:
The system measures linear displacement of the measurement sleeve rather than directly measuring force. By converting the force measurement problem into a displacement measurement problem, the system can use more practical and less demanding measurement technologies while still verifying synchronizer engagement performance.
Data Source
AI summary
An index torque measurement system is provided. The system includes a blocker ring and a source, of index torque. The source of index torque applies a varying amount of index torque to the blocker ring to allow smooth indexing of the blocker ring teeth with synchronizer sleeve teeth. The system includes a synchronizer sleeve drivable to overcome the index torque to engage the blocker ring. The system further includes a measurement system that measures the force to overcome the index torque based on a load required to drive the synchronizer sleeve into engagement with the blocker ring given the applied index torque.