Integrated Synchronizer Layout for Compact Transmission Shifting
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Solution Overview
Problem
Existing synchronizer configurations in transmission systems are not compact enough, leading to increased length and volume, which can be improved by enhancing the engagement and disengagement mechanism between shafts and speed gears.
Innovation Solution
A complex synchronizer design featuring first and second connection gears, external gears with sleeves, and an intermediate gear that allows axial sliding to connect or disconnect the sleeves, along with synchro-rings for synchronization, reducing the number of required components and enhancing power transmission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional synchronizer configurations are used, then the transmission system can achieve basic shifting functionality, but the length and volume of the transmission system increase
Solution Approach 1:
The patent combines multiple synchronizer functions into a single integrated configuration where the first and second synchronizers share common components including the intermediate gear, connection gears, and sleeves. This merging of functions allows the transmission system to achieve compact dimensions while maintaining the capability to synchronize multiple gear pairs simultaneously or sequentially.
Solution Approach 2:
The intermediate gear serves multiple functions: it acts as a connection element between the first and second synchronizers, provides synchronization surfaces for both synchronizers, and enables power transmission pathways for multiple shifting stages. This multi-functionality reduces the overall number of components needed, thereby reducing transmission volume without sacrificing functionality.
2Length of moving object
If the number of synchronizer components is reduced to decrease volume, then the transmission system becomes more compact, but the engagement and disengagement mechanism becomes more complex
Solution Approach 1:
The patent employs a nested arrangement where the first and second sleeves are positioned concentrically or adjacently on the same shaft, with the intermediate gear nested between the connection gears. This nesting allows multiple engagement mechanisms to occupy overlapping spatial volumes, reducing the overall length of the transmission system while containing the complexity within a compact footprint.
Solution Approach 2:
The intermediate gear acts as a mediator between the first and second synchronizer systems, providing synchronization surfaces that interface with both sleeves and connection gears. This intermediary component simplifies the engagement mechanism by providing a unified synchronization interface that manages the complexity of coordinating multiple gear engagements through a single mechanical element.
Data Source
AI summary
A complex synchronizer may include a first connection gear and a second connection gear that are fixed to a shaft; a first external gear having a first sleeve, which can engage with the first connection gear by sliding along the shaft, and rotatably mounted on the shaft; a second external gear having a second sleeve, which can engage with the second connection gear by sliding along the shaft, and rotatably mounted on the shaft; and an intermediate gear being able to connect or disconnect the first sleeve and the second sleeve, depending on axial sliding states of the first sleeve and the second sleeve.