Strut-Holding Clip for 1-Way and 2-Way Synchronizer Conversion
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Solution Overview
Problem
Existing synchronizer configurations require permanent modifications and additional machining to convert between 2-way and 1-way synchronizer types, necessitating separate struts and geometry changes in the hub, which complicates conversion and increases costs.
Innovation Solution
A strut-holding clip with a polymeric design featuring an end wall, angled legs, and barbed prongs that straddle the gear selection strut, preventing axial movement and allowing the same synchronizer to be configured as either 2-way or 1-way without altering the strut or hub geometry, using existing strut slots and allowing for synchronized and non-synchronized gear pairs in the same transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If permanent modifications are made to the strut to convert between 2-way and 1-way synchronizer configurations, then the synchronizer can be reconfigured, but additional machining and redesign steps are required
Solution Approach 1:
The patent introduces a strut holder as an intermediary component that attaches to the existing strut to convert synchronizer configuration. This mediator allows conversion between 2-way and 1-way synchronizer modes without permanently modifying the strut itself, thereby reducing conversion complexity while maintaining adaptability
Solution Approach 2:
The conversion mechanism is segmented into a separate removable strut holder component rather than being integrated into the strut itself. This segmentation allows the conversion function to be independently managed and replaced without affecting the main strut or requiring permanent modifications
2Adaptability or versatility
If the strut is redesigned for different synchronizer configurations, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent creates a universal strut holder design that can convert a single strut design to work with both 2-way and 1-way synchronizer configurations. This multi-functional approach eliminates the need to manufacture different strut variants, thereby simplifying manufacturing while maintaining broad adaptability
Solution Approach 2:
The strut holder is designed as a simpler, potentially disposable conversion component rather than a permanent modification to the expensive strut. This allows easy conversion between configurations without the high cost and complexity of redesigning and remanufacturing the strut itself
3Adaptability or versatility
If machining is performed on the synchronizer for conversion, then configuration change is achieved, but production time and cost increase
Solution Approach 1:
The strut holder is pre-configured with the necessary structural features to enable conversion without requiring machining operations on the synchronizer during assembly. This preliminary preparation of the conversion component eliminates time-consuming machining steps and accelerates the conversion process
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
Enables the conversion of a stock synchronizer between 2-way and 1-way configurations without machining or replacing the strut, reducing complexity and weight, while maintaining synchronization functionality, and allowing for mixed synchronization in a single transmission.
Implementation Method 1
A first prong is configured to flex within the first leg. The first prong terminates in a first barb. A second prong is configured to flex within the second leg. The second prong terminates in a second barb. A first foot is angled with respect to the first leg and is configured to elastically oppose the first barb. A second foot is angled with respect to the second leg and is configured to elastically oppose the second barb.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A strut-holding clip (100) comprises an end wall (101) configured to block a gear selection strut (9) from travelling. A first leg (104) and a second leg (105) extend from the end wall (101). The first leg (104) and the second leg (105) are configured to straddle the gear selection strut. A first prong (110) is configured to flex within the first leg. The first prong (110) terminates in a first barb. A second prong (111) is configured to flex within the second leg (105). The second prong terminates in a second barb (113). A first foot (106) is angled with respect to the first leg (104) and is configured to elastically oppose the first barb. A second foot (107) is angled with respect to the second leg (105) and is configured to elastically oppose the second barb (113). A synchronizer (20) which comprise the strutholding clip. A transmission is coupled with the synchronizer.