Synchronizer Catch Wings for Anti-Tilting Locking
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Solution Overview
Problem
Existing locks in manual transmissions are prone to tilting and jamming under angled forces, requiring additional installation space and material, which increases the complexity and cost of synchronization units.
Innovation Solution
A lock design with inwardly oriented wings that are flush with the radial surface, reducing the overall height and allowing for one-piece production, which enhances stability and reduces the risk of tilting, while minimizing material removal from the synchronizer body and allowing for a more compact synchronization device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the locking element is designed as a pressure piece that can tilt under angled forces, then the lock can engage with locking recesses, but the locking element may tilt and cause jamming or snagging between the synchronizer body and the switching sleeve
Solution Approach 1:
The patent introduces a new dimensional constraint by adding wings that extend radially outward from the pressure piece. These wings engage with guide surfaces on the synchronizer body teeth, creating a lateral guidance dimension that prevents the pressure piece from tilting in the radial direction while maintaining its ability to engage locking recesses axially.
Solution Approach 2:
The wings act as intermediary elements between the pressure piece and the synchronizer body. They provide a mediating guidance function by contacting the guide surfaces on the teeth, thereby preventing direct tilting contact between the pressure piece and the synchronizer body, which eliminates jamming.
2Reliability
If wings are made long to provide good guidance for the pressure piece, then tilting is prevented, but the installation space required increases
Solution Approach 1:
The patent applies partial action by providing guidance only where needed - the wings extend radially outward to engage with the guide surfaces on the synchronizer body teeth, providing sufficient lateral guidance without excessive length. The wings are dimensioned to provide just enough guidance to prevent tilting while minimizing space consumption.
Solution Approach 2:
The guidance function is localized to specific areas where it is most needed. The wings contact the guide surfaces on the synchronizer body teeth at critical locations, providing localized guidance that prevents tilting without requiring long wings throughout the entire circumference.
3Device complexity
If stop lugs are replaced by tongues that take on the locking function, then the locking function is integrated, but the synchronizer body is additionally weakened or requires increased axial width
Solution Approach 1:
Instead of modifying the synchronizer body structure (which would weaken it), the patent creates a copy of the locking function in the form of wings on the pressure piece itself. These wings replicate the guidance and locking functions that would otherwise require modifications to the synchronizer body, thereby preserving the body's structural integrity.
4Ease of operation
If roller-bearing locks are used to reduce squeaking, then operator feel is improved, but the locking device becomes more complex and expensive
Solution Approach 1:
The patent replaces expensive roller-bearing locks with a simpler, cheaper pressure piece design that uses elastic deformation of the spring element to provide smooth engagement. Instead of using durable but complex roller bearings, the invention uses a simpler elastic spring mechanism that achieves the same squeak-reduction effect at lower cost and complexity.
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 design ensures robust locking without tilting, even at high speeds, reduces manufacturing complexity, and allows for a more compact and lightweight synchronization unit with increased load capacity and torque transmission.
Implementation Method 1
a locking element loaded with a spring element for locking in a position
Data Source
Figure 1a
Figure 1b
Figure 2~3
AI summary
The invention relates to a catch (6) of a synchronization device (27) that can be axially displaced in the installed state with regard to a synchronous body (1) comprising teeth at the outer circumference thereof, wherein the catch (6) comprises a catch element (8) acted on by an engagement element (15) for engaging in a rest position and a housing (14) having an approximately rectangular radial surface (16) having axial edges (17, 18) aligned outward and side edges (19, 20) oriented in the circumferential direction, wherein the catch element (8) is disposed in the interior of the radial surface (16), the wings (21, 22) being formed flush with the radial surface (16) as seen in the radial direction, and the axial width of the wings (21, 22) being smaller than the minimal axial width of the radial surface (16), and a method for producing the same.