Synchronizer Assembly Jig for Key and Spring Positioning
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Solution Overview
Problem
The existing methods for assembling synchronizers face challenges due to the limited space between the recesses of the synchronizer hub and sleeve, making it difficult to insert the spring and synchronizer key, which increases assembly time and reduces productivity.
Innovation Solution
A jig is used to locate and position the synchronizer key and spring on the synchronizer hub before engaging the synchronizer sleeve, featuring inner and outer portions that restrict the synchronizer key's radial position and facilitate easy insertion, thereby preventing interference and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the synchronizer hub and synchronizer sleeve are engaged first, then the structural assembly is complete, but the space between recesses becomes too small to insert spring and synchronizer key
Solution Approach 1:
The spring and synchronizer key are inserted into the recesses before the synchronizer sleeve is engaged to the synchronizer hub. This preliminary action is performed when the recesses are more accessible, avoiding the space constraints that would exist after sleeve engagement. The method then completes the assembly by engaging the sleeve, achieving both ease of insertion and proper structural assembly.
2Productivity
If the spring and synchronizer key are inserted after engagement, then the structural assembly is complete, but the assembling time increases
Solution Approach 1:
The spring and synchronizer key are inserted into the recesses before the synchronizer sleeve is engaged to the synchronizer hub. This preliminary action is performed when the recesses are more accessible, avoiding the space constraints that would exist after sleeve engagement. The method then completes the assembly by engaging the sleeve, achieving both ease of insertion and proper structural assembly.
Data Source
AI summary
A method for assembling a synchronizer by using a jig, the synchronizer including a synchronizer hub, at least one of recesses formed radially at an external circumference of the synchronizer hub, a synchronizer key disposed in the recess, a synchronizer sleeve enclosing the exterior circumference of the synchronizer hub and axially movably engaged to the synchronizer hub, and a spring disposed between the synchronizer hub and the synchronizer key, may include locating the synchronizer key and the spring in the recess of the synchronizer hub, engaging the jig to the synchronizer hub by inserting a rear portion of the jig in the recess axially, engaging the synchronizer sleeve to the synchronizer hub, and removing the jig from the synchronizer hub.