Single-Piece Synchronizer Ring With Elastic Cutouts for Stable Shifting
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Solution Overview
Problem
Conventional synchronizer rings with three ring segments face issues of unstable performance, increased manufacturing costs, and operational instability due to complex manufacturing processes and large number of parts, which degrade gear change sensation and capacity.
Innovation Solution
A high-capacity synchronizer ring with a single structure formed by cutting and bending an iron plate, featuring protrusion and cutout portions that impart elasticity, allowing for a stable gear change sensation and simplified manufacturing process using a thin iron plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a triple synchronizer ring with three ring segments is used to increase capacity, then the friction surface area is increased, but the device complexity and manufacturing cost increase
Solution Approach 1:
The synchronizer ring is divided into three elastic segments that can independently deform and contact the synchronizer cone. Each segment has protrusion portions that engage with the cone surface, providing distributed friction contact areas while maintaining a single integrated ring structure that reduces manufacturing complexity
Solution Approach 2:
The synchronizer ring transitions from a rigid 2D structure to a 3D elastic structure with segments that can deform radially. This dimensional change allows the ring to create multiple friction contact points through elastic deformation, effectively increasing the friction surface area without adding multiple separate rings
2Quantity of substance
If a small taper angle is used to increase capacity, then the friction capability is improved, but the gear change sensation is degraded due to being caught
Solution Approach 1:
The synchronizer ring segments are designed with elastic properties that allow dynamic deformation during engagement. The segments can radially expand to increase friction contact with the synchronizer cone during the engagement process, then return to their original shape to facilitate smooth disengagement, creating a responsive gear change sensation
Solution Approach 2:
The elastic segments change their radial position and contact pressure dynamically during operation. When engaged, the segments deform to increase the normal force and friction capability on the synchronizer cone. This parameter change allows the system to achieve high friction capability with small taper angles while maintaining good gear change sensation through controlled elastic deformation
3Quantity of substance
If multiple ring segments are used to increase friction surface, then the capacity is increased, but the operational stability is reduced
Solution Approach 1:
Three elastic segments are integrated into a single synchronizer ring structure rather than using three separate rings. This merged structure ensures synchronized deformation and contact of all segments, eliminating relative motion between segments and improving operational stability while maintaining increased friction surface area
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 solution provides a stable gear change sensation, reduces manufacturing costs, and increases capacity by utilizing a single structure with uniform inner and outer angles, enhancing operational reliability and material efficiency.
Implementation Method 1
elasticity is imparted to the synchronizer ring by forming cutout portions in the synchronizer ring and the ring is separated and restored by the elasticity
Data Source
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AI summary
Disclosed herein are a high-capacity synchronizer ring (100) for a manual transmission and a method for manufacturing the same. The high-capacity synchronizer ring for a manual transmission includes a ring formed by working an iron plate having a uniform thickness. The ring has a single structure in which a plurality of protrusion portions (120) is formed on the inner side thereof and a plurality of cutout portions (110) located at the centers of the respective protrusion portions is formed in the outer side thereof. The ring is bent to be tapered inward.