Synchronizer Ring Step Portion Centering Collar Thickness
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Solution Overview
Problem
Existing synchronizer rings face challenges in achieving sufficient centering collar thickness without weakening the sheet-metal cone, as material removal from the first sheet portion for forming the centering collar compromises the cone's stability.
Innovation Solution
Incorporating a step portion with a reduced first sheet portion thickness and using the removed material to enhance the collar thickness of the second sheet portion, allowing for a higher centering collar without additional material, and using tools to form the step and centering collar efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the collar thickness is increased to ensure effective centering, then the centering performance is improved, but the sheet-metal cone becomes excessively weakened
Solution Approach 1:
The sheet-metal cone is designed with non-uniform thickness: the first sheet portion has reduced thickness to provide material for the centering collar, while the second sheet portion maintains sufficient thickness for structural integrity. This local differentiation allows the centering collar to achieve adequate thickness without excessively weakening the overall cone structure.
Solution Approach 2:
The first sheet portion is intentionally thinned beyond what would be minimally required, creating a material reservoir that can be redistributed to form the centering collar with sufficient thickness. This partial over-thinning ensures adequate material availability for collar formation while maintaining overall structural balance.
2Strength
If additional material is applied to increase collar thickness, then the centering collar can be made higher, but the manufacturing complexity increases
Solution Approach 1:
The sheet-metal cone itself serves as the material source for forming the centering collar. By strategically thinning the first sheet portion during cone formation, the material required for the collar is already present in the workpiece, eliminating the need for additional material application steps or complex multi-stage manufacturing processes.
Solution Approach 2:
The first sheet portion is thinned in advance during the cone formation process, preparing the material distribution before collar formation begins. This preliminary material redistribution ensures that when the collar is subsequently formed, the necessary material is already positioned and ready, simplifying the overall manufacturing sequence.
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
This design enables a synchronizer ring with a stable and high centering collar, ensuring effective radial centering without excessive weakening of the sheet-metal cone, while maintaining efficient manufacturing from a flat sheet.
Implementation Method 1
the centering collar only is formed by the forming step, namely in that in the sheet-metal cone the first sheet portion is integrally molded by a tool, whereby the centering collar is obtained in the second sheet portion by material forming
Data Source
AI summary
A synchronizer ring for a synchronization unit has a substantially constant sheet-metal cone which tapers in direction of its ring axis from a first axial cone end towards a second axial cone end. At the sheet-metal cone a centering collar is integrally molded and the sheet-metal cone includes a first sheet portion and axially adjacent a second sheet portion. In addition, the sheet-metal cone includes a step portion which axially extends between the second axial cone end and the first sheet portion, wherein a radial outer side of the step portion is offset with respect to a radial outer side of the first sheet portion towards the ring axis. Furthermore, there is shown a method for manufacturing a synchronizer ring.