Synchronizer Rings Connected by Form-Fit Straps
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Solution Overview
Problem
Existing manual transmission synchronization assemblies face challenges in efficiently coupling synchronizing rings due to the risk of material property changes from heat introduction during welding and the difficulty in producing high-quality weld seams within the shift sleeve.
Innovation Solution
The synchronizing rings are connected via a form-fit design using connecting straps with a positive locking mechanism, eliminating the need for deep-seated welding, allowing for easy assembly and using identical parts to reduce costs and logistical complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the two synchronizing rings, then a reliable connection is achieved, but heat is introduced into the synchronizer rings causing material property changes and production becomes complex
Solution Approach 1:
The patent replaces the welding process (thermal/chemical connection) with a mechanical interlocking system consisting of protrusions on one synchronizing ring that engage with corresponding recesses in the other ring. This mechanical connection achieves reliable coupling without introducing heat that would alter material properties, and simplifies production by eliminating complex welding operations inside the shift sleeve.
2Reliability
If welding is used to connect the synchronizing rings, then a secure connection is achieved, but a great deal of effort is required to produce high-quality weld seams inside the shift sleeve
Solution Approach 1:
The connection system is segmented into discrete mechanical elements: protrusions on one synchronizing ring and corresponding recesses in the other ring. These segmented features can be independently manufactured and assembled, eliminating the need for complex welding operations inside the confined space of the shift sleeve while ensuring reliable connection through precise mechanical interlocking.
3Ease of manufacture
If identical parts are used for both synchronizing rings, then manufacturing costs are reduced, but a reliable connection mechanism between the rings must be designed
Solution Approach 1:
While both synchronizing rings are identical in overall design and material, they feature asymmetric connection elements: one ring has protrusions while the other has corresponding recesses. This asymmetric detail enables reliable mechanical interlocking between identical rings, allowing mass production of standardized components while ensuring secure connection through the complementary protrusion-recess geometry.
Data Source
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AI summary
The invention relates to an assembly for a synchronisation device of a gear box, comprising a first and a second synchroniser ring (30) which are interconnected. Said invention is characterised in that both synchroniser rings are connected together by means of a form-locking connection (40, 42).