Transmission Synchronizer Phasing with Round Cavities and Pins
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Solution Overview
Problem
The manufacturing process of synchronizers for mechanical transmissions is complicated due to the rectangular cross-section of phasing system components, which requires dedicated machining and reduces the mechanical strength and compact size of the hub.
Innovation Solution
The phasing system is redesigned with arc- or round-shaped cavities and connecting pins, allowing for simpler manufacturing and increased mechanical strength by eliminating the need for complex machining and reducing the size of blocking elements, enabling a larger hub diameter and improved resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rectangular cross-section teeth and cavities are used in the phasing system, then proper angular positioning is achieved, but manufacturing complexity increases and mechanical strength decreases
Solution Approach 1:
The patent replaces rectangular cross-section teeth and cavities with arc-shaped or round-shaped cross-section teeth and cavities. This curvature allows the components to engage properly for angular positioning while being manufacturable through simpler processes such as drilling and molding, thereby reducing manufacturing complexity while maintaining positioning precision.
2Manufacturing precision
If rectangular cross-section teeth and cavities are used in the phasing system, then proper angular positioning is achieved, but mechanical strength of the hub is reduced
Solution Approach 1:
The arc-shaped or round-shaped cross-section of the teeth and cavities eliminates stress concentration points that are inherent in rectangular designs. The curved geometry distributes mechanical stresses more evenly throughout the hub structure, thereby enhancing the overall mechanical strength while still achieving the required angular positioning functionality.
3Reliability
If blocking elements with radial engaging members are used, then pre-synchronization function is achieved, but radial size increases reducing hub strength and shaft diameter options
Solution Approach 1:
The patent changes the orientation of the engaging members from radial to tangential direction. This dimensional change allows the blocking elements to perform the pre-synchronization function while having a reduced radial profile, thereby increasing the effective hub diameter and providing more options for shaft diameter selection without compromising the pre-synchronization reliability.
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 new phasing system simplifies manufacturing, enhances mechanical strength, and allows for larger shaft diameters while reducing the weight and cost of synchronizers through the use of plastic materials and tangentially oriented engaging members.
Implementation Method 1
a coil spring accommodated in the hollow body and extending with its axis in a radial direction
Implementation Method 2
a friction surface (in particular a conical surface) arranged to be brought into engagement with a corresponding friction surface associated to the respective gear wheel to allow the generation of a friction torque
Data Source
AI summary
A synchronizer for mechanical transmissions having a phasing system configured so as to include a plurality of first cavities on an internal cylindrical surface of a rim of a hub, the hub torsionally connected with a transmission shaft, forming the external teeth of the hub and, for each of the first cavities, either a tooth which radially protrudes from an external cylindrical surface of a synchronizing ring of the synchronizer and is arranged to engage in the first cavity, or a connecting pin arranged to engage on one side the first cavity and on the other a respective second cavity on the external cylindrical surface, wherein the first cavities have an arc- or round-shaped cross-section.