Trapezoidal Synchronizer Ring Pressure Piece Gear Rattle
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Solution Overview
Problem
Synchronizer rings in motor vehicle manual transmissions often produce noise due to backlash, leading to gear rattle, increased drag torque, and potential damage from relative movements and friction issues.
Innovation Solution
The synchronizing ring is designed with a trapezoidal index tab and a pressure piece featuring a corresponding receiving recess with undercuts, ensuring a defined press against the synchronizing hub, which minimizes or eliminates noise and drag torque by creating a resultant force that attracts the rings to the hub.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a compensating lever is pivotably mounted to avoid gear rattle, then the gear rattle is reduced, but the device complexity increases
Solution Approach 1:
The patent extracts the harmful relative movements between the synchronizing ring and hub by introducing a dedicated pressure piece that applies axial force to press the synchronizing ring against the hub, separating the noise reduction function from the complex compensating lever mechanism
Solution Approach 2:
The pressure piece acts as an intermediary element between the synchronizing ring and hub, applying controlled axial force to eliminate backlash and prevent gear rattle without requiring the synchronizing ring itself to have complex compensating mechanisms
2Object-affected harmful factors
If the synchronizing ring is pressed against the synchronizing hub, then the gear rattle is reduced, but the drag torque increases
Solution Approach 1:
The pressure piece applies partial axial force only when needed to eliminate backlash and prevent gear rattle, rather than maintaining continuous excessive pressure that would increase drag torque during normal operation
Solution Approach 2:
The axial force applied by the pressure piece can vary depending on operational conditions, allowing optimization between preventing gear rattle and minimizing drag torque through dynamic adjustment of the pressing force
3Ease of manufacture
If the index tab engages with play in the receiving recess, then the manufacturing is easier, but the relative movements cause damage and noise
Solution Approach 1:
The pressure piece applies preliminary axial force to press the synchronizing ring against the hub before damaging relative movements can occur, preventing the harmful effects of play in the index tab engagement while maintaining easy manufacturing
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 effectively reduces or eliminates gear rattle and drag torque, preventing damage to the friction lining and index cams, while maintaining the locking position and reducing noise.
Implementation Method 1
a ball or ball pin-compression spring arrangement (18)
Implementation Method 2
a peripheral force occurs between the synchronizing ring and the pressure piece, with the interacting trapezoidal surfaces of the recess and the projection being inclined in such a way that an axial force results from this peripheral force
Data Source
Figure 1
Figure 2~4
AI summary
The synchronizing device (20) has a synchronous body (10) with an external toothing (11), in which a pressure piece (15,16,17) is arranged. The synchronizing device has a clutch sleeve (13) which is guided on the synchronous body and a synchronizer ring (1,1 ') with an index lobe (6,7,8). The pressure piece has a trapezoidal receiving recess facing the synchronizer ring, in which the corresponding trapezoidal index lobe engages.