Welded Transmitter Disk for Manual Transmission Synchronizer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing synchronizing assemblies for manual transmissions, such as the BorgWarner synchronization, are costly to produce and require complex components, which increases manufacturing expenses.
Innovation Solution
A transmitter design featuring a transmitter disk with at least one clutch disk fixed by local welding points, allowing for direct torque transmission and reduced material stress, along with spacers and pressure pieces for precise guidance and robust compression springs, enabling efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex components and traditional manufacturing methods are used for synchronizing assemblies, then reliability and performance are maintained, but manufacturing costs increase
Solution Approach 1:
The transmitter is divided into separate components (transmitter disk and clutch disks) that are manufactured independently and then joined through welding. This segmentation allows each component to be optimized and manufactured separately, reducing overall manufacturing complexity and cost while maintaining reliability.
Solution Approach 2:
The transmitter disk and clutch disks are merged into a single functional unit through local welding points, creating a unified torque transmission system. This merging reduces the need for additional complex fastening mechanisms and simplifies the overall assembly structure, lowering manufacturing costs.
2Strength
If traditional fastening methods are used to connect clutch disk and transmitter disk, then connection strength is ensured, but manufacturing complexity and cost increase
Solution Approach 1:
The fastening function is extracted from complex mechanical fastening mechanisms and replaced with a simplified welding process. This extraction eliminates the need for additional fastening components while maintaining connection strength, thereby reducing device complexity.
Solution Approach 2:
Traditional mechanical fastening systems are replaced with a welding process that directly fuses the clutch disk and transmitter disk. This substitution eliminates complex mechanical fastening components and reduces assembly complexity while ensuring strong connections.
3Power
If welding points are subjected to high torque loads, then torque transmission is effective, but welding point reliability decreases
Solution Approach 1:
The welding points are designed with localized reinforcement and optimized positioning to concentrate strength where needed. The clutch disks are configured to distribute torque loads away from the welding points, creating local quality variations that protect the welds from excessive stress while maintaining effective torque transmission.
4Manufacturing precision
If material properties are optimized for welding, then welding quality improves, but post-welding strength may be compromised
Solution Approach 1:
The material properties are carefully selected and adjusted to optimize welding characteristics. The clutch disk and transmitter disk materials are chosen to have properties that facilitate high-quality welding while maintaining adequate post-weld strength. Parameters such as carbon content, alloy composition, and heat treatment are optimized to balance weldability and final strength.
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 enables low-cost production of transmitters with optimized shifting behavior and precise guidance, reducing manufacturing costs while maintaining robustness and efficiency in torque transmission.
Implementation Method 1
a comparatively robust compression spring to be arranged in the transmitter disk
Implementation Method 2
The clutch disk and the transmitter disk are fixedly connected together by local welding points
Data Source
AI summary
A transmitter for a synchronizing assembly of a manual transmission has a transmitter disk and at least one clutch disk which is arranged on a side surface of the transmitter disk. The clutch disk and the transmitter disk are fixedly connected together by local welding points. A method for producing a transmitter for a synchronizing assembly of a manual transmission consists of providing a clutch disk and a transmitter disk. Then, the clutch disk and the transmitter disk are fastened together by means of projection welding. Finally, the thus formed assembly is hardened.