Zero-Drag Baulk Ring Synchronizer With Interlocking Cone Rings
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Solution Overview
Problem
High output transmissions, particularly for truck applications, face challenges due to complex actuation and service requirements of concentric clutches, unwanted friction losses from pre-energizer spring systems, and multiple interfaces that increase design complexity and introduce failure points.
Innovation Solution
A synchronizer assembly with a central ring and pair of cone rings featuring interlocking clips and spring-supported rollers to minimize friction and simplify shifting, allowing for efficient torque transfer and reduced wear by ensuring proper alignment and engagement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-energizer spring systems are used to create torque for shifting into engaged positions, then shifting capability is achieved, but unwanted friction losses occur during operation
Solution Approach 1:
The patent removes the pre-energizer spring system entirely from the synchronizer assembly. The springs that were previously used to create torque for shifting are extracted and replaced with a different mechanism that does not maintain continuous contact or pressure, thereby eliminating the source of unwanted friction losses while preserving shifting capability through the dog clutch engagement mechanism.
2Power
If concentric clutches are used for high output transmissions, then torque handling capability is improved, but actuation and service complexity increases
Solution Approach 1:
The patent divides the clutch mechanism into separate concentric components - a dog clutch assembly and a synchronizer ring assembly - that operate independently. This segmentation allows each component to be simpler in design while collectively handling high torque, reducing the actuation complexity compared to integrated concentric clutches while maintaining the required power transmission capability.
3Adaptability or versatility
If multiple interfaces are included in high output transmissions, then system functionality is enhanced, but design complexity and failure points increase
Solution Approach 1:
The synchronizer assembly is designed as a multi-functional component that simultaneously provides synchronization, gear engagement, and torque transmission capabilities through its integrated dog clutch and synchronizer ring design. This universal approach consolidates multiple functions into a single assembly, reducing the number of separate interfaces and components needed while maintaining enhanced system functionality.
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 synchronizer assembly enhances torque transfer efficiency, reduces friction losses, and simplifies the shifting process, addressing the complexity and reliability issues of existing high output transmissions by minimizing wear and eliminating unwanted drag during gear changes.
Implementation Method 1
A hub of the synchronizer ring supports a spring biased plunger that engages a roller on an interior surface of the sliding synchronizer sleeve
Data Source
AI summary
A synchronizer assembly includes a pair of engageable members each including an exterior cone surface and first exterior splines. A central synchronizer ring is disposed between the pair of engageable members and having second exterior splines. A pair of synchronizer cone rings are disposed on opposite sides of the central synchronizer ring and each include third exterior splines and an interior cone surface that oppose the exterior cone surface of respective ones of the pair of engageable members. A sliding synchronizer sleeve engages the second exterior splines of the central synchronizer ring and movable for engaging the third exterior splines of the pair of synchronizer cone rings and the first exterior splines of the pair of engageable members. A plurality of interlocking clips engage the pair of synchronizer cone rings.