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Content
1. Introduction
2. Driveline / Transmission / Shift Mechanism
3. The Synchronization
4. Basics for Synchronizer Calculation
5. Interfaces
6. Functional Problems and Solutions
7. HOERBIGER Capabilities
7.1. Design & Development
7.2. Manufacturing
Basics of Synchronizers
1. Introduction
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
1. Introduction
Synchronizers are the key elements in manual transmissions (MT) as well
as in double-clutch transmissions (DCT) and automated manual
transmissions (AMT).
This paper gives an overview of their function, layout and design and
explains possible problems and solutions.
Finally it is shown what tools and processes are needed to develop, test
and manufacture components and complete synchronizer systems.
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
2. Driveline / Transmission /
Shift Mechanism
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
Driveline
engine
transmission
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
Driveline
stub axle
damper mass
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
Transmission
3
bell housing
side shaft
right
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
Shift Mechanism
Shift
Select
Inner shift
mechanism
Outer shift
mechanism
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
10
3. The Synchronization
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Basics of Synchronizers
11
3. The Synchronization
Synchronizers can be structured by the number of cones used. The
next 3 pages show the exploded views of single-, dual- and triple-cone
synchronizers and the descriptions of the single components.
The synchronization process always follows the same sequences. The
sleeve is moved by the shift fork towards the gear to be engaged. As
long as there is a speed difference between the sleeve/hub-system and
the gear wheel the sleeve is blocked by the blocker ring and the
synchronizer rings create a friction torque. When the speeds are
synchronized the sleeve can be moved further and engages into the
spline of the engangement ring at the gear wheel.
The sequences can be followed by clicking through the pages 16 to 21.
They are then explained in detail on pages 22 to 28.
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
12
3. The Synchronization
Single-cone Synchronizer
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
13
3. The Synchronization
Dual-cone Synchronizer
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Basics of Synchronizers
14
3. The Synchronization
Triple-cone Synchronizer
Intermediate ring
Engagement ring
Inner ring coated
Sleeve
Blocker ring
Detent
Hub
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Basics of Synchronizers
15
3. The Synchronization
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Basics of Synchronizers
16
3 .The Synchronization
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Basics of Synchronizers
17
3. The Synchronization
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Basics of Synchronizers
18
3. The Synchronization
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
19
3. The Synchronization
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
20
3. The Synchronization
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Basics of Synchronizers
21
3. The Synchronization
fork
sleeve
3D-picture
detent
blocker ring
engagement ring
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
22
3. The Synchronization
3D-picture
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
23
3. The Synchronization
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Basics of Synchronizers
24
3. The Synchronization
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Basics of Synchronizers
25
3. The Synchronization
3D-picture
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Basics of Synchronizers
26
3. The Synchronization
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Basics of Synchronizers
27
3. The Synchronization
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Basics of Synchronizers
28
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Basics of Synchronizers
29
Basics of Synchronizers
30
Input
installation space
inertia to be synchronized
speed difference to be synchronized
torque to be transmitted
transmission oil
customers requirements (e.g. synchronizing time, shift travel,
shift impulse, shift force, drag torque, load cycles, ...)
interfaces (spline data, clearance of gear wheels, sleeve groove...)
test definition for validation
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
31
Limiting Factors
The capacity of a synchronizer is limited by
torque capacity of Sleeve/Hub-System and Engagement Ring
capacity of Friction Material (sliding speed, surface pressure,
friction power, friction work)
heat dissipation through the oil, the synchro rings and the gear cone
transmission oil (viscosity and thermal stability)
(see also next page)
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Basics of Synchronizers
32
Transmission Oil
basic functions and requirements:
cooling
lubrication / wear protection
corrosion protection
anti foam
friction characteristic
compatibility with elastomeres (sealings)
temperature and viscosity characteristic
low viscosity
high viscosity
Basics of Synchronizers
33
Layout Calculation
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
34
nc d m Fa
TF =
[Nm]
2 sin
d D cos 2 D sin 2
[Nm]
TZ = Fa
2 sin 2 + D cos 2
TF > TZ
Blocking Safety:
TZ
TF
D
dm
dD
Fa
nc
[]
[]
[-]
[-]
[mm]
[mm]
[N]
[-]
cone angle
chamfer angle
c.o.f. of cone
c.o.f. of chamfers
mean cone diameter
pitch diameter
shift force at sleeve
number of cones
Basics of Synchronizers
35
W
qA =
A
[J/mm]
1
W = J 2 TV tR
2
= nSYN 2 / 60
tR
TV
J
nSYN
A
W
[s]
[Nm]
[kgm]
[min-1]
[mm]
[J]
slipping time
drag torque
mass moment of inertia
speed difference to synchronize
total friction surface
friction work
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Basics of Synchronizers
36
PmA
qA
= [W/mm]
tR
tR
Pm
qA
A
W
[s]
[W]
[J/mm]
[mm]
[J]
or
Pm
PmA =
A
[W/mm]
Pm =
W
tR
slipping time
mean friction power
specific friction work
total friction surface
friction work
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Basics of Synchronizers
37
dmax
nSYN
[mm]
[min-1]
[m/s]
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Basics of Synchronizers
38
pm =
tR
J
TF
nc
dm
FN
A
FN
( A / nc )
[N/mm]
[s]
[kgm]
[Nm]
[-]
[mm]
[-]
[N]
[mm]
FN = (TF /( dm / 2)) / nc
TF = J / tR
slipping time
mass moment of inertia
friction torque
number of cones
mean cone diameter
coefficient of friction c.o.f.
normal force on cone
total friction surface
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Basics of Synchronizers
39
P max = pm v max
vmax
pm
[W]
[-]
coeffiecient of friction c.o.f.
[m/s]
max. sliding speed
[N/mm] mean specific pressure
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Basics of Synchronizers
40
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Basics of Synchronizers
41
5. Interfaces
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Basics of Synchronizers
42
5. Interfaces
The definition of interfaces between the synchronizer system and the
transmission is essential for a proper function and durability.
The neutral position of the shift fork determines the clearance of the
synchronizer rings. Low clearance will cause drag torque and in
extreme cases overheat and destroy the friction lining.
The clearance of the gear wheels determine the maximum possible
axial space for the synchro rings. Too much clearance can cause a
decoupling of blocker rings from the hub or what is more likely from
blocker rings and inner rings in multi-cone synchronizers.
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
43
5. Interfaces
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
44
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
45
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Basics of Synchronizers
46
Fa =
2 sin J
nc d m t F
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Basics of Synchronizers
47
The 2nd load bump occurs when the sleeve enters into the engagement ring. If the
resistance is too high, it can be felt at the shift knob.
shift force
shift travel
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Basics of Synchronizers
48
The 2nd load bump occurs when the sleeve enters into the engagement ring. If the
resistance is too high it can be felt at the shift knob.
Reasons for 2nd load bumps can be:
high drag torque, esp. in cold transmission
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Basics of Synchronizers
49
TZ
TF
clash event
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Basics of Synchronizers
50
high wear
Possible measures:
increase blocking safety (chamfer angle, cone angle, friction lining)
improve groove geometry (cold clash)
improve c.o.f. increase in presynchronization (detent force)
increase wear gap
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
51
Copyright by HOERBIGER Antriebstechnik GmbH (Germany), 2013. Any kind of use in part or in full provides HOERBIGER Antriebstechnik GmbH's prior written consent.
Basics of Synchronizers
52
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Basics of Synchronizers
53
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Basics of Synchronizers
54
7. HOERBIGER Capabilities
7.1. Design & Development
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Basics of Synchronizers
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Basics of Synchronizers
56
Development Tools
Development follows Stage-Gate Pocess
Simulation
Testing
Tribology
Design
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Basics of Synchronizers
57
Development Tools
Concept Layout / Design
System Layout
Concept Definition
Design Engineering
Analysis of Functionality
Optimization of existing Systems
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Basics of Synchronizers
58
Development Tools
Modeling
modular model design
efficient modeling
adapted to vehicle environment
dynamic 3-dimensional visualization
Simulation
statistical parameter variation
parameter variation with DoE
analysis of complex interactions
and optimization of subsystems
Validation
check of characteristic values at components
system validation by rig and vehicle measurements
Shift fork +
Sleeve
Shift tube +
Shift weight
Shift rope
Shift lever
Catch
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Basics of Synchronizers
59
Development Tools
tribometer
synchronizer test rig HOERBIGER -comp
synchronizer test rig ZF SSP180
torsional and linear pulser
transmission test rig
drive train test rig
in vehicle shift quality measurement
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Basics of Synchronizers
60
Inc. Angle
Detector
Potentiometer
Hydraulic
Cylinder
Oil
Supply
Shift
Fork
Center
Shaft
Synchro
Unit
Base
Frame
El. Engine
Flywheel(s)
Oil Outlet
Measurement
Device
Hoerbiger
Antriebstechnik 1097RR
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Basics of Synchronizers
61
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Basics of Synchronizers
62
7.2. Manufacturing
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Basics of Synchronizers
63
7.2. Manufacturing
As a result of the efficient and flexible use of metal forming technology, machining, heat
treatment, and friction lining production, HOERBIGER has efficient manufacturing
technologies at its disposal - with sustainable cost advantages for the customer.
Metal-forming and Machining
HOERBIGER employs powerful metal-forming presses and modern machining equipment to produce
ready-to-install synchronizer components and systems. In-house tool & die design as well as
automated production lines assure high quality standards. This consistently allows HOERBIGER to
offer products with excellent features at an excellent cost-benefit ratio.
Heat treatment
Modern heat treating equipment assures high-quality as well as careful finishing of HOERBIGER
synchronizer components.
Basics of Synchronizers
64
7.2. Manufacturing
machining
metal forming technology
heat treatment
friction material production and friction material bonding
assembly
testing technology
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Basics of Synchronizers
65
7.2. Manufacturing
turning
milling
broaching
chamfering
back taper milling
heat treatment
washing
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Basics of Synchronizers
66
7.2. Manufacturing
deep drawing
stamping
fine blanking
cold forming
bending
heat treatment
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Basics of Synchronizers
67
7.2. Manufacturing
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Basics of Synchronizers
68
7.2. Manufacturing
friction systems
sleeve/hub systems
complete synchronizer groups
running-in
functional testing
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Basics of Synchronizers
69
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Basics of Synchronizers
70
Synchronizer Systems
Most innovative and competent partner for
synchronizer development
Basics of Synchronizers
71
Friction Systems
HOERBIGER - Classic Line
The proven synchronizer for all applications
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Basics of Synchronizers
72
Blocker Rings
HOERBIGER - Classic Line
The proven synchronizer for all applications
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Basics of Synchronizers
73
Synchronizer Sleeves
HOERBIGER - Classic Line
The proven synchronizer for all applications
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Basics of Synchronizers
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Engagement Rings
HOERBIGER - Classic Line
The proven synchronizer for all applications
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Basics of Synchronizers
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9. Summary
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Basics of Synchronizers
76
9. Summary
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Basics of Synchronizers
77
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Basics of Synchronizers
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