The Development Of New Type Of Double-Cone Synchronizer

Synchronizer is one of the most important parts which affect the shifting performance in the automobile gearbox. The single-cone synchronizer, which is used widely, can not meet the demands of the heavy-duty gearbox because of the space limit, so the bad shiftability and clash appeared frequently. Using the double-cone synchronizer with reasonable structure and design parameters can solve this problem effectively. In the present study, the synchronizing and blocking performance was studied, the synchronizing and blocking process was analyzed, and the simplified model of process was established according to the actual conditions. The mathematical formulas which were suitable for both the computation and the precision were derived, the main parameters of the synchronizer which affect the synchronizing and blocking performance were investigated, and the design principles were put forward. According to the study of the theory and the demands of the mass production and the actual conditions, two types of the double-cone synchronizers were compared, and the unconnected type of double-cone synchronizers was chosen as the final structure. Then, the main parameters of the synchronizer were designed by the way of computation. The bench tests were carried out in the CA7-95 gearbox assembled with the double-cone synchronizer to test the performance and life, which proved the design proposed in the study to be excellent, so the development of new type of double-cone synchronizer was finished. The development has been put into use in the heavy-duty gearbox, and great benefits were gained.