Study On The Detection System Of Self-sliding Performance And Tilting Amount Of Double-cone Synchronizers

The synchronizer assembly quality is mainly characterized by self-sliding performanceand tilting amount, in order to ensure the quality of the use of synchronizer, enterprises needto test and control these two kinds of performance indexes.It is understood that there is noreport of the practical application of special instruments and equipment about automotivesynchronizer’s detection of self-sliding performance and tilting amount, and self-slidingperformance is often evaluated by artificial means and tilting amount is detected by dialindicators in the production field. This kind of extensive evaluation method is difficult tosatisfy the increasing requirements of the precision and quality of modern cars. And therefore,a research on an automatic and accurate method and instrument of the detection aboutsynchronizer’s self-sliding performance and tilting amount has great practical value andsignificance. In this paper, double cone synchronizer of a machinery company in Ganzhou isselected as object of research, and a research is taken about the methods of synchronizer’sself-sliding performance and tilting amount. Based on the methods, a corresponding detectionsystem of synchronize’s self-sliding performance and tilting amount is developed, which is fitfor automatic assembly system and make up the synchronizer’s automatic assembly.Through analyzing the main factors of synchronizer’s self-sliding performance andtilting amount, based on the measurement of micro-friction from synchronizer’s gear huband synchronizer’s sleeve, a method to test synchronize’s self-sliding performance isestablished. Through putting a couple in the diameter direction, a detection method to detectsynchronize’s tilting amount is established through tilting angle from synchronizer’s gear huband synchronizer’s sleeve. With electronic scales and suspension device, a simple detectionexperiment is used to detect a number of synchronizers, and the results prove range ofsynchronizer’s axial micro-friction:0.2N≤f≤0.7N; a dial indicator and a goniometer areused to measure statistics, which determine the amount of value range0.4mm~0.9mm(displacement volume) of synchronous tilting amount detection. Thus, a detection system isdeveloped to detect synchronizer’s self-sliding performance and tilting amount with highefficiency, low cost and automation. The detection system use sensors to detect themicro-friction of synchronizer’s gear hub and synchronizer’s sleeve to measure thesynchronize’s self-sliding performance, and use a laser displacement sensor to measure themicro tilting amount of the synchronizer. This article is also based on a manufacturing error from synchronizer’s gear hub and synchronizer’s sleeve. Through those manufacturing error,a theoretical estimation model about synchronizer’s tilting amount is derived, and then usingMATLAB programming to take a estimation analysis about synchronizer’s tilting amount, andfinally further studying the variation of factors of synchronizer’s self-sliding performance anderror. The result of analysis showed that the theoretical estimates and experimentalmeasurements of synchronizer’s tilting amount basically are the same amount and error about1%, showing that the theoretical estimation method has a certain practicality.On the basis of testing methods and experimental study of the self-sliding performanceand tilting amount of synchronizer. This paper designed a automatic detection system of theself-sliding performance and tilting amount of synchronizer, analyzed the function of systemand designed the overall scheme, then designed the mechanical structure of the detectionsystem and control system in detail. The mechanical system is consist of two degrees offreedom linear manipulator by the wrist with a tension sensor, detection platform, tiltingamount testing agency, synchronizer’s sleeve of compaction mechanism, etc. It selected PLCas the automatic control center of the whole detection system, and designed the mainhardware and software of the system. The detection system of self-sliding performance andtilting amount in this paper can realize on-line detection. With the simple operation and highdetection efficiency, the system provides a means to control the automotive synchronizerassembly quality.