Research On Modern Design Methods Of Automobile’s Single Cone Synchronizer Of Lock Ring Type

The synchronizer is an important part of automotive manual transmission, which has the advantages of reducing the shift impact and noise, meanwhile increasing the life of transmission. When it comes to the traditional design methods, it is not only difficult to ensure the quality of synchronizer but also needs a long design cycle. Therefore, it is of vital significance to design synchronizer with high performance requirements. In this paper, as the research object, single cone synchronizer of lock ring type is studied to provide evidence and guidance for the modern design methods of synchronizer. The main contents, including four folders, are as follows:(1) The working process of synchronizer is divided into four stages through in-depth analysis of the principle of the synchronizer, and then the mechanical model of the synchronizer and its mathematical model of synchronization time, apart with locking ring wear’s mathematical model, are established.(2) Based on the mathematical model of the synchronizer, the optimization mathematical model is built using optimized design method in which course the synchronizer life is taken as the objective function, and then optimal structural parameters of the synchronizer are got under the help of Adaptive Particle Swarm Optimization. The synchronizer of life of pre-optimization and after-optimization are compared. The results show that, the synchronizer life expectancy of after-optimization increased by 40.909%, which reached the design requirements.(3) In order to shorten the development cycle when designing synchronizer, the synchronizer parametric design system is built based on Visual Studio 2010 and UG secondary development technology in this paper. 3D parametric models of the main parts of synchronizer are completed using UG/Open API to call the UG/Open GRIP, which also uses MenuScript to customize user menu and uses UIstyler to establish the user dialog. Then the synchronizer is assembled and inspected the interference with automatic. The results show that, the computer aided parametric design can greatly improve the efficiency of modeling.(4) At last, the simulation anslysis in ADAMS virtual prototype is carried out when the 3D model of synchronizer are import into ADAMS in Parasolid format, verifying the accuracy of the designed synchronizer. The results of simulation working process of the synchronizer coincide with theoretical analysis. At the same time, the synchronizer shift life represented by unit area friction work shows good accordance with the optimization design. Therefore the correctness of the synchronizer optimization design and parametric design is verified.The results show that, using the modern design methods could design synchronizer with high performance requirements and it has direct instructional meaning for engineering.