汽车同步器基础理论
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© Ricardo plc 2005
A
B
C
D
E
15
Typical Gear Shift Quality Problems
Clash
This occurs following the non synchronous engagement of the sleeve and gear, represented by a harsh grating sound as the chamfers run into each other. Clash is likely to lead to significant damage to both the sleeve and the engagement ring. In applications requiring long serviceable lives e.g. heavy truck the engagement rings are splined onto the gears rather than welded or forged as part of the gear.
Synchroniser Operation SYNΒιβλιοθήκη BaiduHRO Training
Presented By: Mark Ingram Ricardo Driveline & Transmission Systems Ltd
© Ricardo plc 2005
1
‘SYNCHRO’ Training – Agenda
© Ricardo plc 2005
8
Introduction to Gear Shifting
The Gear Shift Operating Sequence
3. Neutral Detent - Sleeve starts to move pass neutral, energising strut / blocker system and initiating oil wipe.
– The balance of inputs around e.g. steering & clutch operation
45
3
6
2
7
In order to be clear about what is important for shift quality we split
1
the characteristics into groups to reduce bias judgement
Start of shift End of shift
© Ricardo plc 2005
5
Introduction to Gear Shifting
A Typical Gear Shift Plot
© Ricardo plc 2005
6
Ricardo GSQA
Common Objective Shift Measures
© Ricardo plc 2005
10
Introduction to Gear Shifting
The Gearshift Operating Sequence
7. Blocking Release - As sleeve moves forward blocker ring moves circumferentially with gear body. Force drops of until sleeve moves past blocker ring where force becomes virtually zero (ignoring inertias of internal shift system).
speed between input and output shafts.
9
Introduction to Gear Shifting
The Gear Shift Operating Sequence
5. Synchronising - Sleeve remains stationary while speed difference continues to reduce. Continued increase in input force is seen, although this is driver dependant.
using GSQA
Pedal Forces
Handball Forces
Effort Comparison
Feel Comparison
Feel/Effort Variability Assessment Definition Assessment
© Ricardo plc 2005
3
Introduction to Gear Shifting
2. Neutral - Synchroniser sleeve in central position, small negative force is seen caused by detent system. Transmission / Clutch drag starts to decelerate input shaft (Speed Vs time 600 - 800 ms)
© Ricardo plc 2005
8. Engagement Tooth Contact Sleeve continues to move axially until contact is made with engagement teeth. Second load problems can occur as a result, i.e. nibble or double bump.
Gearshift Quality can typically be split into four distinct areas:
– Shift Effort
– Shift Feel
– Gate Definition
– Ergonomics (H-Point)
Ricardo has a method of assessing the first 3 areas objectively
© Ricardo plc 2005
2
What is Gear Shift Quality?
A Driver will Assess Gearshift Quality based on:
– The last vehicle driven
Steering Forces
– The type of vehicle to be assessed: Sports / Luxury / Lo-cost
© Ricardo plc 2005
12
Introduction to Gear Shifting
Animations – Upshift – Downshift
© Ricardo plc 2005
13
Typical Gear Shift Quality Problems
High Synchronising Impulse Clash High Second Load Nibble Blocking Release
© Ricardo plc 2005
4. Pre Synchronisation - Strut force causes blocker ring to index and generate cone torque. Sleeve teeth move into contact with blocker teeth. Cone torque increases with axial force leading to a reduction in differential
Figure B shows high 2nd - 1st impulse levels - typical of a Japanese car where 2nd - 1st is not considered as a dynamic shift.
Figure E shows 2nd - 3rd has a higher impulse level than 1st - 2nd - which may lead to customer complaints.
2ND LOAD REGION - Load / Impulse / No of Peaks
7
Introduction to Gear Shifting
The Gear Shift Operating Sequence
1. Disengagement - Shift out of gear causes a small force (0 - 600 ms) due to clutch clearance drag / timing and locked in torque (i.e. transmission drag) reacted through back rake angles
© Ricardo plc 2005
Double Cone Design
4
Introduction to Gear Shifting
The Gear Shift Operating Sequence:
– The 9 fundamental stages of gear shifting for synchronised shifts are: 1. Disengagement 2. Neutral 3. Neutral Detent 4. Pre Synchronisation 5. Synchronising 6. Synchronisation 7. Blocking Release 8. Engagement Tooth Contact 9. Full Engagement
6. Synchronisation - Speed difference reaches 0, no more cone torque can be generated, input force starts to drop rapidly as sleeve begins to move forward.
The course for the SYNCHRO analysis spreadsheet training will include: z Introduction to synchronised gear shifting. z Introduction to SYNCHRO spreadsheet with example. z Run through of SYNCHRO manual. z SYNCHRO exercises.
© Ricardo plc 2005
14
Typical Gear Shift Quality Problems
High Synchronising Impulse
This malfunction results in unacceptable shift efforts and synchronising times, due to inadequate torque capacity for the application.
Synchroniser Pack Components
Hub
Sleeve
Baulk/Blocker or Outer ring
Strut spring
Struts usually located here
Intermediate Inner ring ring
Single Cone Design
11
Introduction to Gear Shifting
Gearshift Operating Sequence
9. Full Engagement - Second load problems aside sleeve moves through engagement teeth to final position. Force starts to build up against end stop. Movement of handball is seen to continue forward and return back to a final position due to compliance in the external shift system.
PULL OUT FORCE - load / smoothness
INTO GEAR SWITCH - load / blend into sync
SHIFT EFFORT - Impulse
END STOP - Stiffness / No of Peaks
© Ricardo plc 2005
BLOCKING PHASE - Time / Effort / Variability
A
B
C
D
E
15
Typical Gear Shift Quality Problems
Clash
This occurs following the non synchronous engagement of the sleeve and gear, represented by a harsh grating sound as the chamfers run into each other. Clash is likely to lead to significant damage to both the sleeve and the engagement ring. In applications requiring long serviceable lives e.g. heavy truck the engagement rings are splined onto the gears rather than welded or forged as part of the gear.
Synchroniser Operation SYNΒιβλιοθήκη BaiduHRO Training
Presented By: Mark Ingram Ricardo Driveline & Transmission Systems Ltd
© Ricardo plc 2005
1
‘SYNCHRO’ Training – Agenda
© Ricardo plc 2005
8
Introduction to Gear Shifting
The Gear Shift Operating Sequence
3. Neutral Detent - Sleeve starts to move pass neutral, energising strut / blocker system and initiating oil wipe.
– The balance of inputs around e.g. steering & clutch operation
45
3
6
2
7
In order to be clear about what is important for shift quality we split
1
the characteristics into groups to reduce bias judgement
Start of shift End of shift
© Ricardo plc 2005
5
Introduction to Gear Shifting
A Typical Gear Shift Plot
© Ricardo plc 2005
6
Ricardo GSQA
Common Objective Shift Measures
© Ricardo plc 2005
10
Introduction to Gear Shifting
The Gearshift Operating Sequence
7. Blocking Release - As sleeve moves forward blocker ring moves circumferentially with gear body. Force drops of until sleeve moves past blocker ring where force becomes virtually zero (ignoring inertias of internal shift system).
speed between input and output shafts.
9
Introduction to Gear Shifting
The Gear Shift Operating Sequence
5. Synchronising - Sleeve remains stationary while speed difference continues to reduce. Continued increase in input force is seen, although this is driver dependant.
using GSQA
Pedal Forces
Handball Forces
Effort Comparison
Feel Comparison
Feel/Effort Variability Assessment Definition Assessment
© Ricardo plc 2005
3
Introduction to Gear Shifting
2. Neutral - Synchroniser sleeve in central position, small negative force is seen caused by detent system. Transmission / Clutch drag starts to decelerate input shaft (Speed Vs time 600 - 800 ms)
© Ricardo plc 2005
8. Engagement Tooth Contact Sleeve continues to move axially until contact is made with engagement teeth. Second load problems can occur as a result, i.e. nibble or double bump.
Gearshift Quality can typically be split into four distinct areas:
– Shift Effort
– Shift Feel
– Gate Definition
– Ergonomics (H-Point)
Ricardo has a method of assessing the first 3 areas objectively
© Ricardo plc 2005
2
What is Gear Shift Quality?
A Driver will Assess Gearshift Quality based on:
– The last vehicle driven
Steering Forces
– The type of vehicle to be assessed: Sports / Luxury / Lo-cost
© Ricardo plc 2005
12
Introduction to Gear Shifting
Animations – Upshift – Downshift
© Ricardo plc 2005
13
Typical Gear Shift Quality Problems
High Synchronising Impulse Clash High Second Load Nibble Blocking Release
© Ricardo plc 2005
4. Pre Synchronisation - Strut force causes blocker ring to index and generate cone torque. Sleeve teeth move into contact with blocker teeth. Cone torque increases with axial force leading to a reduction in differential
Figure B shows high 2nd - 1st impulse levels - typical of a Japanese car where 2nd - 1st is not considered as a dynamic shift.
Figure E shows 2nd - 3rd has a higher impulse level than 1st - 2nd - which may lead to customer complaints.
2ND LOAD REGION - Load / Impulse / No of Peaks
7
Introduction to Gear Shifting
The Gear Shift Operating Sequence
1. Disengagement - Shift out of gear causes a small force (0 - 600 ms) due to clutch clearance drag / timing and locked in torque (i.e. transmission drag) reacted through back rake angles
© Ricardo plc 2005
Double Cone Design
4
Introduction to Gear Shifting
The Gear Shift Operating Sequence:
– The 9 fundamental stages of gear shifting for synchronised shifts are: 1. Disengagement 2. Neutral 3. Neutral Detent 4. Pre Synchronisation 5. Synchronising 6. Synchronisation 7. Blocking Release 8. Engagement Tooth Contact 9. Full Engagement
6. Synchronisation - Speed difference reaches 0, no more cone torque can be generated, input force starts to drop rapidly as sleeve begins to move forward.
The course for the SYNCHRO analysis spreadsheet training will include: z Introduction to synchronised gear shifting. z Introduction to SYNCHRO spreadsheet with example. z Run through of SYNCHRO manual. z SYNCHRO exercises.
© Ricardo plc 2005
14
Typical Gear Shift Quality Problems
High Synchronising Impulse
This malfunction results in unacceptable shift efforts and synchronising times, due to inadequate torque capacity for the application.
Synchroniser Pack Components
Hub
Sleeve
Baulk/Blocker or Outer ring
Strut spring
Struts usually located here
Intermediate Inner ring ring
Single Cone Design
11
Introduction to Gear Shifting
Gearshift Operating Sequence
9. Full Engagement - Second load problems aside sleeve moves through engagement teeth to final position. Force starts to build up against end stop. Movement of handball is seen to continue forward and return back to a final position due to compliance in the external shift system.
PULL OUT FORCE - load / smoothness
INTO GEAR SWITCH - load / blend into sync
SHIFT EFFORT - Impulse
END STOP - Stiffness / No of Peaks
© Ricardo plc 2005
BLOCKING PHASE - Time / Effort / Variability