The short-stroke synchronizer offers significant advantages, including a shorter shifting stroke and a more compact axial installation size. It has become a key component in many of our company's products, greatly enhancing the torque capacity of the transmission while reducing the shifting distance. This not only improves the overall performance of the vehicle but also supports lightweight design goals. Compared to traditional synchronous devices in the same class, the short-stroke synchronizer demonstrates improved synchronization time and reduced shifting force, resulting in a smoother and more efficient gear-shifting experience.
However, due to its more compact structure, this type of synchronizer is more prone to shifting faults. To address this issue, the author conducted a detailed comparison and analysis between the short-stroke synchronizer and the conventional one, aiming to find a more reliable solution that ensures smooth and consistent performance.
**Key Features of the Short-Stroke Synchronizer**
1. **Structural Improvements**
(1) **Simplified Design**
The short-stroke synchronizer is based on the lock-ring inertial design, with a molybdenum steel ring used as the synchronizing ring. Its main structure and synchronization mechanism are similar to those of a standard lock-ring synchronizer. As shown in Figure 1, the synchronizing tooth base connects to two shafts via splines and is secured by a circlip. The gears are positioned using needle bearings, and the synchronizing cone hub is connected to the gears through splines. The synchronizing ring fits tightly against the tapered surface of the cone hub, and the spring is mounted on the push block within the tooth holder. The push block is guided by a groove in the sliding sleeve, which is splined to the tooth holder.
The design of the synchronizing push block and tooth holder has been modified (as seen in Figures 2 and 3), reducing machining complexity and the number of springs used. The new push block eliminates unnecessary holes and adds a positioning pin for better accuracy. The tooth holder now features a simplified groove design, making manufacturing more efficient.
(2) **More Compact Structure**
The total axial length of the cone hub has been reduced from 22 mm to 18 mm, and the tapered joint thickness has decreased from 7.5 mm to 6.5 mm. The synchronizing ring’s axial dimension has also been shortened from 12.6 mm to 11.5 mm, and the tooth thickness of the ring joint has been reduced from 4 mm to 2.5 mm. In fully engaged conditions, the joint surface between the cone hub and the sleeve measures up to 3.45 mm, compared to 5.65 mm in standard synchronizers. The push block has transitioned from a dual-spring to a single-spring system, and its size has been reduced from 10 mm to 7 mm, contributing to a shorter shift stroke of just 10 mm.
(3) **Enhanced Friction Torque**
The design includes an increased friction torque between the synchronizing ring and the cone hub. By optimizing the friction cone’s average diameter and ensuring sufficient synchronization clearance, the synchronizer achieves greater efficiency. This not only reduces shifting force and time but also enhances the overall shifting experience. The increased contact area between the ring and the cone hub improves synchronization performance while maintaining reliability and durability.
To learn more about the innovative features of the MW1950 series and explore additional content, download the attached file.
FUJI Elevator Light Curtain,Elevator Infrared Outer Screen,Elevator Light Curtain Protection System,Elevator Beam Scanning Mechanism
Suzhou FUJI Precision Elevator Co.,Ltd , https://www.profuji.com