Assembly for a synchronization unit of a variable ratio gear transmission

Abstract

Assembly for a synchronization unit of a variable ratio gear transmission. Assembly has a synchronizer ring and a friction ring. The friction ring has a friction surface and an installation surface and the synchronizer ring has a contact surface directed toward the installation surface. To allow a high efficiency of the synchronizing unit and simultaneously a functionally safe and comfortable operation of the variable ratio gear transmission, the synchronizer ring and the friction ring are configured and arranged such that the geometrical shape of the installation surface of the friction ring differs from the geometrical shape of the contact surface of the synchronizer ring in a relief state of a synchronizing process; and that the geometrical shape of the installation surface of the friction ring corresponds to the geometrical shape of the contact surface of the synchronizer ring in a load state of the synchronizing process.

Claims

1. A synchronizer unit of a variable ratio gear transmission, said synchronizer unit comprising: a friction ring comprising: a first annular end arranged on a smaller diameter side; a second annular end arranged on a larger diameter side: a conical inner surface arranged between the first and second annular ends and extending at a first conical angle; a conical outer installation surface arranged between the first and second annular ends and being coaxial with the conical inner surface; a synchronizer ring comprising: a conical inner installation surface structured and arranged to, during gear synchronization, directly engage with the conical outer installation surface of the friction ring; and said conical inner installation surface being coaxial with the conical outer installation surface, wherein the friction ring is at least one of: a one-piece member that, in a relaxed state, assumes a first geometrical shape, that in a plane perpendicular to a center axis of the friction ring, having a varying, radius of curvature and that in a pre-loaded state, assumes a second geometrical shape different from the first geometrical shape; and a metal member that, in a relaxed state, assumes a first geometrical shape, that in a plane perpendicular to a center axis of the friction ring, having a varying radius of curvature and that in a pre-loaded state, assumes a second geometrical shape different from the first geometrical shape, wherein the conical outer installation surface has portions which are spaced from the conical inner installation surface when the friction ring assumes the first geometrical shape, and wherein the conical outer installation surface conforms to a shape of the conical inner installation surface when the friction ring assumes the second geometrical shape.

2. The unit of claim 1, wherein, in the relaxed state, the conical outer installation surface of the friction ring extends at a first conical angle that is different from a second conical angle of the conical inner installation surface of the synchronizer ring.

3. The unit of claim 2, wherein the first conical angle is larger than the second conical angle relative to a center axis of the friction ring.

4. The unit of claim 1, wherein the synchronizer ring further comprises: a conical outer surface; a first annular end arranged on a smaller diameter side; a second annular end arranged on larger diameter side; and teeth arranged on a radially projecting flange located at the larger diameter side.

5. The unit of claim 1, wherein the conical inner surface of the friction ring is adapted to be in contact with a gear wheel during a synchronization process in which the synchronizer ring is displaced.

6. The unit of claim 1, wherein the friction ring and the synchronizer ring comprise different materials.

7. The unit of claim 6, wherein the friction ring comprises sheet-metal and the synchronizer ring comprises brass.

8. A variable ratio gear transmission for a vehicle, comprising the unit of claim 1.

9. A method of making a variable ratio gear transmission for a vehicle, comprising assembling the unit of claim 1.

10. A method of using a variable ratio gear transmission for a vehicle, comprising moving the synchronizer ring of claim 1 toward a gear wheel to cause the friction ring to assume the pre-loaded state.

11. A synchronizer unit of a variable ratio gear transmission, said synchronizer unit comprising: a friction ring comprising: a first annular end arranged on a smaller diameter side; a second annular end arranged on a larger diameter side; a conical inner surface arranged between the first and second annular ends and extending at a first conical angle, a conical outer installation surface arranged between the first and second annular ends and being coaxial with the conical inner surface; a synchronizer ring comprising: a conical inner installation surface structured and arranged to, during gear synchronization, directly engage with the conical outer installation surface of the friction ring; and said conical inner installation surface being coaxial with the conical outer installation surface, wherein the friction ring is at least one of: a one-piece member that, in a relaxed state, assumes a rounded polygon geometrical shape and that in a pre-loaded state; assumes a circular geometrical shape; and a sheet-metal member that, in a relaxed state, assumes a rounded polygon geometrical shape and that in a pre-loaded state, assumes a circular geometrical shape, wherein the conical outer installation surface has portions which are spaced from the conical inner installation surface when the friction ring assumes the first rounded polygon geometrical shape, and wherein the conical outer installation surface conforms to a shape of the conical inner installation surface when the friction ring assumes the circular geometrical shape.

12. A variable ratio gear transmission for a vehicle, comprising the unit of claim 11.

13. A method of making a variable ratio gear transmission for a vehicle, comprising assembling the unit of claim 11.

14. A method of using a variable ratio gear transmission for a vehicle, comprising moving the synchronizer ring of claim 11 toward a gear wheel to cause the friction ring to assume the pre-loaded state.

15. A synchronizer unit of a variable ratio gear transmission, said synchronizer unit comprising: a friction ring comprising: first annular end arranged on a smaller diameter side; a second annular end arranged on a larger diameter side; a conical inner surface arranged between the first and second annular ends and extending at a first conical angle; a conical outer installation surface arranged between the first and second annular ends and being coaxial with the conical inner surface; a synchronizer ring comprising: a conical inner installation surface structured and arranged to, during gear synchronization, directly engage with the conical outer installation surface of the friction ring; and said conical inner installation surface being coaxial with the conical outer installation surface, wherein the friction ring is a one-piece sheet-metal member that, in a relaxed state, assumes a non-circular geometrical shape and that in a pre-loaded state, assumes a circular geometrical shape, wherein the conical outer installation surface conforms to a shape of the conical inner installation surface when the friction ring assumes the circular geometrical shape, and wherein the non-circular geometrical shape is one of: oval; rounded polygon; or, rounded triangle.

16. A variable ratio gear transmission for a vehicle, comprising the unit of claim 15.

17. A method of making a variable ratio gear transmission for a vehicle, comprising assembling the unit of claim 15.

18. A method of using a variable ratio gear transmission for a vehicle, comprising moving the synchronizer ring of claim 15 toward a gear wheel to cause the friction ring to assume the pre-loaded state.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages, features and details of the invention result with reference to the following description of embodiments and with reference to drawings in which elements which are the same or have the same function are provided with identical reference numerals.

(2) There are shown:

(3) FIG. 1 a synchronization unit with an assembly of friction ring and synchronizer ring;

(4) FIG. 2a a section along the line I-I in accordance with FIG. 1 through a first embodiment of an assembly in accordance with the invention that is in a relief state of a synchronizing process;

(5) FIG. 2b a section along the line I-I in accordance with FIG. 1 through a first embodiment of an assembly in accordance with the invention that is in a load state of a synchronizing process;

(6) FIG. 3a a part side view X in accordance with FIG. 1 of a second embodiment of an assembly in accordance with the invention that is in a relief state of a synchronizing process; and

(7) FIG. 3b a part side view X in accordance with FIG. 1 of a second embodiment of an assembly in accordance with the invention that is in a load state of a synchronizing process.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(8) The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

(9) FIG. 1 shows in a schematic representation a synchronizing unit 2 having an assembly 1 comprising a friction ring 4 and a synchronizer ring 6. The synchronizing unit 2 furthermore has, in addition to the assembly 1, in a manner known per se a sliding coupling 9 having a synchronizer body 10 and a gear wheel 8, wherein the aforesaid components are arranged coaxially with respect to a friction ring axis 5 such that the synchronizer ring 6 is displaceable by the sliding coupling 9 together with the friction ring 4 along the friction ring axis 5 in the direction toward the gear wheel 8 during the synchronization process such that the friction ring 4 can be brought into engagement with the gear wheel 4.

(10) The friction ring 4 comprises a conical friction ring body 3 having an inner friction surface 301 and an outer installation surface 302 which respectively bound the friction ring body 3 in a radial peripheral direction U extending perpendicular to an axial friction ring axis 5. Securities against rotation 11 are provided at the friction ring body 3 that extend along the friction ring axis 5 and that prevent a rotation of the friction ring 4 in the operating state.

(11) A friction coating, not shown explicitly, can be provided at the inner friction surface 301, in particular a friction coating in the form of a carbon friction layer that can inter alia serve to at least partly compensate a resulting high mechanical and/or thermal load of the friction pairing.

(12) The friction ring body 3 in the assembly unit 1 in accordance with FIG. 1 is closed in the peripheral direction U. It is, however, also possible that the friction ring body 3 has a separation point in the peripheral direction U, i.e. is designed as a slit ring body 3.

(13) The synchronizer ring 6 has a contact surface 7 directed toward the installation surface 302 of the friction ring 4 and has coupling pockets, not shown in any more detail, for receiving the securities against rotation 11 of the friction ring 4.

(14) In the assembly 1 in accordance with FIG. 1, the friction ring 4 and the synchronizer ring 6 comprise different materials. The friction ring body 3 is thus produced from a sheet metal and the synchronizer ring 6 from brass.

(15) In accordance with a first embodiment of an assembly 1 in accordance with the invention in accordance with FIGS. 2a and 2b, the installation surface 302 of the friction ring 4 extends at an installation angle .sub.1 and the contact surface 7 of the synchronizer ring 6 extends at a contact angle .sub.2, in each case conically along the friction ring axis 5.

(16) FIG. 2a shows the assembly 1 in the relief state of the synchronizing process in which the synchronizer ring 6 is moved away from the gear wheel 8 to be synchronized. The installation angle .sub.1 and the contact angle .sub.2 are different in the relief state such that a minimal difference angle is adopted between the installation surface 302 and the contact surface 7 in the relief state; it is 3 in the embodiment. In the relief state, the contact surface 7 and the installation surface 302 are substantially released from one another in the peripheral direction U due to the difference angle . In the embodiment shown, the installation angle .sub.1 is larger than the contact angle .sub.2 in the relief state.

(17) In the described embodiment, the installation surface 302 of the friction ring 4 is elastically deformable. If now the assembly 1 is transitioned from the relief state into the load state, the installation surface 302 of the friction ring 4 is tilted or elastically deformed by the contact surface 7 of the synchronizer ring 6 by so much until the installation angle .sub.1 has adapted to the contact angle .sub.2. The installation surface 302 hereby undergoes a preload.

(18) FIG. 2b shows the assembly 1 in the load state of the synchronizing process. The synchronizer ring 6 is in this respect displaced in the direction of the gear wheel 8 to be synchronized such that the contact surface 7 of the synchronizer ring 6 contacts the installation surface 302 of the friction ring 4, whereby a friction contact arises between the friction surface 301 and the gear wheel 8 and a speed of revolution matching takes place between the gear wheel 8 and the friction ring 4 and thus the synchronizer ring 6. The installation angle .sub.1 and the contact angle .sub.2 are the same in the load state such that the difference angle disappears in the load state.

(19) The installation surface 302 of the friction ring 4 returns into its original load-free state again on the transition of the assembly 1 from the load state into the relief state due to its elastic deformation or preload such that the difference angle is again adopted between the installation surface 302 of the friction ring 4 and the contact surface 7 of the synchronizer ring 6 in the relief state.

(20) On the transition of the assembly 1 from the load state into the relief state, some of the adhesion force that acts between the installation surface 302 and the contact surface 7 is overcome by a restoring force of the installation surface 302 of the friction ring 4. The restoring force of the installation surface 302 thus supports the release of the installation surface 302 from the contract surface 7 on the transition from the assembly 1 from the load state into the relief state.

(21) FIG. 3a and FIG. 3b show a side view X in accordance with FIG. 1 of a second embodiment of an assembly 1 in accordance with the invention in which the friction body 3 of the friction ring 4 is configured in the relief state such that the installation surface 302 of the friction ring 4 has a varying first radius of curvature R.sub.1 in the peripheral direction U.

(22) FIG. 3a shows the assembly 1 in the relief state of the synchronizing process in which the synchronizer ring 6 is moved away from the gear wheel 8 to be synchronized. The geometrical shape of the installation surface 302 of the friction ring 4 is configured as a rounded triangle in the relief state, i.e. the geometrical shape of the installation surface 302 differs from a circular shape in the relief state. The geometrical shape of the contact surface 7 of the synchronizer ring 6 is in contrast configured as circular such that the contact surface 7 has a constant second radius of curvature R.sub.2 in the peripheral direction U. The contact surface 7 and the installation surface 302 are therefore substantially released from one another in the peripheral direction U in the relief state due to the different geometrical configuration.

(23) The installation surface 302 of the friction ring 4 is also elastically deformable in this embodiment. If the assembly 1 is now transitioned from the relief state into the load state, the installation surface 302 is elastically deformed by the contact surface 7 of the synchronizer ring 6 by so much until the installation surface 302 has adapted to the geometrical shape of the contact surface 7 in the load state. The installation surface 302 hereby undergoes a preload.

(24) FIG. 3b shows the assembly 1 in the load state of the synchronizing process. The synchronizer ring 6 is in this respect displaced in the direction of the gear wheel 8 to be synchronized such that the contact surface 7 of the synchronizer ring 6 contacts the installation surface 302 of the friction ring 4, whereby a friction contact arises between the friction surface 301 and the gear wheel 8 and a speed of revolution matching takes place between the gear wheel 8 and the friction ring 4 and thus the synchronizer ring 6. In the load state, the geometrical shape of the installation surface 302 is circular, i.e. the first radius of curvature R.sub.1 of the installation surface 302 is likewise constant in the peripheral direction U in the load state.

(25) The installation surface 302 of the friction ring 4 returns into its original, load-free state again on the transition of the assembly 1 from the load state into the relief state due to its elastic deformation. On the transition of the assembly 1 from the load state into the relief state, some of the adhesion force that acts between the installation surface 302 and the contact surface 7 is overcome by a restoring force of the installation surface 302 of the friction ring 4. The restoring force of the installation surface 302 thus supports the release of the installation surface 302 from the contract surface 7 on the transition from the assembly 1 from the load state into the relief state.

(26) In the embodiment in accordance with FIGS. 3a and 3b, the geometrical shape of the installation surface 302 of the friction ring 4 is configured as a rounded triangle in the relief state. It is, however, also possible that the geometrical shape of the installation surface 302 differs from a circular shape of the contact surface 7 in a different geometrical manner in the relief state.

(27) It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.