Overview
This document contains information on:
General
Function requirements
Function
General
The task of the synchronization is to adjust the rpm between the output shaft and the associated idler gear. The rpm adjustment causes a positive connection to be set up between the output shaft and the associated idler gear.
Function requirements
Engine in operation
Clutch of sub-transmission disengaged
Function
Synchronization
The sliding sleeve, which is non-rotatably connected to the synchronizer body, is pushed axially along the output shaft by the shift fork. Locking splines on the synchronizer ring prevents the sliding sleeve from moving onto the interlock teeth of the idler gear if the synchronizer body (non-rotatably connected to the output shaft) and the idler gear have different rpms. The axial movement along the output shaft causes the sliding sleeve to exert force on the synchronizer ring; the sliding sleeve then pushes the synchronizer ring into the cone ring of the idler gear. The resulting friction equalizes the rotational speeds of the idler gear and output shaft. At the same time, the locking splines of the synchronizer ring turn radially to a parallel position relative to the interlock teeth of the idler gear, thereby allowing the sliding sleeve to overlap. The sliding sleeve can then by pushed by the shift fork onto the interlock teeth of the idler gear and generates a positive connection to the output shaft via the synchronizer body.
A distinction is made between the following types of synchronizer:
Single cone synchronization
Double-cone synchronizer
Multiple cone synchronization
Sectional view of single-cone synchronization |
1 | Synchronizer ring |
2 | Clutch plate |
3 | Idler gear |
4 | Needle bearing |
5 | Shaft |
6 | Synchronizer body |
7 | Thrust piece |
8 | Sliding sleeve |
P27.10-2655-72
Single cone synchronization
When the sliding sleeve (8) is moved, the idler gear (3) is braked or accelerated via the synchronizer ring (1).
Sectional view of double-cone synchronization |
1 | Thrust piece |
2 | Synchronizer ring |
3 | Clutch plate |
4 | Cone ring |
5 | Friction ring |
6 | Idler gear (e.g. 4th gear) |
7 | Shaft |
8 | Needle bearing |
9 | Idler gear (e.g. 3rd gear) |
10 | Synchronizer body |
11 | Sliding sleeve |
P27.10-2657-81
Double-cone synchronizer
When the sliding sleeve (11) is moved on the synchronizer body (10) with the synchronizer ring (2), the respective idler gear is braked or accelerated quickly and with little force via the following components:
Cone ring (4),
Friction ring (5),
Clutch plate (3)
Use of the cone ring (4) and friction ring (5) means that two friction surfaces are in use. The friction surfaces of the nested cone ring (4), friction ring (5) and clutch plate (3) add up.
Sectional view of multi-cone synchronization |
1 | Thrust piece |
2 | Synchronizer ring |
3 | Idler gear (e.g. 2nd gear) |
4 | Clutch plate |
5 | Cone ring |
6 | Friction ring |
7 | Needle bearing |
8 | Shaft |
9 | Idler gear (e.g. 1st gear) |
10 | Synchronizer body |
11 | Sliding sleeve |
P27.10-2656-81
Multiple cone synchronization
When the sliding sleeve (11) is moved on the synchronizer body (10) with the synchronizer ring (2), the respective idler gear is braked or accelerated via the following components:
Cone ring (5)
Friction ring (6)
Clutch plate (4)
The multi-cone synchronization uses the following components:
Clutch plate (4)
Cone ring (5)
Synchronizer rings (2)
Friction rings (6)
The friction surfaces of the nested cone ring (5), synchronizer ring (2), friction ring (6) and clutch plate (4) add up.