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200822008 IIEEEIEEE PPacific-Asiaacific-Asia WWorkshoporkshop onoon CComputationalomputational IIntelligencentelligence andaand IIIndustrialndustrial ApplicationApplication
Analyses and Evaluation on Synchronizer of Manual Transmission
Zongyang Gong1,2, Weigong Zhang1,2, Gang Chen1,2, Wanjun Wang1
1 School of Instrument Science and Engineering,
Southeast University, Nanjing, JiangSu, 210096, China
2 Suzhou Key Laboratory of Automotive Electronics and
Intelligent Transportation, Suzhou, JiangSu, 215123, China
gzyseu@, zhangwg@
Abstract
main transmission and auxiliary transmission are
analysed.
Modern manual transmissions are equipped with
synchronizer systems for better and more comfortable
shifting performance. In this paper the typical structure of
manual transmission assemble for heavy-duty vehicle is
2. Synchronizer principle
1.1. Transmission structure
[1]
firstly introduced with emphasis on the power flow of 3
rd
gear. Then the components of the synchronizer are
introduced and the working process is analyzed
theoretically. The synchronizer performance test rig is
developed with which the actual working conditions are
simulated. The shift robot is adopted instead of human
being driver. The test data are recorded at 1K sample rate
while shifting. The test methods and evaluate methods are
The typical structure of the heavy-duty transmission
assemble equipped with three synchronizers is shown in
figure 1. The transmission assemble is composed of one
main transmission with five gears and one auxiliary
transmission with two gears. The main transmission is
manual controlled and the auxiliary transmission is
pneumatic controlled. The transmission includes nine
forward gears and one reverse shelve to meet the
transmission requirements of more gears and higher
torque and wider speed
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