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The structure of a classic self-energizing synchronizer is presented, and a simulation model is developed for analyzing the synchronizer performance. The self-energizing synchronizer has a disk spring and several energizing teeth on the sleeve for increasing the shift force. Besides, the asymmetric arrangement of chamfer teeth is applied to increase the torque for rotating ring and shift gears smoothly. The parameterized model of the typical synchronizer is developed with ADAMS for studying the synchronizer performance. In order to truly reflect the reality, the teeth of the claw plate are connected to the gear ring through bushing force alone, and the stiffness coefficient are obtained through the analysis of finite element model. Based on the dynamic model, the behavior of synchronizer with asymmetric arrangement of chamfer teeth, and the energizing effect of stiffness of the disk spring are studied. The simulation results can be used to design the synchronizer.

This paper presents the dynamic and analysis models of a typical synchronizer, which are mainly used to analyze the sensitivity of parameters of synchronizer on the gear shift performance. Because there are so many parameters namely coefficient of friction, cone angle, mean radius, blocker angle, etc, affected the synchronizer performance, which the times of experience will increase in a geometrical ratio if tested them one by one, it is almost impossible to evaluate all parameters by experience alone. Due to virtual prototype technology, the synchronizer parameterized virtual models can be built for the synchronizer studies. The parameterized virtual models of the typical synchronizers are developed with ADAMS. Then the gear shift process is simulated and analyzed for the given input parameters respectively. The models also predict the shift time and the peak of the shift force, and the model is validated by the good correlation between simulation results and test data.