GEAR SYNCHRONIZER FOR POWER TRANSMISSION

Abstract: In a gear synchronizer, a clutch sleeve (12) has internal splines in continual engagement with external splines of a hub member (11) fixed to a shaft (21) and is axially shiftable to be engaged at its internal splines with external splines of a spline piece (24) integral with a gear member (22) rotatable on the shaft. The gear synchronizer includes a support ring (13) encircling the spline piece and having a radial projection (13a) axially movable in a corresponding radial recess (24b) in the spline piece (24), a first synchronizer ring (14) coupled with the support ring and having an external conical surface (14a) for frictional engagement with an internal conical surface (12c) formed on one side of the clutch sleeve, a second synchronizer ring (15) axially movably coupled with the first synchronizer ring for relative rotation and coupled with the support ring for rotation therewith and having an internal conical surface (15a) for frictional engagement with an external conical surface (12d) formed on the one side of the clutch sleeve, and an annular waved spring (16) disposed between the synchronizer rings. In shifting operation, the second synchronizer ring (15) is brought into frictional engagement with the external conical surface (12d) of the clutch sleeve against the waved spring (16) after frictional engagement of the first synchronizer ring with the internal conical surface (12c) of the clutch sleeve.

Description: The present invention relates to a gear synchronizer for power transmissions, and more particularly, but not exclusively, to a gear synchronizer of the type which comprises a gear member rotatable on a transmission shaft, a spline piece formed thereon with external splines and provided on a hub portion of the gear member for rotation therewith, a hub member formed thereon with external splines and mounted on the transmission shaft for rotation therewith, a clutch sleeve encircling the hub member and having an internal conical portion formed at one side thereof and internal splines in continual engagement with the external splines of the hub member, the clutch sleeve being axially shiftable toward and away from the gear member to be engaged at the internal splines thereof with the external splines of the spline piece, and a synchronizer ring encircling the spline piece and having a radial projection axially movable in a corresponding recess formed in the spline piece and an external conical surface for frictional engagement with the conical portion of the clutch sleeve, the synchronizer ring being loaded radially outwardly by means of a spring to be retained in a neutral position where it is disengaged from the conical portion of the clutch sleeve. In Japanese Patent Publication No. 51-48540, there has been proposed such a gear synchronizer as described above, wherein the external conical surface of the synchronizer ring can be formed larger in diameter than internal conical surface of a synchronizer ring in a conventional synchronizer of the Borg-Warner type. In operation of the gear synchronizer, the synchronizer ring acts to effect relatively large synchronous action or capacity in comparison with the synchronizer of the Borg-Warner type. In the case that the gear synchronizer is designed to obtain the same synchronous capacity as that of the Borg-Warner type synchronizer, the synchronizer ring can be constructed small in size to reduce an axial displacement amount of the clutch sleeve in shifting operation in order to minimize the shift stroke of a manual shift lever. In the case that the shift stroke of the manual shift lever is determined in the same amount as that in the Borg-Warner type synchronizer, the lever ratio of the manual shift lever can be increased to reduce the operator's effort applied to the shift lever for shifting the clutch sleeve. A primary object of the present invention is to provide an improved gear synchronizer capable of further increasing the synchronous capacity of the synchronizer described above. US-A-3,175,412 describes a gear synchronizer having the features of the preamble of Claim 1. The invention provides a gear synchronizer which includes the features of the characterizing clause of Claim 1. For a better understanding of the present invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Fig. 1 illustrates in cross-sectional form one of the circumferentially equi-spaced parts of a gear synchronizer according to the present invention; Fig. 2 is a cross-sectional view of a support ring shown in Fig. 1; Fig. 3 is a front view of the support ring shown in Fig. 2; Fig. 4 is an enlarged cross-sectional view of a portion of the support ring shown in Fig 2; Fig. 5 is a cross-sectional view of a first synchronizer ring shown in Fig. 1; Fig. 6 is a front view of the first synchronizer ring shown in Fig. 5; Fig. 7 is an enlarged cross-sectional view of a portion of the first synchronizer ring shown in Fig. 5; Fig. 8 is a sectional view illustrating a cam mechanism of the first synchronizer ring; Fig. 9 is a cross-sectional view of a second synchronizer ring coupled with the first synchronizer ring shown in Figs. 5-7; Fig. 10 is a rear view of the second synchronizer ring shown in Fig. 9; Fig. 11 is an enlarged cross-sectional view of a portion of the second synchronizer ring shown in Fig. 9; Fig. 12 is a front view of a ring-shaped thrust spring shown in Fig. 1; Fig. 13 is a front view of a spline piece shown in Fig. 1; Fig. 14 illustrates the mode of shifting operation of the gear synchronizer assembly, showing the relative positions of the components thereof; Fig. 15 is a sectional side view of a support spring coupled within a corresponding radial recess formed in the spline piece as shown in Fig. 1; Fig. 16 is a front view of the support spring shown in Fig. 15; and Fig. 17 is a bottom view of the support spring shown in Fig. 15. Referring now to the drawings, wherein like reference numerals represents the same or corresponding parts throughout the figures, there is illustrated, in Fig. 1, a transmission shaft 21 on which are rotatably supported a pair of axially spaced change-speed gears 22 and 23. Disposed between the change-speed gears 22 and 23 is a pair of synchronizer assemblies 10 which are operable to cause selective speed synchronization between the shaft 21 and the gears 22 and 23, respectively. The synchronizer assemblies have a common hub assembly which includes a hub member 11 fixed to the transmission shaft 21 by means of a spline connection to rotate therewith. The synchronizer assemblies are arranged to be operated through a clutch sleeve 12 which is connected by a yoke groove 12e to a conventional manual shift mechanism (not shown). The hub member 1L is formed thereon with external splines 11a. The clutch sleeve 12 is arranged in surrounding relationship with the hub member 11 and has an annular body portion 12a which is formed with internal splines 12b in continual engagement with the external splines 11a of hub member 11. The clutch sleeve 12 is axially shiftable to be engaged at its internal splines 12b with external splines 24a of a spline piece 24. The spline piece 24 is fixedly mounted on each hub portion of change-speed gears 22 and 23 for rotation therewith. In this embodiment, the clutch sleeve 12 has an outer cylindrical flange formed at its inner periphery with a pair of first internal conical surfaces 12c and an inner cylindrical flange formed thereon with a pair of second external conical surfaces 12d. The outer cylindrical flange of clutch sleeve 12 is further formed thereon with a reverse gear 12f. The right-hand synchronizer assembly is substantially the same as the left-hand synchronizer assembly such that a detailed description of the left-hand synchronizer assembly only is believed necessary. The left-hand synchronizer assembly includes a support ring 13 arranged in surrounding relationship with the spline piece 24, a first synchronizer ring 14 coupled with the support ring 13, a second synchronizer ring 15 coupled with the first synchronizer ring 14, an annular waved spring 16 disposed between the synchronizer rings 14 and 15, a plurality of circumferentially equally spaced support springs 17 contained within corresponding radial recesses 24b formed in the spline piece 24, and a ring-shaped thrust spring 18 retained in place by engagement with an inner periphery of the outer cylindrical flange of clutch sleeve 12. As shown in Figs. 2 to 4, the support ring 13 is integrally formed at its inner periphery with three circumferentially equally spaced radial projections 13a and at its outer periphery with six circumferentially equally spaced radial recesses 13b and an annular projection 13c. The radial projections 13a are each formed with first and second engagement portions 13a₁ and 13a₂. The radial recesses 13b each open radially outwardly. As shown in Figs. 5 to 7, the first synchronizer ring 14 is formed thereon with an external conical surface 14a and at its inner periphery with an annular groove 14b and a plurality of circumferentially equally spaced cam grooves 14c. As shown in Fig. 8, the cam grooves 14c each are in the form of a V-groove having a pair of inclined cam surfaces. As shown in Figs. 9 to 11, the second synchronizer ring 15 is formed at its inner periphery with an internal conical surface 15a and six circumferentially equally spaced radial projections 15b and at its outer periphery with an annular groove 15d. The second synchronizer ring 15 is formed at its one side with a plurality of circumferentially equally spaced cam projections 15c. In a condition where the second synchronizer ring 15 has been coupled with the first synchronizer ring 14 as shown in Fig 1, the cam projections 15c of the former ring 15 are engaged with the cam grooves 14c of the latter ring 14. Disposed within an annular space between the grooves 14b and 15d of respective rings 14 and 15 is an annular waved spring 16 which acts to position the synchronizer rings 14 and 15 is an axial direction. As shown in Fig. 8, the cam projections 15c of ring 15 are each formed with a semicircular cam surface which is in contact with the inclined cam surfaces of the corresponding cam groove 14c under the load of wave spring 16. When relative rotation of the synchronizer rings 14 and 15 is caused by shifting operation of the clutch sleeve 12, the cam projections 15c of ring 15 cooperates with the cam grooves 14c of ring 14 to effect relative displacement of rings 14 and 15 in an axial direction against the biasing force of wave spring 16. When the synchronizer rings 14 and 15 have been coupled with the support ring 13 after coupled with each other, the inner circumference of synchronizer ring 14 is engaged with the annular projection 13c of support ring 13, and the radial projections 15b of synchronizer ring 15 are engaged with the radial recesses 13b of support ring 13 as shown in Fig. 1. In such a condition, the first synchronizer ring 14 is fixed to the support ring 13 by means of a snap ring 19 coupled thereto, while the second synchronizer ring 15 is positioned to be axially movable against the biasing force of waved spring 16. When the support ring 13 has been arranged in surrounding relationship with the spline piece 24 as shown in Fig. 1, the external conical surface 14a of synchronizer ring 14 is arranged to be frictionally engaged with the first internal conical surface 12c of clutch sleeve 12, while the internal conical surface 15a of synchronizer ring 15 is arranged to be frictionally engaged with the second external conical surface 12d of clutch sleeve 12. As shown in Fig. 12, the ring-shaped thrust spring 18 has large and small diameter portions 18a and 18b alternately formed thereon. In a condition where the thrust spring 18 has been retained in place by engagement with an annular stepped portion 12g of clutch sleeve 12 as shown in Fig. 1, the small diameter portions 18b of spring 18 are arranged to be engaged with an inner end of synchronizer ring 14. As shown in Figs. 13 and 14, the spline piece 24 has three sets of circumferentially spaced external splines 24a engageable with the internal splines 12b of clutch sleeve 12. The radial recesses 24b are each formed between the external splines 24a and defined by a pair of external end splines 24c to contain the support springs 17 therein. As shown in Figs. 15 to 17, the support springs 17 are each integrally formed with a pair of legs 17a, a leaf spring part 17b, a recessed part 17c and a head part 17d. The support springs 17 are each retained in place at its legs 17a by engagement with the bottom part of the corresponding radial recess 24b in such a manner that the respective recessed parts 17c of support springs 17 are resiliently engaged with the radial projections 13a of support ring 13 and that the respective head parts 17d of support springs 17 extend radially outwardly from the inner circumference of internal splines 12b of clutch sleeve 12. Thus, the support springs 17 act to resiliently receive the support ring 13 thereon and to restrict axial displacement of the support ring 13. In such a condition, as shown in (a) of Fig. 14, the radial projections 13a of support ring 13 are each positioned between the pair of end splines 24c to be rotated relatively to the spline piece 24 in a predetermined extent (L₁-L₂). When the support ring 13 is rotated relatively to the spline piece 24 as shown in (b) of Fig. 14, a chamfer 13a₃ of radial projection 13a is opposed to a corresponding chamfer 24c₁ of end spline 24c. Assuming that the clutch sleeve 12 is shifted to the left by the operator to engage the change-speed gear 22 to the transmission shaft 21, the thrust spring 18 will move with the clutch sleeve 12 to abut against and urge the first synchronizer ring 14 to the left which will cause slight relative rotation between the support ring 13 and the spline piece 24. At this initial stage, as shown in (b) of Fig. 14, the radial projections 13a of support ring 13 are engaged with the end splines 24c of spline piece 24 and further engaged at their chamfers 13a₃ with the chamfers 24c₁ of end splines 24c as shown in (c) of Fig. 14. Subsequently, the first internal conical surface 12c of clutch sleeve 12 is brought into frictional engagement with external conical surface 14a of synchronizer ring 14 to cause relative rotation between the synchronizer rings 14 and 15. As a result, the cam projections 15c of ring 15 cooperates with the cam grooves 14c of ring 14 to effect relative axial displacement of rings 14 and 15 against the biasing force of waved spring 16. This causes frictional engagement of the internal conical surface 15a of synchronizer ring 15 with the second external conical surface 12d of clutch sleeve 12. Under this condition, the operator's effort applied to clutch sleeve 12 is transmitted as a synchronous torque to the support ring 13 from the synchronizer ring 14 through second synchronizer ring 15 and is further transmitted as a synchronous torque directly to the support ring 13 from the second synchronizer ring 15. When the thrust pressure acting on support ring 13 exceeds a predetermined value, synchronism between the relatively rotating parts is established, and the radial projections 13a of support ring 13 ride over the support springs 17 thereby compressing them radially inwardly, as shown in (d) of Fig. 14. Thus, the internal splines 12b of clutch sleeve 12 will be brought into engagement with the external splines 24a of spline piece 24 to accomplish the synchronization. Immediately after the synchronization has been accomplished, the waved spring 16 acts to disengage the second synchronizer ring 15 from the second conical surface 12d of clutch sleeve 12. Under such a condition, the respective head parts 17d of support springs 17 are compressed radially inwardly by engagement with the internal splines 12b of clutch sleeve 12 to disengage the support springs 17 from the support ring 13 and to retain the clutch sleeve 12 in its shifted position. When the clutch sleeve 12 is returned rightwards to the neutral position, the support springs 17 are disengaged from the internal splines 12b of clutch sleeve 12 and engaged with the support ring 13 to thrust it toward the neutral position. Thus, the synchronizer rings 14 and 15 are smoothly returned to and retained in the neutral position under the biasing force of support springs 17.

Claims: 1. A gear synchronizer including a gear member (22) rotatable on a transmission shaft (21); a spline piece (24) formed thereon with external splines (24a), and disposed at a hub portion of said gear member for rotation therewith; a hub member (11) formed thereon with external splines (11a) and mounted on said transmission shaft for rotation therewith; a clutch sleeve (12) encircling said hub member and having internal splines (12b) in continual engagement with the external splines (11a) of said hub member, said clutch sleeve being axially shiftable toward and away from said gear member to be engaged at the internal splines thereof with the external splines of said spline piece; a first synchronizer ring (14) having an external conical surface (14a) for frictional engagement with an internal conical surface (12c) formed on one side of said clutch sleeve (12); a second synchronizer ring (15) carried by the first synchronizer ring; and support means (17) for resiliently supporting the synchronizer ring assembly with respect to the gear member, characterized in that the gear synchronizer comprises: a support ring (13) encircling said spline piece (24) and having a radial projection (13a) formed at an inner periphery thereof and disposed axially movably in a corresponding radial recess (24b) formed in said spline piece, said support means (17) being disposed in the radial recess (24b) of said spline piece (24) to resiliently receive the radial projection (13a) of said support ring (13) thereon, said first synchronizer ring (14) being coupled with said support ring (13) and said second synchronizer ring (15) being disposed between said support ring (13) and said first synchronizer ring (14) and being axially movably coupled with said first synchronizer ring for relative rotation and axially movably coupled with said support ring for rotation,therewith, with said second synchronizer ring (15) having an internal conical surface (15a) for frictional engagement with an external conical surface (12d) formed on the one side of said clutch sleeve; resilient means (16) disposed between said first and second synchronizer rings (14, 15) to bias said first synchronizer ring for engagement with said support ring (13) and to bias said second synchronizer ring for engagement with said first synchronizer ring; and cam means (14c, 15c) arranged to effect relative axial displacement of said synchronizer rings (14, 15) against the biasing force of said resilient means (16) in response to relative rotation between said synchronizer rings. 2. A gear synchronizer as claimed in Claim 1, wherein said clutch sleeve (12) has an outer cylindrical flange formed at an inner periphery thereof with the internal conical surface (12c) for frictional engagement with the external conical surface (14a) of said first synchronizer ring (14) and an inner cylindrical flange formed thereon with the external conical surface (12d) for frictional engagement with the internal conical surface (15a) of said second synchronizer ring (15). 3. A gear synchronizer as claimed in Claim 1, wherein said support ring (13) is formed at an outer periphery thereof with a plurality of circumferentially spaced radial recesses (13b), and said second synchronizer ring (15) is formed at an inner periphery thereof with a plurality of circumferentially spaced radial projections (15b) which are engaged with the radial recesses (13b) of said support ring (13) in such a manner as to permit axial movement of said second synchronizer ring (15) toward and away from said clutch sleeve (12). 4. A gear synchronizer as claimed in Claim 1, wherein said first synchronizer ring (14) is formed at an inner periphery thereof with an annular groove (14b), and said second synchronizer ring (15) is formed at an outer periphery thereof with an annular groove (15d) which corresponds with the annular groove (14b) of said first synchronizer ring to form an annular space therebetween, and wherein said resilient means (16) is in the form of an annular waved spring disposed within the annular space between said first and second synchronizer rings. 5. A gear synchronizer ring as claimed in Claim 1, further comprising a ring-shaped thrust spring (18) retained in place by engagement with an annular stepped portion (12g) formed on the one side of said clutch sleeve (12), said thrust spring being formed to be engaged with an inner end of said first synchronizer ring (14) in shifting operation of said clutch sleeve (12) toward said first synchronizer ring. 6. A gear synchronizer as claimed in Claim 1, wherein said cam means comprises a plurality of circumferentially spaced cam grooves (14c) formed in an inner periphery of said first synchronizer ring (14), and a plurality of circumferentially spaced cam projections (15c) formed on one side of said second synchronizer ring (15) which are engaged with the cam grooves (14c) of said first synchronizer ring under the biasing force of said resilient means (16). 7. A gear synchronizer as claimed in Claim 1, wherein said support means is in the form of a support spring (17) contained within the radial recess (24b) of said spline piece (24) to resiliently receive the radial projection (13a) of said support ring (13) thereon. 8. A gear synchronizer as claimed in Claim 7, wherein said support spring (17) is integrally formed with a pair of legs (17a), a leaf spring part (17b), a recessed part (17c) and a head part (17d), the legs (17a) of said support spring being retained in place by engagement with a bottom part of said radial recess (24b) off said spline piece (24) in such a manner that the recessed part (17c) of said support spring is resiliently engaged with the radial projection (13a) of said support ring (13) and that the head part (17d) of said support spring is positioned to be compressed radially inwardly by engagement with the inner circumference of the internal splines (12b) of said clutch sleeve (12) in shifting operation of said clutch sleeve.

Inventors: INUI, MASAKI
Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA
Application year: 1988
Main classification: F16H3
IPC codes: F16D23, F16H63, F16H3