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Gearshift Systems and Synchronizati On: at The Threshold of Mechatronics
Gearshift Systems and Synchronizati On: at The Threshold of Mechatronics
Gearshift Systems and Synchronizati On: at The Threshold of Mechatronics
duction Cost reducon Gear detecon the cover reverse gear detecon selector shaft and the
housing must be ma-
Magnet cover chined for assembling
Along with the electri- of components. Due to
fied drive train, con- Selecng
Shiing detent pin many work steps and
ventional combustion
technology with manu-
detent pin
Housing
partly very big and
therefore expensive 5
al and automated man- components unneces-
ual transmissions still sary costs are being
Sensor unit Reverse lights
will play an important generated.
switch
role in the future. This
An integrated solution,
is thanks to the low
that substitutes all
system costs, high effi-
ADD-ON components,
ciency and robustness
Space opmizaon, Gear actuaon is limited to only one
of manual transmis- Cam for R-switch
Length opmizaon AMT, DCT installation location,
sions.
and is more economi-
In addition, new re- Figure 2 A conventional ADD-ON sensor system of first generation cal to install, is more ef-
quirements are being Figure 1 New requirements for manual transmissions fective. INA has devel-
placed on manual the magnet has to be designed very large. For pro- oped a new sensor system for neutral gear
transmissions in conjunction with hybridization, Friction pad system (FPS) for synchronization tection against damage, contamination and for as- detection – the sensor detent pin (Figure 3). The
stop-start systems and automation (AMT, DCT) systems sembling process a magnet housing is essential. basic idea involves fitting a sensor for measuring
(Figure 1): stroke onto the shifting detent pin already mount-
Clutch bodies for synchronization systems More often than not a reverse lights switch is still
ed in the gearshift system that is actuated during
Neutral detection and gear detection required, which is activated by a cam.
Gearshift sleeves for synchronization systems gearshift operations.
Gear actuating elements manufactured by forming A conventional ADD-ON sensor system of first gen-
eration therefore consists of several individual The characteristic of the shifting cam profile
Reducing weight and costs
Optimizing space and length components that are placed in three different loca- shows that the detent stroke along the neutral
Optimizing space and length
Flat struts for synchronization systems
Gear shift transmission
requirements
INA offers suitable innovative solutions for these
Neutral detection
new requirements:
and gear detection
Neutral detection and gear detection
Sensor detent pin as neutral
Sensor detent pin as neutral gear sensor
gear sensor
Sensor bearing with position detection and
detent function In combination with manual transmissions, stop-
start systems and mild hybrids require new func-
Gear actuating elements tions in gearshift systems such as reliable detection
of neutral gear.
Integrated hydraulic gearshift fork actuator
The neutral detection of first generation often con-
sists of an ADD-ON sensor and a separate Magnet
Reducing weight and costs as the target. The sensor in most applications is lo- Components necessary for INA sensor detent pin
cated on the transmission housing, and the mag- ADD-ON neutral and
Gearshift forks for gear shift transmissions reverse gear detecon
net is mounted on the selector shaft. Due to the
Plastic housing for gearshift systems distance to the sensor and the long selecting stroke Figure 3 INA sensor detent pin – integration of single components in one unit
Same level all R-gear output via the same connector designed accord- nents, various fixing elements and manufactur-
forward gears level ing to customer requirements and is usually ing operations can be omitted. This results in
equipped with three contacts. lower system costs in comparison to a conven-
tional ADD-ON sensor system (Figure 2). Volume
Both analog and digital signal can be provided
production of the sensor detent pin will begin in
by the sensor. In the case of digital signals, a
2010 and it will be available for stop-start appli-
Shi moment
in Nm
pulse width modulation signal (PWM) is very
cations.
common. If redundancy is required, the elec-
Neutral
groove
Same level all
forward gears
tronic system can be equipped with two sepa-
rate Hall effect sensors and two separate signal
Sensor bearing with 5
: Shiing = rotaon
paths with their own signal output pins in the position detection and
connector.
= detent stroke
: Selecng = translaon
Shi
angle in ° detent function
In order to create customer-specific require-
= no detent stroke Along with the basic gearshift actuation function,
ments for shifting and selection forces, the
Shi moment
in Nm
the gearshift forks in current AMTs and DCTs have
Figure 4 Detent cam profile for INA sensor detent pin mode of operation of the shifting and selection
additional components and functions:
detent pins has been combined. In this way the
groove does not change so that the signal re- required shift moment characteristic is fulfilled Bearing support (usually with a ball bearing in
mains constant (Figure 4). The sensor uses this (Figure 6). Here, the shift moment in neutral is transmission housing)
fact to detect neutral gear within the whole se- only defined by the sensor detent pin. Thus, the
Shi Detent cam profile
lecting alley. Two additional levels “same level sensor detent pin positions the selector shaft in angle in °
all forward gears” and “R-gear level” are clearly neutral and also detects this position, which is Components for position detection (Figure 7)
defined and can therefore be detected by the the optimum regarding tolerances. Superposion = requirement
sensor. Integrating these functions enables saving of
Figure 5 shows the setup and function of the INA
Conclusion Figure 6 Fulfilling customer requirements in terms of
shift moment space, costs and reducing of assembly outlay.
sensor detent pin. The detent stroke is trans- The sensor detent pin essentially comprises two
ferred to the magnet on the linkage pin that is components – a detent pin and a sensor unit.
guided in the sensor. The sensor measures the Both components are based on proven technolo-
stroke of the magnet during the gearshift prog- gies and represent a highly-integrated solution
ress and generates a defined signal. The sensor for detection of neutral gear and reverse gear. Sensor
unit is supplied with current and the signal is This solution means that some single compo-
Magnet pair
Signal
Connector in %PWM Detent pin Housing
Sensor, board
Magnet
Linkage pin
Signal
Ball bearing
Detent stroke detent stroke in mm
Neutral groove
Housing
Shi rotaon Shi rotaion in °
Figure 5 Setup and signal output of INA sensor detent pin Figure 7 A typical gearshift fork design with bearing supports, detent cam profile and magnet retaining element
Figure 8 Sensor bearing: Bearing with integrated position sensor and detent function Gear actuating
In conjunction with Continental, INA is developing The INA sensor bearing is designed as an integrat-
elements
a sensor bearing with detent function that per- ed solution for DCTs and AMTs. This saves space Sensor bearing module
forms the additional functions and is designed as a inside the transmission and enables several, Integrated hydraulic
module (Figure 8). sometimes costly, operations and components to
be omitted that are necessary for conventional
gearshift fork actuator
The sensor bearing with position detection and
solutions: Several transmission manufacturers are currently
detent function (Figure 9) comprises a sleeve –
developing a series of double clutch transmissions
bearing raceway, sensor housing – shift travel Detent pin and housing bore
(DCT), which are mostly hydraulic operated. Two
measuring system and an inserted detent spring.
Magnet with retaining element and cover different hydraulic systems are used:
In conjunction with a detent cam profile at the
end of the shift shaft, the spring performs the Sensor carrier ADD-ON power pack as a separate hydraulic
detent function. The four pairs of ball rollers are Transmission system
Various assembly operations housing
arranged at 90° angles to each other and are
ADD-ON gearshift fork actuators integrated into
guided in the pockets of the sensor housing. The
However, the level of integration can be increased the transmission housing wall
sensor housing supports the sensor circuit board
even further. Four sensor bearings can be com-
and contains an integrated connector with the The space available for the gearshift forks is severe-
bined to create a sensor bearing module (Fig-
pins for supplying current and for signal output. ly limited in a DCT due to the double clutch. It is
ure 10).
The connector can be positioned either inside or therefore advisable to use gearshift forks movable
outside the transmission. As an output signal a The four sensor bearing units and the base plate on a fixed shaft. They are not moving inside the
digital or analog signal can be used. then form a common housing with a common housing bores during actuation and therefore re-
Inside quire less axial length. In addition, two gearshift
Figure 10 Integration of four sensor bearings in one
forks can be mounted on a common fixed shaft
module since they can be actuated independently of each
Sensor / board Transmission other.
housing INA has developed a gearshift fork actuator espe-
electronic unit. The common connector that re-
Connector cially for DCTs that is integrated into the gearshift
places four individual connectors is located on the
4x2 Ball caster fork, and in comparison with the systems men-
outside in the illustrated example. It can also be
tioned above, it is a cost-efficient alternative with
Sensor housing used as a direct interface to the control unit on
optimized length (Figure 11).
/ bearing cage Shi stroke
the inside of the transmission. It can be mounted
in the transmission in accordance with the cus- One or two gearshift forks on one shaft are advis-
tomer’s requirements. able, depending on the design of the transmission.
Detent spring Here, the focus is either on minimizing the number
Shi sha The sensor module offers additional benefits to
of shafts or simplifying the oil supply. The INA inte-
those of the sensor bearing solution already men-
Cam profile grated gearshift fork actuator represents a new in-
Bearing sleeve tioned:
tegration level for hydraulic actuating elements for
Figure 9 INA sensor bearing: Setup Only one common connector DCTs.
Oil supply Seals Bearing Cylinder Fixed piston Housing Thin sheet metal design Steel-aluminum design
Sha
Shi fork
Shi stroke
and costs Thin sheet metal gearshift forks (Figure 13) are de-
signed for relatively low overload gearshift forces
and achieve precision requirements due to the low
distortion of laser welding. The injection molded
tion of that new technology gearshift forks will
begin 2010.
contact pads form the interface to the gearshift
Gearshift forks sleeve.
Automated manual transmissions usually re-
quire the gearshift fork and shift rod to be de-
for gear shift transmissions High accuracy Gearshift forks in “pot” design (Figure 13) are signed as one fixed assembly. The shift actuator
suitable for higher loads, which means the rele- system is usually located in the housing of the
In gear shift transmissions, gearshift forks transfer
Low weight Space saving vant welding methods such as MAG and TIG are transmission so that the shift rod ends are actu-
the gearshift motion to the gearshift sleeve. The
required. The required accuracy is achieved by ated. Due to the extremely short design of the
gearshift motion is usually introduced via the strik-
reworking the parts by machining and/or pairing DCT, the axial space available for the gearshift
er jaw and transferred to the rotating gearshift
of contact pads. The contact pads are joined to forks is extremely limited, which often requires a
sleeve through the contact pads.
the gearshift forks using ultrasonic welding. flat punched thick sheet metal gearshift fork
The varied requirements placed on the design of (Figure 13). The method of fixing the gearshift
Steel-aluminum gearshift forks (Figure 13) com-
current gearshift forks can be summarized in cer- fork to the shift rod must be selected according
prising a die cast gearshift fork and a flat, preci-
tain focal points (Figure 12). to the application.
sion punched striker jaw are suitable for certain
In order to meet these requirements, INA uses package spaces. Two self-tapping screws secure All gearshift technologies can be supported by
various technologies depending on customer the striker jaw to the fork with a friction fit. This both sliding and rolling contact, which must be
specifications and the space available. These Low cost cost-efficient joining method enables the toler- defined in accordance with the requirements of
High loads
technologies are thin sheet metal forming, alumi- ances to be compensated due to the precise po- each individual case. INA’s portfolio of gearshift
num die casting, thick sheet metal forming and sitioning of the striker jaw during screwing pro- forks offers the adequate gearshift fork technol-
High sffness
thick sheet metal fine blanking. Depending on the cess. This makes the complex reworking by ogy for each customer requirement.
technology of the individual parts, different join- machining required for costly die cast steel in-
ing methods are used such as MAG, TIG and laser Figure 12 Requirements of gearshift forks sert components unnecessary. Volume produc-
Firicon coefficient μ
FPS FPS Cost-efficient tech-
nology optimized for
Carbon Carbon large-scale volume
production
Similar performance 5
compared with clutch
Shi cylces (lifeme) Synchronizaon me bodies manufac-
tured by machining
INA clutch bodies can
be flexibly adapted to
meet customer re-
Wear Cost Figure 19 Clutch body in a synchronization package quirements and can be
provided with addi-
up to comparably high costs. Sintered clutch bodies tional functional surfaces. Along with a lower
- 30 %
have higher friction and a little less mechanical piece price they have high surface quality and low
Axial wear
Carbon
Cost
load carrying capacity due to the sintered mate- deviations in actual dimensions thanks to the
rial. The surfaces of the teeth manufactured forming technology, which is oriented on the
FPS
with both technologies are not optimized to the mass market.
function.
Flate stripe and length sign and, compared with manual transmissions,
have a significantly higher gearshift frequency. It
mounting. INA ball struts are characterized by sim-
ple mounting due to the single-piece design, no
bores in the selector hub and the low price.
is for this reason that modern struts must meet
Flat struts for the following requirements: The transmission can be shortened due to the
shallow design of the INA flat strut (Figure 25)
synchronization systems • Modular one-piece design since it shortens the distance between two gear
Ring forming
and joining wheels. The low overall height is achieved by uti-
Axially movable struts are used for presynchroni- • Low overall height
lizing the space under the profile for the length
zation in shift transmissions (Figure 24). The con-
• Short axial length (distance between two gear of the spring.
tact head (often a ball) is preloaded against a
wheels)
slot in the gearshift sleeve and centers the gear- INA has developed the so-called “strut-in-sleeve”
Figure 22 Manufacturing the body shift sleeve in neutral. During the initiation of • Contribute to reducing system costs design (Figure 26). This arrangement facilitates fur-
33,4
5
31,5
selector hub
crical
cross-secon
Figure 27 Minimizing stresses in the critical cross-
section