Simulation and analysis of synchronisation and engagement on manual transmission gearbox

Abstract

This paper presents a dynamic simulation and analysis model of the synchroniser, which is mainly used to avoid the abnormal impact during shifting in a Manual Transmission (MT) gearbox. Because the complicated mechanism and random engagement of the synchroniser occur in a short time, it is difficult to realise the synchronisation process by experiment. Using ADAMS(TM), not only the entire shift process but also two minor phase modules, separate from the entire shift process, can all be constructed to realise the synchronised action and random meshing between the sleeve and the clutch gear. After verifying the results from the simulation model, the paper discusses the influence of cone surface abrasion on synchronisation and the random meshing process. The results described here can help to understand the synchronisation process as well as it provides a way for improving two major demands, vehicle operational comfort and the lifespan of the synchroniser in a MT gearbox.