Synchro Shift Feel Tester

Foreword

DYNASPEDE….Your Reliable Technology Partner

- with three decades of First Time Right solutions

News Bulletin from the house of DYNASPEDE

Editorial Note

This newsletter brings in a gist of the test bed technology, concepts adopted and the

broad architecture of Test solutions for Gear Shift Quality Assessment

.

3rd

Edition

Tran

smis

sion

Sys

tem

s

GLANCE

Synchronizers in transmission serve the objective of smooth gear shift and a good

shift feel by reducing the time of synchronization inside the gearbox. Tribological

properties of Syncho-cone is decisive to prevent transmission gears from shocking, reduce noise, gear wearing and ensure shift quality. The test solution for Synchroniser

evaluates friction and lubricating oil properties of synchronizer-rings used in the synchronous meshing mechanism of manual transmissions …Read more

Heavy Commercial Vehicle (HCV) runs under the condition of heavy load

demanding larger torque in the drive train. Study of the gear shift mechanism and the synchronizer as an aggregate in manual transmission of HCV & MPV closely relates to the

shift performance in a vehicle. Gear Shift Quality assessment and durability studies on the gear shift mechanism of the HCV transmission is performed in this test solution ...Read

more.

Shift feel test rig permits performance study of a transaxle gear shifter mechanism

for checking manual gear shift in dynamic conditions observe abnormal noise at different gear positions in a production environment ...Read more.

Static gear shift... the behavior, criteria like shift and select strokes, friction and free

plays, load characteristics are prominent for any shift operation and have a high priority

for functional study. These characteristics are objectified in Static Gear shift test rig for study of manual gear shift ...Read more.

Test bench gear shift actuation for MT and AMT to simulate the vehicle

conditions to ensure the desired performance and deliver a reliable platform for repeated

usage...Read more.

Shift-O-Matic Analyzer from dynaspede is a Gear Shift Quality Assessment system

to examine the characteristic gear shift behavior of an automobile transmission in the pre-synchronizing, synchronizing and double bump zone for real time quality judgments...Read more.

Test Solutions for Gear Shift Mechanism

Other Test solutions for Transmissions...

Automotive Gearboxes/ Transaxles (MT/AMT versions) Commercial Vehicle Driveline Farm Vehicle Transmission (PTO/4WD/Wheel Test) Axle Test Rig (Front/Rear)

For more details, write to [email protected]

mailto:mailto:[email protected]

SYNCHROCONE TEST RIG .....for Passenger cars to Heavy commercial vehicles

Synchronizers in transmission serve the objective of smooth gear shift and a good

shift feel by reducing the time of synchronization inside the gearbox. Tribological

properties of synchro-cone are decisive factors to prevent transmission gears from

shocking, reduce noise, gear wearing and ensure shift quality. The test solution for

synchronizer evaluates friction and lubricating oil properties of synchronizer-rings

used in the synchronous meshing mechanism of manual transmissions.

Test System Mechanics

The system design permits to conduct performance study on synchronizer ring-cone

assembly to evaluate its friction and lubricating oil properties used in the synchro

mesh transmissions.

The rig also enables to predict the service load of

the synchronizer by testing it through varying

field conditions of static & dynamic test.

Ruggedized base frame & Custom built

adapters to mount multiple pairs of test

synchronizer ring - cone combination.

High torque motor and High speed motor in

tandem to accomplish static properties test and slip test

Variable inertia wheels for energy absorption test.

Servo controlled axial thrust mechanism.

Oil bath with level keep & temperature control

Precise Instruments for speed, torque, force, temperature, displacement

Data processing for secular change of coefficient of friction.

PLC and PC based control, interface and data processing.

Transmission version : Manual synchromesh

Synchronizer ring mean diameter : 200 mm

Ring travel : <2mm

Rotation speed for drag & dynamic test : 50 to 2500 rpm by AC motor

Axial force : ≤ 250 Kgs

Inertia for Energy simulation : 0.05 - 0.35 Kgm^2

Additional Inertia : 0.01 - 0.175 Kgm^2

Rotation speed for static test : 5 - 25 rpm by Geared motor

Oil circulation system : Custom built system with level maintenance

Oil Temperature : 125°C ± 5°C (Max) Control system : PC based real time control

Instrumentation : Synchro speed Axial thrust load no ring

Reaction torque on ring Ring wear (through displacement sensor) Oil temperature

Synchro ring temperature

Test modes : High speed slip test Static properties test

Energy absorption test

Graphs : Force vs Time Frictional torque Vs Time

Cone speed Vs Time

Ring displacement Vs Time Coefficient of Friction Vs Time

Technical Data:

For more details and application assistance, contact:

Dynaspede Integrated Systems (P) Limited 136 A, Sipcot Industrial Complex, Hosur – 635 126 (TN), INDIA phones: 04344-276915 / 401100 fax : 04344-400185 email : [email protected]; web : www.dynaspede.com

Bangalore Chennai Delhi Kolkata Lucknow Mumbai Secunderabad Vadodara

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Copyright © 2014 Dynaspede. All rights reserved.


SYNCHRONIZER TEST RIG .....for Passenger cars to Heavy commercial vehicles

Heavy Commercial Vehicle (HCV) runs under the condition of heavy load demanding larger torque in the drive train. Study of the gear shift mechanism and the synchro-

nizer as an aggregate in manual transmission of HCV & MPV closely relates to the shift performance in a vehicle. Gear Shift Quality assessment and durability

studies on the gear shift mechanism of the HCV transmission is performed in this test solution….

The system design permits to conduct Durability & Performance study on the synchro-nizer assembly under accelerated conditions, while it is fitted in the completely assembled

transmissions.

Performance test is intended for the study of effect of moment of inertia, rotational speed difference on the synchronizing force and shift time, whereas in the Durability test the

Transmission gear shift performance with the combined effect of change in coefficient of friction, wear in the synchronizer ring-cone thru sustained usage is studied.

Ruggedized bed plate with fixture on slides

to accommodate multiple variants.

Adjustable speed and variable inertia.

AC motor-drive and fly wheel to induce

vehicle energy

Flywheel at wheel shaft and at input shaft.

for vehicle inertia and Clutch inertia simulation

Robotic gear shift with highly flexible 3 axes control

for repeated shifts for repeated cycles.

Real time controller with dedicated software for control sequencing & data processing.


Technical Data:

Transmission version : Manual synchromesh

Gear shifter : Direct shift, Rod based

Gear shifting : Servo electric Robotic Gear Shift (RGS) or Pneumatic actuated Gear shift

Robotic Gear Shift : Gate selection stroke ± 300 mm Gear shifter stroke ± 200 mm Gear shifter / Gate selection force ± 250 Kg

Drive speed : Up to 5000 rpm for medium energy vehicles Up to 10000 rpm for heavy energy vehicles

Inertia @ wheel shaft end : 10, 20 & 30 kgm^2

Inertia @ clutch shaft end : 0.03 - 0.5 kgm^2 Synchronization time : 0.4 - 3 secs

Control system : PC based real time control Shift-o-matic analyzer for shift force analysis

Instrumentation : Clutch / Wheel shaft speed Gear shift force / Select force Gear shift / Select stroke

Computation : Oil Temperature Disengagement time Neutral time Synchronization time Unblocking time Engagement time Peak Disengagement / Engagement /Synchronization Load Average Synchronization /Average Engagement Load Disengagement / Synchronization Impulse Total Shift Impulse

Test modes : Shift ability test /Durability test

Test graphs : Shift Position vs Time Shift Force vs Time Speed vs Time/Position Gate/Shift Force vs Gate/Shift Position H-Pattern (Shift position vs Gate Position)




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SHIFT FEEL TEST RIG .....for Passenger cars to Heavy commercial vehicles

Gear Shift performance is the most important evaluation index of transmission and

commonly concerned in transmission design and improvement. Shift feel test rig

permits performance study of a transaxle gear shifter mechanism for checking

manual gear shift in dynamic conditions observe abnormal noise at different gear

positions in a production environment.


Ruggedized bed plate for mounting the electro mechanical elements

Common fixture to accommodate multiple models.

AC motor to drive the transaxle from wheel shaft end to simulate coast mode

Vehicle mass simulation through

adjustable inertia wheel

Gear shifting station for manual

gear shifts.

PLC based control system and

dedicated software for real time

control and data acquisition

GEAR SHIFT

STATION

Transaxle : Manual synchromesh

No of variants : 3

Gear shifter : Remote shift, Cable based

Gear shifting : Manual Options: Pneumatic based Robotic based

Drive speed : Upto 1800 rpm by AC motor

Inertia @ Drive shaft end : 10 Kgm^2

Speed @ Transaxle end : 900 rpm

Inertia @ Transaxle end : 40 Kgm^2 for vehicle mass simulation

Oil filling & draining arrangement : Provision provided to accommodate the same

Control system : PC based real time control

Measurements : Clutch shaft speed Wheel shaft speed Oil Temperature

Test modes : Manual Shift in Dynamic Condition Options:

Manual Shift in Static condition Automated Shifting in Static Condition Automated Shifting in Dynamic Condition




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Technical Data:


STATIC SHIFT FEEL TEST RIG .....for Passenger cars to Heavy commercial vehicles


commonly concerned in transmission design and improvement. Static shift test rig

permits performance study of a gear shifter mechanism in static condition for

studying manual gear shift in an H pattern and monitor the force and travel

characteristics of the transmission in a production environment for quality audit.

The behavior, criteria like shift and select strokes, friction and free plays, load characteris-

tics are prominent for any shift operation and have a high priority for functional study.

These characteristics are objectified in this Test solution for study of manual gear shift


The system design permits EOL Study on gear

shifter assembly for its performance validation.

The system mechanics include a portable

mechanical structure, common fixture to

accommodate multiple models, custom built

gear shift lever to suit vehicle shifter, precise

instrumentation and data acquisition system

The displacement and force applied during gear

shift is continuously monitored and acquired

for functional analysis with a specially

structured algorithm running in the back-

ground.

Gear shifterLever assy.

Gear shifterLever

Shifterlinkage

DisplacementSensor

ForceSensor

DisplacementSensor

ForceSensor

GateSelectionlinkage

Interchangeablepush/pull cable

QuickDisconnectAdaptor

Technical Data:

Transaxle : Manual synchromesh

No of variants : 3

Gear shifter : Remote shift, cable based

Gear shifting : Manual

Options: Pneumatic based Robotic based

Shift axis force : Up to 20 Kg

Select axis force : Up to 20 Kg

Shift axis travel distance : Up to 100 mm

Shift axis travel distance : Up to 100 mm

MMI : PC based with shift-o-matic analyzer

Measurements : Shift Axis Force Select Axis Force Shift Axis Displacement

Select Axis Displacement

Graphs : Shift Position Vs Time

Shift Force Vs Time Gate Force Vs Time

Gate Position Vs Time Gate Force Vs Gate Position Shift Force Vs Shift Position

H – Pattern (Shift Position Vs Gate Position)

Test modes : Manual Shift in Static condition

Options: Manual Shift in Dynamic condition

Automated Shifting in Static Condition Automated Shifting in Dynamic Condition




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Gear shifting options for Automated Manual Transmission

In an automated manual transmission (AMT), high performance gearshift system is

desired to achieve short shift time, high efficiency and shift quality.

Dynaspede Gear shift solution caters to both hydraulic and electric actuated AMT

controlled by test bench TCU. The test bench TCU is a high response, real time

control unit which simulates the vehicle TCU to achieve the desired shift quality

The AMT with hydraulic actuated gear shifting

comprises of pump, motor, control valves etc. in built

with the transmission. This hydraulic system

perform the clutch actuation, gear shifts based on the

command it receives from the Controller (TCU)

Dynaspede test system simulates the TCU operation

through a real time controller which eliminates the

need for vehicle TCU. The gear shift & select profiles

are initially taught to the control system that perform

gear shifts as desired

Hydraulic Actuated Shifting

An automated manual transmission (AMT) is an automobile transmission that does not

change gears automatically, but rather facilitates manual gear changes by dispensing with

the need to press a clutch pedal at the same time as changing gears. It uses electronic

sensors, hydraulics, processors and actuators to execute gear shifts on the command of the

controller.

REAL TIME

CONTROLLER

TEST

TRANSMISSION

PUMP & MOTOR

TEST

TRANSMISSION

REAL TIME

CONTROLLER

ELECTRIC

MOTOR

Electric Actuated Shifting

The AMT with electric actuated gear shifting

comprises of electric motor in built with the transmission. This electric motor performs the clutch

actuation, gear shifts based on the command it

receives from the Controller (TCU).

Dynaspede test system simulates the TCU operation

through a real time controller which eliminates the

need for vehicle TCU. The gear shift & select profiles

are initially taught to the control system that

performs gear shifts as desired.

Gear shifting options for Automated Manual Transmission

Clutch Actuator for AMT Transmission

The clutch pedal characteristic in AMT similar to the gear engage load characteristic and

functional behaviour such as the engagement and disengagement stroke needs to be assessed and analyzed in parallel with the Gear Shift Assessment system.

Dynaspede solution for clutch actuation caters to both hydraulic and electrically actuated

AMTs by means of a precisely controlled test bench TCU, which in combination with the gear shift & select actuators facilitates the sequenced automatic gear shifting.

GEAR SHIFT MECHANISM FOR MANUAL TRANSMISSION .....for Passenger cars to Heavy commercial vehicles


is commonly concerned in transmission design and improvement.

Gear shifting solution for the transmission testing from Dynaspede for the produc-

tion and R&D environment are available for both manual and Automated Manual

Transmissions. The gear shift mechanisms simulate the vehicle conditions to ensure

the desired performance and deliver a reliable platform for repeated usage.

Test bench Gear shift options for Manual Transmission

Gear shift mechanisms for manual transmission are available in rod shift for direct and

cable shift for remote operation. The design and manufacturing technologies of the

mechanism combines performance with reliability and ensures optimal free-play, maximum

stiffness for a quick response and repetitive gear shift.

Test

Transmission

Gear Shift

Lever (Rod)

Gear Shift

Cables

The cable shifter assembly is with shift cables for

select & shift co-ordinates, shifter rod, linkages,

mechanicals built for repeated gear shifts. This unit

is flexible to locate at a remote location with easy

access to the operator for EOL tests in the produc-

tion environment.

The gear shift can be operated manually or

automated per test transmission pattern.

Cable Shifter

The rod shifting mechanism is a direct shifter with

custom built interface to suit the transmission. This

shift lever is flexible to travel in the select and shift

co-ordinates and is directly mounted on the transmis-

sion to perform the gear shifts. This unit is suitable for

the EOL tests as well as durability test.

The gear shift can be operated manually or automated

per test transmission pattern.

Rod Shifter

Custom built

Shift Rod

Robotic Gear Shifter is a highly flexible actuation system for

gear shifts used for automation of power train test benches.

The robotic shifter consists of servo motors, motion control-

ler, drive systems, Force and displacement sensors. Besides,

it includes core Control system with two closed loop position

and force controlled servo system for moving a shift lever

through a transmission shift position.

Servo Actuated Robotic Gear Shift system

The pneumatic actuated automatic gear shift system

is a compact version for gear shifts used in automa-

tion of power train test benches. It consists of

pneumatic cylinder, stroke adjustment linkages, force

and displacement sensors. Sequence of selecting and

shifting of gears shall be as per the preset sequence

from the control system.

Pneumatic Actuated Automatic Gear Shift system

SHIFT-O-MATIC Analyzer from Dynaspede is a Gear

Shift Quality Assessment system to examine the

characteristic gear shift behavior of an automotive

transmission in the pre-synchronizing, synchronizing

and double bump zone for real time quality

judgments.

PLOTS:

Shift Position Vs Time

Shift Force Vs Time

Gate Force Vs Time

Gate Position Vs Time

Gate Force Vs Gate Position

Shift Force Vs Shift Position

H – Pattern (Shift Position Vs Gate Position)

Shift - O - Matic Analyzer

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Synchro Shift Feel Tester

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