synchro shift feel tester
DESCRIPTION
Synchro Shift Feel TesterTRANSCRIPT
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]
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
...Back
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.
Test System Mechanics
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)
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
...Back
Copyright © 2014 Dynaspede. All rights reserved.
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.
Test System Mechanics
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
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
...Back
Copyright © 2014 Dynaspede. All rights reserved.
Technical Data:
STATIC 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. 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
Test System Mechanics
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
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
...Back
Copyright © 2014 Dynaspede. All rights reserved.
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
Gear Shift performance is the most important evaluation index of transmission and
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
...Back