Synchronizers Rivoli, May 2007
Why? EFFICIENCY SIMPLICITY DIMENSIONS WHY SYNCHRONIZERS? EASY AUTOMATIC SHIFTING TORQUE COST
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Key Figures TURNOVER: ANNUAL PRODUCTION: 700.000 SYNCHRONIZERS 87 mn MARKETS: TRACTORS FULL DESIGN & TESTING CAPABILITIES RANGE OF SIZES: PASSENGER CARS TRUCKS CONSTRUCTION SPECIAL VEHICLES FROM 62 mm UP TO 135 mm WORLD LEADER FOR TRACTORS APPLICATIONS
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The Products TYPOLOGIES STRUT TYPE S/C D/C T/C PIN TYPE FRICTION MATERIALS: BRONZE MOLY HIGH MOLY LOW SINTERED BRONZE CARBON
The Products CATALOGUE
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Manufacturing PLANTS Noida Plant (Uttar Pradesh) Components, H.T. and assembly Headquarters and Plant Cascine Vica (To) Sliding sleeves Comp. finishing Final assembly Garessio Plant Hubs Clutch body rings I.T.T. Plant Heat Treatments WORLDWIDE INDIAN MARKET
Manufacturing Hub machining PRODUCTION FLOW Sliding sleeve machining Clutch body ring machining H.T. H.T. H.T. finishing finishing finishing Balls Springs poppets Dimensional and functional 100% assembly Test Oiling and packaging customer Friction rings
Manufacturing SLIDING SLEEVE PROCESS FLOW stoppers milling tooth chamfering tooth rulling from broaching to final H.T. fine broaching
Manufacturing ELECTRON BEAM WELDING CLUTCH BODY RING UP TO 15mm WELDING DEPTH GEAR
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Design INPUT DATA FROM CUSTOMER..PLEASE FILL IN THIS DATASHEET: Customer name: Transmission code: Vehicle type: Synchronizer displacement: Speed Range Forward-Reverse Other Axial load on synchronizer slinding sleeve [N] Min: Max: Reflected inertia on synchronizer cone [kgm 2 ] Max Drpm to be synchronized [rpm] Max engine rpm [rpm] Max continuous torque on synchronizer [Nm].....
Design SYNCHRO TIPOLOGY DEFINITION Synchronizer Synchronizer type: type: Application: Application: single single cone cone d.82 d.82 mm mm moly moly 1st/2nd; 1st/2nd; 3rd/4th 3rd/4th Outside cone diam. Mean diam. Cone angle Cone band Cone area Friction Friction material coeff. Total inertia Delta RPM Relative speed Axial force Torque Drag torque Total torque Synchro. time Specific energy Specific power Specific pressure SHIFT [mm] [mm] [deg] [mm] [mm 2 ] [Kgm 2 ] [rpm] [m/s] [N] [Nm] [Nm] [Nm] [sec] [J/mm 2 ] [W/mm 2 ] [N/mm 2 ] I-II 82 81 6,5 8,3 2113 Moly 0,1 0,141 597 2,563 1500 53,66 30 83,66 0,105 0,13 1,24 6,27 II-III 82 81 6,5 8,3 2113 Moly 0,1 0,141 577 2,477 1500 53,66 30 83,66 0,102 0,12 1,20 6,27 III-IV 82 81 6,5 8,3 2113 Moly 0,1 0,141 585 2,512 1500 53,66 30 83,66 0,103 0,125 1,21 6,27 IV-III 82 81 6,5 8,3 2113 Moly 0,1 0,141 827 3,551 1500 53,66-30 23,66 0,516 0,25 0,48 6,27 III-II 82 81 6,5 8,3 2113 Moly 0,1 0,141 810 3,478 1500 53,66-30 23,66 0,505 0,24 0,47 6,27 II-I 82 81 6,5 8,3 2113 Moly 0,1 0,141 851 3,654 1500 53,66-30 23,66 0,531 0,26 0,499 6,27
Design FEM ANALYSIS ON CRITICAL COMPONENTS
Design ITI-SIM SIMULATIONS FOR SHIFTABILITY IMPROVEMENTS DRIVELINE MODEL ANALITICAL RESULTS
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Testing FRICTION COMPONENTS (test (test bench bench picture picture confidential) confidential) COMPARATIVE TESTS ON: FRICTION MATERIALS GEOMETRIES RING-C.B.R. MANUFACTURING PROCESS STICKING SUPPLIERS
Testing COMPLETE SYNCHRONIZER: ENDURANCE TESTS MEASUREMENT OF: SHAFTS SPEED FRICTION COEFF. SYNCHRO. TIME AXIAL LOAD RPM GAP WEAR Speed shaft 2 Speed shaft 1 (test (test bench bench picture picture confidential) confidential) Friction Coefficient Stroke
Testing COMPLETE GEARBOX CLIMATIC CELL FOR LOW TEMPERATURE TESTS (-40 C) (test (test bench bench picture picture confidential) confidential)
Testing COMPLETE GEARBOX Y=20,00 dan X=50,00 mm Y=10,00 dan X=39,58 mm X=32,31mm Punto di arresto asta comando SHIFTABILITY: TRAVEL-LOAD CHART X=24,70 mm Punto di arresto Asta comando Y=10,00 dan X=31,43 mm Y=20,00 dan X=41,34 mm KINEMATIC SHIFTING CHAIN STIFFNESS: LOAD-STRAIN CHART
Testing VEHICLE TESTS NOISE COMFORT SHIFTABILITY
Testing TRUCKS
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New Projects SINGLE CONE D74 FOR CARS AND TRACTORS SAME ASSY DIMENSIONS AS D68 WITH LARGER CONE SELF-QUENCHING SINTER MATERIAL RING INTEGRATED SPRING-BALL-POPPET ACTUATORS (ON PRODUCTION 2005)
New Projects D/C T/C D 90/95/100 TO PREVENT DOUBLE BUMP AND IMROVE SHIFTABILITY Initial Initial geometry geometry (geometries (geometries picture picture confidential) confidential) Final Final geometry geometry (geometries (geometries picture picture confidential) confidential) MODULAR DESIGN LOW MODULE NOT-SYMMETRIC CHAMFERINGS
New Projects MODULAR DESIGN S/C D/C T/C D 105/113/119 FOR HEAVY APPLICATIONS (UNDER DEVELOPMENT STUDY)
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Environment UNI EN ISO 9001:2000 UNI EN ISO 14001: 1996 ISO/TS 16949: 2002
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The Customers AGRICULTURAL MARKET
The Customers CONSTRUCTION, TRUCKS, PASSENGER CARS, SPECIAL VEHICLES
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GRAZIANO TRASMISSIONI S.p.A. Via Cumiana 14 10098 Rivoli (Torino - Italy) T : +39.011.9570.1- F : +39.011.9594803 info@grazianotrasmissioni.it www.grazianotrasmissioni.it www.oerlikon.com