Shiftability and GSA introduction

Date

Customers of GSA (Chinese Market) GSA

Shiftability attribution
Shiftability

Subjective Assessment Defined manoeuvers

Objective Assessment Measurements, e.g. of force travel dimensions

Ratings

Subjective assessment matters ! There is a relationship between subjective and objective assessment. Objective measurements can be used to explain subjective phenomena, and to systematically improve the attribute.
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Subjective assessment
Typical drive maneuvers:
assess in varying ambient conditions, e.g. hot vs cold temperature, etc.; assess in varying transmission conditions, e.g. hot vs cold transmission, new vs run-in, etc.; upshift and downshift at fixed engine speed points (e.g. every 1000 rpm); Sporty or comfort condition.

Typical characteristics to watch out for:

forces: engaging and disengaging shift/select force levels; shift/select force characteristic; comparison of shift/select forces to opposite directions; stickings; end stop characteristic; etc. // travels: shift/select travels; overlap when in-gear; recognition which gear has been selected; etc. / haptics/ergonomics: how to reach shift lever and all in-gear positions; haptics of shift knob; appearance; etc. / NVH: shift cable tizz; shifter creaking; synchro scratching; etc. NVH overall: gear blocker; overall precision; etc.
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Objective measurement
vehicle velocity temperature (environment and vehicle) Speed (engine, Gearbox input/output,half shafts) / shift/select forces (shift lever, shift/select lever shaft) / shift/select travels (shift lever, shift/select lever shaft) / Impulse Power Clutch travel/force/effect //
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Measurement technology GSA

GSA
GSA hardware GSA GSA Data Recorder GSA

GSA Analyzing Software GSA

GSA Capture Software GSA

Task of the GSA GSA

GSA used for GSA:
By comparing of different vehicles,

By assessment of competition products,

By quality assurance by series production,

For the assessment of design modifications,

For the comparability of lubricants,

For the description of shifting behavior depending to their life time,

For the assessment of inner and outer shift mechanics,

For analyzing synchronize behavior

For the development of automated shift schedules as well as their evaluation and comparability.

Standard package of GSA hardware GSA

The main parts of GSA measurement as following: GSA

A 3-a xial load sensor A displacement sensor Clutch pedal force/ travel sensor / Rotational speed sensor Temperature sensor (K type) K Digital thermometer Measurement arm (tripod) imc CRONOS measurement device Wires Pushbutton device TTL converter TTL
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GSA analysis software GSA

Measured channel list: The checkboxes show or hide channels in the time chart

Time chart of a selected shifting Object inspector Selection of typical analysis tools or charts Also a tool to fine adjust the different shifting zones

Shift navigator : Tool to select special groups of shifts

Shift list: The list depends of the selected group of the shift navigator The table informs the user about: Quality and type of the shift the shift from gear / to gear The duration (total shift, shifting zones) Impulses amount (total shift, shifting zones) Maximal forces (total shift, shifting zones) Force ratios Speed lift

Static and Dynamic regular Measurements by GSA GSA Static measurement: Select and shift travel Freeplay of lever Detent forces (shift/select forces) / Snap into gear effect Cross shifts Stiffness

Dynamic measurement:
Synchronizer performance
Sporty shifting Double bump

Conditions: -temperature - -vehicle velocity -transmission input shaft speed -

Shift comfort

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Static Measurements Shift Forces& snap effect

Positive Force Neutral In gear

Snap effect

Negative Force
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Static Measurements Select Forces

Positive Force 3 5

Neutral

or

Negative Force

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Static Measurements shift lever freeplay

Positive Force Neutral In gear 3 5

Neutral

Negative Force

Ideal shift force curve

Ideal select force curve

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Shift changing process display in GSA GSA

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Manual Transmission Synchronization parts

Clutch hub & hub sleeve Strud

Synchronizer ring

Gearclutch

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Synchronization process Neutral position

System is free

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Synchronization process Pre-synchronization

Sleeve is moved by shifting system until the strud gets in contact with the synchro-ring Due to the pre-synchronization-force a torque is generated in the friction package. This torque brings the synchroring into a blocking position.

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Synchronization process Synchronization

The sliding sleeve presses the synchronizing ring against the cone of the gearclutch body. In this case, there is an rpm lift, caused by one or more friction surface, to the target speed of the gearset. up shifts n2 > n1 (decelerate) n2 > n1 downshifts n2 < n1 (accelerate) n2 < n1 Speed difference is decreased until n1n2 n1n2

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Synchronization process Free flight

If there is no more speed difference the blocking position of the synchro-ring is released the sleeve can be moved on.

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Synchronization process Double bump

The sleeve hits the gearclutchbody and this an impact force recognizable in the shift lever, called double bump. The double bump is random and difficult to predict, due to the angular integer division of splines and to the non-definite angular position of mechanical parts.

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Synchronization process Gear engaged

The sleeve engages and hits the end stop once more there is a force peak. Now the sleeve is positive engaged.

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Typical MT-shift travel based analysis

Actual lever travel (mm)

Clutch travel(%) %

mm

Adjusted lever travel (mm) mm

Synchronisation zone

Force (N)

vx (mm/s) mm/s

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Typical MT-shift speed based analysis

Clutch travel(%) %
A ctual lever travel (mm) mm

Force (N) N

Synchronisation zone

Input shaft speed (rpm) rpm

epsilon (rad/sec) rad/se c2

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Shift travel

Shift travel chart : X: select travel Y: shift travel

Colour bar : Tool to classify the shift forces

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Shift travels depending of shift force classes

Changeable colour bar section: Tool to highlight the re gion of the synchronisation zone for example 30N

Synchronisation zone

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Shift forces against shift travels vs

Typical shift characteristics chart used to compare different vehicles different gearboxes different outer and inner shifts different oils different temperatures

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Shift impulses

Shift impulses = F*dt Shift impulses are definite integrals of shift force and shifting time of a comple te shifting or shifting zone
Max value

Mean value

Tabs to select the shifting zone Min value

Different shifting types de pending of the shift navigator and the shifting zone 27

Maximum shift forces

Max value

Maximum shift forces de pending on the shift type and the shifting zone

Mean value

Tabs to select the shifting zone Min value

Different shifting types de pending of the shift navigator and the shifting zone 28

Rpm-lift per shifting

Speed lift of the input shaft during the synchronisation

Max value Mean value

Min value

Different shifting types de pending of the shift navigator and the shifting zone

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Thank you.

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