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News Bulletin from the house of DYNASPEDE

3rd

Foreword

Edition

Transmission Systems

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

DYNASPEDE.Your Reliable Technology Partner


- with three decades of First Time Right solutions

GLANCE

Test Solutions for Gear Shift Mechanism

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.
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 us...mail@dynaspede.com

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.

Technical Data:

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 : 125C 5C (Max)


Control system : PC based real time control

Instrumentation :

Test modes : High speed slip test


Static properties test
Energy absorption test

Graphs

Synchro speed
Axial thrust load no ring
Reaction torque on ring
Ring wear (through displacement sensor)
Oil temperature
Synchro ring temperature

: Force vs Time
Frictional torque Vs Time
Cone speed Vs Time
Ring displacement Vs Time
Coefficient of Friction Vs Time

...Back
For more details and application assistance, contact:

Copyright 2014 Dynaspede. All rights reserved.

Dynaspede Integrated Systems (P) Limited


136 A, Sipcot Industrial Complex, Hosur 635 126 (TN), INDIA
phones: 04344-276915 / 401100 fax
: 04344-400185
email : mail@dynaspede.com; web : www.dynaspede.com

Bangalore

Chennai

Delhi

Kolkata

Lucknow

Mumbai

Secunderabad

Vadodara

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 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.
The system design permits to conduct Durability & Performance study on the synchronizer 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.

Test System Mechanics

Ruggedized bed plate with fixture on slides


to accommodate multiple variants.

Adjustable
speed
and
AC
motor-drive and fly
vehicle energy

variable
inertia.
wheel to induce

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 :

Drive speed :

Gate selection stroke 300 mm


Gear shifter stroke 200 mm
Gear shifter / Gate selection force 250 Kg

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 :
Instrumentation :

Computation :

PC based real time control


Shift-o-matic analyzer for shift force analysis
Clutch / Wheel shaft speed
Gear shift force / Select force
Gear shift / Select stroke

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)

...Back
For more details and application assistance, contact:

Copyright 2014 Dynaspede. All rights reserved.

Dynaspede Integrated Systems (P) Limited


136 A, Sipcot Industrial Complex, Hosur 635 126 (TN), INDIA
phones: 04344-276915 / 401100 fax
: 04344-400185
email : mail@dynaspede.com; web : www.dynaspede.com

Bangalore

Chennai

Delhi

Kolkata

Lucknow

Mumbai

Secunderabad

Vadodara

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

Technical Data:

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 :

Test modes : Manual Shift in Dynamic Condition


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

Clutch shaft speed


Wheel shaft speed
Oil Temperature

...Back
For more details and application assistance, contact:

Copyright 2014 Dynaspede. All rights reserved.

Dynaspede Integrated Systems (P) Limited


136 A, Sipcot Industrial Complex, Hosur 635 126 (TN), INDIA
phones: 04344-276915 / 401100 fax
: 04344-400185
email : mail@dynaspede.com; web : www.dynaspede.com

Bangalore

Chennai

Delhi

Kolkata

Lucknow

Mumbai

Secunderabad

Vadodara

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 characteristics 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 background.

Gear shifter
Lever assy.
Gear shifter
Lever
Shifter
linkage

Force
Sensor
Displacement
Sensor

Quick
Disconnect
Adaptor

Gate
Selection
linkage

Force
Sensor
Displacement
Sensor
Interchangeable
push/pull cable

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 :

Graphs :

Test modes : Manual Shift in Static condition


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

Shift Axis Force


Select Axis Force
Shift Axis Displacement
Select Axis Displacement

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)

...Back
For more details and application assistance, contact:

Copyright 2014 Dynaspede. All rights reserved.

Dynaspede Integrated Systems (P) Limited


136 A, Sipcot Industrial Complex, Hosur 635 126 (TN), INDIA
phones: 04344-276915 / 401100 fax
: 04344-400185
email : mail@dynaspede.com; web : www.dynaspede.com

Bangalore

Chennai

Delhi

Kolkata

Lucknow

Mumbai

Secunderabad

Vadodara

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

Gear shifting options for Automated Manual Transmission


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.

Hydraulic Actuated Shifting

PUMP & MOTOR

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)

TEST
TRANSMISSION

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
REAL TIME
CONTROLLER

Gear shifting options for Automated Manual Transmission

Electric Actuated Shifting


TEST
TRANSMISSION
ELECTRIC
MOTOR

REAL TIME
CONTROLLER

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.

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 production 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.

Cable Shifter
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 production environment.
The gear shift can be operated manually
automated per test transmission pattern.

Test
Transmission
Gear Shift
Cables
Gear Shift
Lever (Rod)

or

Rod Shifter

Custom built
Shift Rod

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 transmission 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.

Servo Actuated Robotic Gear Shift system


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 controller, 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.

Pneumatic Actuated Automatic Gear Shift system


The pneumatic actuated automatic gear shift system
is a compact version for gear shifts used in automation 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.

Shift - O - Matic Analyzer


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)

...Back