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Modeling and control of engaging gears in gearboxes without synchromesh towards specific angles between gear and coupling sleeve

When engaging a new gear in an automated manual transmission (AMT) the gear needs to be synchronized with the main shaft’s angular velocity in the gearbox. This is so that the parts can be connected through a cog wheel and torque can be transferred. To synchronize the angular velocities, mechanical synchronization components can be used. These components synchronize the velocities during the engagement and can be used with larger differences in angular velocities. Should no mechanical synchronization components be used it puts higher demands on the components rotating at similar velocities to avoid mechanical wear and ensure that the gear can be engaged. In today’s systems without mechanical synchronization components the gear is engaged when the angular velocities are within a certain difference. This leads to random angle connections between the cogs and gaps that are to be engaged on the gear and main shaft. This can lead to extended or incomplete engages should the components connect cog to cog. This thesis evaluates the possibility to control the angle at which the components connect by using existing sensor signals in the studied system and known parameters. A model of the system is created and simulated to evaluate the probability of predicting the system over the gear engage. Results indicate that it is possible to predict the connection angle close enough to its real value so that a control strategy could be implemented to control the angle to some level.

Martin Blomgren


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Last updated: 2021-11-10