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On the Optimisation of a Double Cone Synchroniser for Improved Manual Transmission Shiftability

[+] Author Affiliations
Massimiliano Gobbi, Gianpiero Mastinu

Politecnico di Milano, Milano, Italy

Augusto D’Orazio, Massimo Caudano, Giorgio Faustini

Centro Ricerche FIAT, Orbassano, TO, Italy

Paper No. IMECE2002-32911, pp. 21-31; 11 pages
  • ASME 2002 International Mechanical Engineering Congress and Exposition
  • Design Engineering
  • New Orleans, Louisiana, USA, November 17–22, 2002
  • Conference Sponsors: Design Engineering Division
  • ISBN: 0-7918-3628-2 | eISBN: 0-7918-1691-5, 0-7918-1692-3, 0-7918-1693-1
  • Copyright © 2002 by ASME


The paper presents a method to optimise the synchroniser of a road vehicle gearbox in order to improve shiftability and driver comfort. A multi-body physical model of the synchroniser has been developed and validated experimentally. The optimisation method is based on a Multi-objective Programming approach, and it allows to tune the thirty-two parameters of the synchroniser in order to achieve the desired dynamic behaviour of the system during a reference shift action, defined by seven performance indices. A Global Approximation procedure has been followed to solve numerically the optimisation problem. A special study has been performed and implemented in order to explore all of the feasible design solutions within the design variables domain. A global sensitivity method has been applied in order to analyse the relationships among the thirty-two design variables and the seven performance indices. Pareto-optimal design solutions have been computed in a very short time. These Pareto-optimal solutions have been checked for robustness by applying the minimum sensitivity method. The optimisation method has been applied with successful results. A number of optimised synchronisers have been defined, all of them featuring relevant improvements in the dynamic behaviour (shiftability) with respect to the reference synchroniser, aleady effective and under production.

Copyright © 2002 by ASME



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