In order to analyze the cause for the difficulty of gear engagement for passenger car transmission, harmonic analysis was conducted on the friction cone of the driving and driven gear synchronizer of two manual transmissions returned from users, it was found that the high-order harmonic amplitude of the synchronizer friction cone was abnormal, which was consistent with the user’s hand feel. Therefore, the harmonic amplitude of the synchronizer friction cone of the driving and driven gear parts must be controlled in the manufacturing process. After several bench tests, it was concluded that the each order harmonic amplitude of the friction cone of the synchronous gear parts of the manual transmission was in line with the range, which was added to the monitoring plan for manufacturing process quality control, and no similar quality problems occurred after that.

Harmonic analysis  /  Shaft tooth disc ring  /  Quality control  /  Application practice