RESEARCH ARTICLE | MARCH 17 2017

Design of synchromesh mechanism to optimization manual

transmission’s electric vehicle 
Fuad Zainuri; Danardono A. Sumarsono; Muhammad Adhitya; Rolan Siregar
AIP Conf. Proc. 1823, 020031 (2017)
https://doi.org/10.1063/1.4978104

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 Design Of Synchromesh Mechanism To Optimization
Manual Transmission’s Electric Vehicle
Fuad Zainuri 1,2,a; Danardono .A. Sumarsono 2,b; Muhammad Adhitya 2,c ; Rolan
Siregar 2d
1
Department of Mechancal engineering State Polytechnic of Jakarta 16425, Indonesia
2
Department of Mechanical Engineering Universitas Indonesia 16424, Indonesia;
a Corresponding author email :[email protected];
Phone Author : +62 813 1579 1630
b [email protected]; c [email protected];
d [email protected]

Abstract. Significant research has been attempted on a vehicle that lead to the development of transmission that can
reduce energy consumption and improve vehicle efficiency. Consumers also expect safety, convenience, and competitive
prices. Automatic transmission (AT), continuously variable transmission (CVT), and dual clutch transmission (DCT) is
the latest transmission developed for road vehicle. From literature reviews that have been done that this transmission is

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less effective on electric cars which use batteries as a power source compared to type manual transmission, this is due to
the large power losses when making gear changes. Zeroshift system is the transmission can do shift gears with no time
(zero time). It was developed for the automatic manual transmission, and this transmission has been used on racing
vehicles to eliminate deceleration when gear shift. Zeroshift transmission still use the clutch to change gear in which
electromechanical be used to replace the clutch pedal. Therefore, the transmission is too complex for the transmission of
electric vehicles, but its mechanism is considered very suitable to increase the transmission efficiency. From this idea, a
new innovation design transmission will be created to electric car. The combination synchromesh with zeroshift
mechanism for the manual transmission is a transmission that is ideal for improving the transmission efficiency.
Installation synchromesh on zeroshift mechanism is expected to replace the function of the clutch MT, and assisted with
the motor torque setting when to change gear. Additionally to consider is the weight of the transmission, ease of
manufacturing, ease of installation with an electric motor, as well as ease of use by drivers is a matter that must be done
to obtain a new transmission system that is suitable for electric cars.

INTRODUCTION
The transmission system is one of the major components that affect power and fuel consumption of the vehicle.
The transmission performance is also associated with gear efficiency, noise, and safety during change gear [2] .
Transmission development has much to do to fulfil the needs of consumers ranging from the manual transmission
models up to the automatic transmission. The development of this transmission is used to engine combustion
vehicles that require fossil fuels as a source of engine power. By looking at the number of vehicles is increasing in
society then it will require increased fuel too. Availability of fuel tends to decline will lead to motivation for
researchers to create more user friendly vehicles as vehicles with electric current as a source of motive power. This
study aims to produce a new transmission design engineering at synchromesh mechanism making it more efficient.
The main thing that will be in engineering is a transmission geometry, the concept of work, gearshift, gearshift
quality, and will automatically increase the power efficiency of the electric motors in vehicles.

International Conference on Chemistry, Chemical Process and Engineering (IC3PE) 2017

AIP Conf. Proc. 1823, 020031-1–020031-8; doi: 10.1063/1.4978104
Published by AIP Publishing. 978-0-7354-1491-4/$30.00

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 LITERATURE REVIEW
There are three types of vehicle transmissions are manual transmission (MT), automatic transmission (AT), and
the continuous variable transmission (CVT). Manual transmission (MT) is the most efficient in fuel consumption,
while AT and CVT is easier to use [4]. MT efficiency level is 96.2 per cent, 86 per cent AT, CVT 84.6 percent, and
AMT equivalent with MT [5]. Expertise driver was extremely influential in the use of manual transmission for
improved fuel efficiency. In this paper will be more present manual transmission as well as its development since
the transmission is considered to be more suitable for electric cars.
Manual transmission is a component that serves to forward the torque from the engine to the drive wheels. There
are several gear box in a box on the transmission system which is the option to set the speed of the vehicle. Election
speed manually done by the driver by utilizing the shifting lever (shift lever). There are several types of manual
transmission that constantmesh and synchromesh. MT synchromesh transmission is widely used on the vehicle.
Synchronizer is a key element which serves to aligning rotation between elements so that it can be done with a
smooth change gear engaged. Some transmission systems, such as the manual transmission (MT), Dual Clutch
Transmission (DCT), and Automatic Manual Transmission (AMT) there synchronizer[1]. In Fig. 1 is shown
Synchronizer manual transmission.

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FIGURE 1. Exploded view synchromesh manual transmission [2]

Based on Figure 1 can be explained that the synchronizer ring is a harmonizing element rotational speed between
the clutch gear cone, hub, and when the sliding sleeve gear set in motion to be paired. Synchronizer works by
utilizing the friction in the cones. Therefore, engineering synchronizer should be considered to reduce the negative
impact due to friction. Wear and tear that may occur will be selected on the components that better be the element
that failure than any other element in this case is usually synchronizer been so elements are ductile than the
surrounding elements.
The latest developments regarding the manual transmission is creating a manual transmission performance as if
the auto is often called the automatic manual transmission (AMT). Broadly speaking AMT interpreted as a manual
transmission without a clutch pedal clutch wherein movement is regulated by electronic sensors, processors,
actuators (hydraulic or electromechanical), and change gear in accordance with the command of the driver. In Fig. 2
is shown schematically AMT.

FIGURE 2. Schematic AMT

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 Furthermore, AMT has developed AMT zeroshift transmission type. This transmission is a transmission that can
shift gears without the need of the time (zero second)[3]. This transmission offers easy to be manufactured, the price
is cheaper than AT, fuel savings, there is no torque interupt on one shaft when the change gear, change gear and
finer (seamless). In Fig. 3 is shown zeroshift AMT. Zeroshift mechanism is replace the components synchromesh on
manual transmission by using zeroshift ring.

FIGURE 3. Zeroshift two gear [3]

NEW SYNCHROMESH’S ELECTRIC VEHICLE

Design Transmisi EV
Starting from the concept zeroshift transmission which has advantages such as fuel economy, performance, shift

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quality, and easy to manufacture then created a draft new transmission for electric cars. The main concept is to
eliminate the clutch to the transmission system then its function replaced by cone friction and torque setting of the
motor. Simplicity of design and working mechanism that is simple is one of the considerations to obtain an effective
transmission of the electric car. The following schematic working mechanism of transmission is made as shown in
Fig. 4.

FIGURE 4. Schematic manual transmission EV

Selection lever is a lever operated by the driver to change gear. When the lever is moved, the sensor will send a
signal to the ECU and signals to be transmitted to the motor to regulate the torque. Torque motor that has declined is
the right time to change gear. Display electrical transmission vehicle can be seen in Fig. 5.

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 FIGURE 5. Manual transmission EV

Clutch manual transmission has been eliminated so that the working mechanism is simpler and easier to use.
Such transmission will be lighter when compared with a conventional transmission. Gear ratios are such that they
can be used for roads that need major traction as well as for high speed. To see more detail the concept of this
transmission work, it can be shown describing elements to change gear as in Fig. 6.

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FIGURE 6. Element synchromesh

Based on Figure 6 can be explained that the shaft merges with the main connecting hub so that the gear is a hub
through the shaft rotation. Sleeve is an element that can be moved by the operator to change gear. When the sleeve
has been shifted then the synchronizer cone will move simultaneously pressing the friction cone and the cone
friction cone will hit the gears which aims to adjust the rotational speed, so that the synchronizer can be paired with
the gears. For more details on how to change gear between two gears consists of several stages. The first stage is the
sleeve is shifted by the driver via the gear shift lever so that the sleeve is pushed synchronizer cone and rotates
together (Fig. 7).

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 FIGURE 7. Synchronizer cone with sleeve is engaged

The next stage is adjustment round by utilizing the friction on the cone (Fig. 8). Cone is the friction between
elements of cone synchronizer friction cone made with different sizes according to the required large friction. Where
things should be considered is how such friction does not cause serious problems such as lifetime due to wear,
temperature and the other.

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FIGURE 8. Element cone

Then the cone friction elements will rub against the gear cone element to add to the reduction of rotation between
elements (Fig. 9).

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 FIGURE 9. Gear cone friction

Cone on the gear elements are expected not easy to wear because it includes vital category. After the rotation of
the cone reduction gear then all elements will be paired to one level gear rotation (Fig. 10).

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FIGURE 10. Engaged for one gear level

It can be concluded that the synchronization is done by utilizing some friction, it is to replace the function of a
conventional clutch transmission that shifts gear can be carried out smoothly.

Calculation of synchronization
Source of the work force is the force exerted by the operator in the direction of the horizontal axis on the sleeve
element of F. Large forces acting on the cone friction is the normal direction F1 sin Ө. Due to the friction at each
cone, the rotational speed will be reduced from the first friction elements that experience to other elements. In Fig.
11 displayed the forces acting on the system synchronizer.

FIGURE 11. Forces acting on the synchronizer system

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 Based on Fig.11 it can be seen that the force that taste of the sleeve is F and F2 will break down into sin Ө
working on the x-axis gear. Rotational speed is also experiencing the same thing that will break down into Z3 due to
the friction that arises. Furthermore, torque and frictional forces acting on the gear can be shown in Fig. 12.

FIGURE 12. Torque and friction

When calculating the torque acting on the paired element between the sleeve with synchronizer cone is the

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distance to the force multiplied by the horizontal axis of the work force. Then the torque acting on the cone
synchronizer with the gear is the distance to the horizontal axis force multiplied by that force.

CONCLUSION
Based on the results of the literature survey and design have made the design for the transmission of electric cars
has been obtained. Additions for the synchromesh transmission mechanism zeroshift a major topic as the
development of new ideas for this research. The synchromesh serves to reduce the round elements will be partnered
by utilizing the friction in some cone. The working mechanism of a manual transmission without using the clutch is
the main aim is to utilize synchromesh and setting the motor torque as a replacement clutch MT. The design will be
its own advantages as it will be very effective for the character of the electric motor. The number of gear changes
made to two (2 speed) is useful for obtaining power efficiency has been considered from various factors.
Transmission weight is one of the considerations to improve the performance of electric motors. In addition, ease of
manufacturing, ease of installation of the electric motor, and ease of use by drivers is a thing to note is also to
acquire new transmission system that is suitable for electric cars. Expected from searches conducted on the
transmission of electric vehicles will help solve the problem of the availability of energy that specifically influence
of transport.

ACKNOWLEDGEMENT
Thanks for organizers of a research grant from the University of Indonesia. All parties in the Jakarta State
Polytechnic who have provided facilities, motivation, and opportunity to participate in education.

REFERENCES
1. Back, O. (2013). Basics of synchronizer. Germany: Hoerbiger.
2. Bedmar, A. P. (2013). Synchronization processes and synchronizer mechanisms. Goteborg: Chalmers
University of Technology.

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3. Cheat, R., & Child, A. (2007). A seamless automatic manual transmission (AMT) with no torque interupt. SAE
International.
4. Heath, R. P. (2007). Seamless AMT offers efficient alternative to CVT. 20075013.
5. Kumbhar, M. S., & Panchagade, D. R. (2014). A Literature Review on Automated Manual Transmission
(AMT). IJSRD, 1236.

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