Claims:We claim:
1. A system (100) for detecting and notifying assembly error in a synchronizer ring assembly (R) of a power transmission unit, said system (100) comprising:
a synchronizer ring matching element (108);
an indicating means (120);
a sensor (112) having a movable member; and
a controller unit (114) adapted to be provided in communication with said sensor (112) and said indicating means (120),
wherein
the movable member of said sensor (112) is moved on engagement of said synchronizer ring matching element (108) with the movable member of said sensor (112) and accordingly said sensor (112) provides a measured value to said controller unit (114); and
said controller unit (114) compares the measured value of said sensor (112) with a reference value and accordingly said controller unit (114) provides an output signal to said indicating means (120) which in turn indicate assembly error status if the measured value is not matching with the reference value and when an outer synchronizer ring (UR) is not correctly assembled with an inner synchronizer ring (IR).

2. The system (100) as claimed in claim 1, wherein the movable member of said sensor (112) is moved on engagement of said synchronizer ring matching element (108) with the movable member of said sensor (112) and accordingly said sensor (112) provides another measured value to said controller unit (114); and
said controller unit (114) compares the another measured value of said sensor (112) with the reference value and accordingly provides an output signal to said indicating means (120) which in turn indicate correct assembly status if the measured value is matching with the reference value and when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR).
3. The system (100) as claimed in claim 1, wherein said system (100) includes a gear and synchronizer locating means (110) adapted to locate and mount a gear (G) and the synchronizer ring assembly (R) thereon.

4. The system (100) as claimed in claim 3, wherein said system (100) includes a presence detecting sensor (116) adapted to detect the presence of the gear (G) and the synchronizer ring assembly (R) and accordingly said presence detecting sensor (116) provides information to said controller unit (114) which in turn switches on said sensor (112).

5. The system (100) as claimed in claim 1, wherein said system (100) includes a pushing assembly (104) adapted to push said synchronizer ring matching element (108) in a direction towards the synchronizer ring assembly (R).

6. The system (100) as claimed in claim 5, wherein said pushing assembly (104) includes,
a first pushing element (104P) adapted to be connected to said synchronizer ring matching element (108);
a second pushing element (104S) adapted to be connected to said first pushing element (104P); and
a locking element (104L) adapted to lock said first locking element (104P) with said second locking element (104S),
wherein
said second pushing element (104S) is adapted to push said first pushing element (104P) which in turn pushes said synchronizer ring matching element (108) in the direction towards an inner synchronizer ring (IR) of the synchronizer ring assembly (R).

7. The system (100) as claimed in claim 6, wherein said system (100) includes a base structure (102), where said base structure (102) includes,
a platform (102F);
a plurality of legs (102L) adapted to support said platform (102F); and
a frame (102F) adapted to be mounted onto said platform (102F),
wherein
said frame (102F) is adapted to support said pushing assembly (104).

8. The system (100) as claimed in claim 7, wherein said system (100) includes,
at least one resilient means (106) adapted to load said pushing assembly (104) onto said frame (102F) of said base structure (102).

9. The system (100) as claimed in claim 8, wherein said system (100) includes a retainer (107) adapted to retain said pushing assembly (104).

10. The system (100) as claimed in claim 9, wherein said system (100) includes a stopper (122) adapted to stop said plunger assembly (104) therein to restrict a movement of said plunger assembly (104) when said plunger assembly (104) is moved beyond a predefined position.

11. The system (100) as claimed in claim 10, wherein said system (100) includes a stopper mounting assembly (124) adapted to mount said stopper (122).

12. The system (100) as claimed in claim 1, wherein said system (100) includes an analog to digital converter (118) adapted to convert an analog signal received from said sensor (112) into digital signal which is sent to said controller unit (114).

13. The system (100) as claimed in claim 1, wherein said synchronizer ring matching element (108) defines a plurality of lugs (108L) corresponding to a plurality of slots (IL) provided in an inner synchronizer ring (IR),
wherein
each lug (108L) is adapted to be engaged with corresponding slot (IL) provided in the inner synchronizer ring (IR) when an outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR).

14. The system (100) as claimed in claim 13, wherein at least one of the plurality of lugs (108L) of said synchronizer ring matching element (108) is not engaged with corresponding slot (IL) provided in the inner synchronizer ring (IR) when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR).

15. The system (100) as claimed in claim 1, wherein said sensor (112) is at least a linear variable displacement transducer (LVDT); and
said indicating means (120) is at least one of a display screen, a flash light and a buzzer.

16. The system (100) as claimed in claim 1, wherein said system (100) is adapted to detect assembly error of the synchronizer ring assembly (R) in power transmission unit of at least one of a vehicle and a machine.

17. A method (200) for detecting and notifying assembly error in a synchronizer ring assembly (R) of a power transmission unit, said method (200) comprising:
locating a gear (G) onto a gear and synchronizer locating means (110), and assembling an inner synchronizer ring (IR) with the gear (G), and assembling an intermediate synchronizer ring (MR) with the inner synchronizer ring (IR), and assembling an outer synchronizer ring (UR) with the inner ring synchronizer ring (IR);
moving by, a pushing assembly (104), a synchronizer ring matching element (108) in a direction towards the synchronizer ring assembly (R);
moving a movable member of a sensor (112) on engagement of the synchronizer ring matching element (108) with the movable member of the sensor (112);
providing, by the sensor (112), a measured value to a controller unit (114) in response to moving the movable member of the sensor (112) by the synchronizer ring matching element (108);
comparing, by the controller unit (114), the measured value of the sensor (112) with a reference value; and
indicating, by an indicating means (120), about assembly error status if the measured value is not matching with the reference value and when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR).

18. The method (200) as claimed in claim 17, wherein said method (200) includes indicating, by the indicating means (120), about correct assembly status if the measured value is matching with the reference value and when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR).

19. The method (200) as claimed in claim 17, wherein said method (200) includes, sensing and communicating, by a presence detecting sensor (116), presence of the gear (G) and the synchronizer ring assembly (R) to the controller unit (114) and accordingly the controller unit (114) switches on the sensor (112) prior to said moving, by pushing assembly (104), the synchronizer ring matching element (108) in the direction towards the synchronizer ring assembly (R).
, Description:TECHNICAL FIELD
[001] The embodiments herein generally relate to a synchronizer ring assembly in a power transmission unit and more particularly, to a system and a method for detecting and notifying assembly error in the synchronizer ring assembly of the power transmission unit.

BACKGROUND
[002] Generally, a power transmission unit in a vehicle is used for transmitting torque from an engine or an electric motor to the wheels of the vehicle for propelling the vehicle and for increasing and decreasing the speed of the vehicle. Usually, the power transmission unit comprises a plurality of synchronizer units for gradual engagement or dis-engagement of corresponding gears in the power transmission unit. There are three types of synchronizer units depending upon the number of synchronizer rings which are dependent on the torque and speed transfer. The types of synchronizer units include a single cone synchronizer unit, a double cone synchronizer unit and a triple cone synchronizer unit. Usually, synchronizer rings in the double cone or triple cone synchronizer units are manually assembled over gears in a specific assembly sequence. Oil is applied over each friction face of the synchronizer ring before the synchronizer rings are assembled onto the gear. During assembly process of the synchronizer ring assembly, the operator fits the lugs of an outer synchronizer ring with corresponding slots provided in an inner synchronizer ring. Sometimes, the outer synchronizer ring is not fitted with the inner synchronizer ring at required slots which in turn results in transaxle performance related quality issues which is undesirable.
[003] Therefore, there exists a need for a system and a method for detecting and notifying assembly error in the synchronizer ring assembly of the power transmission unit, which obviates the aforementioned drawbacks.

OBJECTS
[004] The principal object of embodiments herein is to provide a system for detecting and notifying assembly error in a synchronizer ring assembly of a power transmission unit of at least one of a vehicle and a machine.
[005] Another object of embodiments herein is to provide a method for detecting and notifying assembly error in the synchronizer ring assembly of the power transmission unit.
[006] Another object of embodiments herein is to provide a system for checking orientation of an outer synchronizer ring with respect to an inner synchronizer ring in the synchronizer ring assembly of the power transmission unit.
[007] Another object of embodiments herein is to provide a system for detecting and notifying assembly error in the synchronizer ring assembly of the power transmission unit, which is precise and incurs less cost.
[008] Another object of embodiments herein is to provide a system which facilitates assembly of a synchronizer ring assembly with a gear of a power transmission unit.
[009] Another object of embodiments herein is to provide a system which is user friendly especially for a novice to easily detect assembly error in the synchronizer ring assembly of the power transmission unit.
[0010] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0011] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0012] Fig. 1 depicts a schematic view of a system for detecting and notifying assembly error in a synchronizer ring assembly of a power transmission unit, according to embodiments as disclosed herein;
[0013] Fig. 2 depicts an exploded view of a gear and synchronizer ring assembly;
[0014] Fig. 3a depicts a side view of a synchronizer ring matching element in engagement with a movable member of a sensor, where at least one lug of the synchronizer ring matching element is not engaged with corresponding slot provided in an inner synchronizer ring, and where an outer synchronizer ring is not correctly assembled with the inner synchronizer ring, according to embodiments as disclosed herein;
[0015] Fig. 3b depicts a depicts a side view of the synchronizer ring matching element in engagement with the movable member of the sensor, where at least one lug of the synchronizer ring matching element is engaged with corresponding slot provided in the inner synchronizer ring, and where the outer synchronizer ring is correctly assembled with the inner synchronizer ring, according to embodiments as disclosed herein;
[0016] Fig. 4a depicts a perspective view of a synchronizer ring matching element, according to embodiments as disclosed herein;
[0017] Fig. 4b depicts a perspective view of a gear and synchronizer locating means, according to embodiments as disclosed herein; and
[0018] Fig. 5 depicts a flowchart indicating a method for detecting and notifying assembly error in the synchronizer ring assembly of the power transmission unit, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0019] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0020] The embodiments herein achieve a system for detecting and notifying assembly error in a synchronizer ring assembly of a power transmission unit. Further, embodiments herein achieve a method for detecting and notifying assembly error in the synchronizer ring assembly of the power transmission unit. Furthermore, embodiments herein achieve a system which facilitates assembly of the synchronizer ring assembly with a gear of the power transmission unit. Referring now to the drawings Figs 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0021] Fig. 1 depicts a schematic view of a system (100) for detecting and notifying assembly error in a synchronizer ring assembly (R) of a power transmission unit, according to embodiments as disclosed herein. The system (100) is adapted to detect and notify assembly error in the synchronizer ring assembly (R) of the power transmission unit (gearbox). In an embodiment, the system (100) includes a base structure (102), a pushing assembly (104), at least one resilient means (106), a retainer (107), a synchronizer ring matching element (108), a gear and synchronizer locating means (110), a sensor (112), a sensor mounting bracket (113), a controller unit (114) a presence detecting sensor (116), a presence sensor mounting bracket (117), an analog to digital converter (118), an indicating means (120), a stopper (122) and a stopper mounting assembly (124). For the purpose of this description and ease of understanding, the system (100) is adapted to detect and notify assembly error in in a triple cone synchronizer ring assembly of power transmission unit provided in a vehicle. However, it is also within the scope of embodiment herein to provide the system (100) for detecting and notifying assembly error in a single cone or double cone synchronizer ring assembly or any other type of synchronizer assembly of power transmission unit provided in a vehicle or a machine or any other applications without otherwise deterring the intended function of the system (100) as can be deduced from the description and corresponding drawings. Fig. 2 depicts an exploded view of a gear (G) and synchronizer ring assembly (R). The synchronizer ring assembly (R) includes an inner synchronizer ring (IR), an intermediate synchronizer ring (MR) and an outer synchronizer ring (UR). Assembling the inner synchronizer ring (IR) with the gear (G), and assembling the intermediate synchronizer ring (MR) with the inner synchronizer ring (IR) by engaging lugs (ML) of the intermediate synchronizer ring (MR) with corresponding slots (GS) in the gear (G). The outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR) when at least one lug (UL) of the outer synchronizer ring (UR) is not engaged with corresponding slot (IS) provided in the inner synchronizer ring (IR). The outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR) when a plurality of lugs (UL) of the outer synchronizer ring (UR) is engaged with corresponding slots (IS) provided in the inner synchronizer ring (IR).
[0022] The base structure (102) is the main rigid structure which is adapted to support the pushing assembly (104) and the gear and synchronizer locating means (110). In an embodiment, the base structure (102) includes a platform (102P), a plurality of legs (102L) and a frame (102F). The platform (102P) is adapted to mount the gear and synchronizer locating means (110) and the frame (102F). The plurality of legs (102L) is adapted to support the platform (102P). The frame (102F) is adapted to mount and support the pushing assembly (104) through the retainer (107) and the resilient means (106). The frame (102F) is mounted onto the platform (102P). A portion of the frame (102F) transversely extends from the platform (102P) and another portion of the frame (102F) is parallel and disposed away from the platform (102P). The frame (102F) substantially defines a L-shape configuration. However, it is also within the scope of embodiments herein to provide the frame (102F) in any other shape without otherwise deterring the intended function of the frame (102F) as can be deduced from the description and corresponding drawings. The frame (102F) is provided with reinforcement members (not shown).
[0023] In an embodiment, the pushing assembly (104) is adapted to push the synchronizer ring matching element (108) towards the inner synchronizer ring (IR) of the synchronizer ring assembly (R). The pushing assembly (104) is adapted to be loaded onto the frame (102F) of the base structure (102) through at least one resilient means (106). In an embodiment, the pushing assembly (104) includes a first pushing element (104P), a second pushing element (104S) and a locking element (104L). In an embodiment, the first pushing element (104P) is at least a push rod. However, it is also within the scope of embodiments herein to provide any other means for pushing the synchronizer ring matching element (108) towards the inner synchronizer ring (IR) without otherwise deterring the intended function of first pushing element (104P) as can be deduced from the description and corresponding drawings. The second pushing element (104S) is adapted to push the first pushing element (104P) which in turn pushes the synchronizer ring matching element (108) towards the inner synchronizer ring (IR) of the synchronizer ring assembly (R). The locking element (104L) is adapted to lock the first locking element (104P) with the second locking element (104S).
[0024] The resilient means (106) is adapted to load the pushing assembly (104) onto the frame (102F) of the base structure (102) through the retainer (107). The resilient means (106) is adapted to move the pushing assembly (104) to its initial position. In an embodiment, the resilient means (106) is at least a spring. However, it is also within the scope of embodiments herein to provide elastomeric means or any other means for loading the pushing assembly (104) onto the frame (102F) of the base structure (102) through the retainer (107) without otherwise deterring the intended function of resilient means (106) as can be deduced from the description and corresponding drawings. The retainer (107) is adapted to retain the pushing assembly (104) on the frame (102F) of the base structure (102). The retainer (107) is fixed onto the frame (102F) of the base structure (102).
[0025] Fig. 4a depicts a perspective view of a synchronizer ring matching element (108), according to embodiments as disclosed herein. The synchronizer ring matching element (108) is adapted to movably engage a movable member (not shown) of the sensor (112) therein to move the movable member (not shown) of the sensor (112) in a downward direction when the synchronizer ring matching element (108) is pushed by the pushing assembly (104). The synchronizer ring matching element (108) is matched with inner synchronizer ring (IR) when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR). The synchronizer ring matching element (108) is not matched with the inner synchronizer ring (IR) when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR). The synchronizer ring matching element (108) defines a plurality of lugs (108L). The plurality of lugs (108L) of the synchronizer ring matching element (108) is adapted to engage with corresponding slots ((IL) as shown in fig. 2)) provided in the inner synchronizer ring (IR) when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR) (as shown in fig. 3b)). At least one of the plurality of lugs (108L) of the synchronizer ring matching element (108) is not engaged with corresponding slots (IL) of the inner synchronizer ring (IR) when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring ((IR) as shown in fig. 3a)). It is also within the scope of embodiments herein to provide the synchronizer ring matching element (108) with slots and correspondingly the inner synchronizer ring (IR) provided with lugs for detecting the assembly error in the synchronizer ring assembly (R) without otherwise deterring the intended function of the synchronizer ring matching element (108) as can be deduced from the description and corresponding drawings. The synchronizer ring matching element (108) is connected to a bottom end (not shown) of the first pushing element (104P) of the pushing assembly (104). A space is defined between at least one lug (108L) of the synchronizer ring matching element (108) and the inner synchronizer ring (IR) when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring ((IR) as shown in fig. 3a)). There is no space available between at least one lug (108L) of the synchronizer ring matching element (108) and the inner synchronizer ring (IR) when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring ((IR) as shown in fig. 3b)).
[0026] Fig. 4b depicts a perspective view of a gear and synchronizer locating means (110), according to embodiments as disclosed herein. The gear and synchronizer locating means (110) is adapted to locate and mount the gear (G) and the synchronizer ring assembly (R) thereon thereby locating the gear (G) and the synchronizer ring assembly (R) onto the platform (102P) of the base structure (102). The gear and synchronizer locating means (110) is mounted onto the platform (102P) of the base structure (102). The gear and synchronizer locating means (110) includes a base (110A) and a body (110B), where the body (110B) transversely extends from the base (110A) in a direction towards the synchronizer ring matching element (108). The base (110A) of the gear and synchronizer locating means (110) is connected to the platform (102P) of the base structure (102). The base (110A) of the gear and synchronizer locating means (110) is adapted to mount the gear (G) and the synchronizer ring assembly (R) on to the platform ((102P), (work top)) of the base structure (102). The body (110B) of gear and synchronizer locating means (110) is adapted to guide and support the gear (G) and synchronizer ring assembly (R).
[0027] The sensor (112) includes a movable member (not shown) adapted to be engaged by the synchronizer ring matching element (108) when the synchronizer ring matching element (108) is pushed by the pushing assembly (104) in the direction towards the inner synchronizer ring (IR) of the synchronizer ring assembly (R). The sensor (112) is adapted to be mounted onto the sensor mounting bracket (113). In an embodiment, the sensor (112) is at least a linear variable displacement transducer (LVDT). It is also within the scope of embodiments herein to provide any other sensors for use in detection of assembly error in the synchronizer ring assembly (R). The movable member of the sensor (112) is moved on engagement of the synchronizer ring matching element (108) with the movable member of the sensor (112) and accordingly the sensor (112) provides a measured value to the controller unit (114). A portion of the movable member (not shown) of the sensor (112) is provided at a predefined distance from the synchronizer ring assembly (R). For example, a portion of the movable member (not shown) of the sensor (112) is provided at 2.5 mm from the synchronizer ring assembly (R). The movable member (not shown) of the sensor (112) moves 2.5 mm in a downward direction when the movable member (not shown) of the sensor (112) is pushed by the synchronizer ring matching element ((108) as shown in fig. 3a)) and when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR). The movable member (not shown) of the sensor (112) moves 3.05 mm in a downward direction when the movable member (not shown) of the sensor (112) is pushed by the synchronizer ring matching element ((108) as shown in fig. 3b)) and when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR). The sensor mounting bracket (113) is adapted to mount the sensor (112) into the platform (102P) of the base structure (102). The sensor (112) is switched on by the controller unit (114) when the controller unit (114) receives signal from the presence detecting sensor (116).
[0028] In an embodiment, the controller unit (114) is adapted to receive information from the sensor (112) and accordingly the controller unit (114) compares the measured value of the sensor (112) with a reference value and provides an output signal to the indicating means (120) which in turn indicate correct assembly status to user if the measured value is matching with the reference value and when the outer synchronizer ring (UR) is correctly assembled to the inner synchronizer ring (IR). The controller unit (114) is adapted to compare another measured value of the sensor (112) with the reference value and provides another output signal to the indicating means (120) which in turn indicate assembly error status to user if the measured value is not matching with the reference value and when the outer synchronizer ring (UR) is not correctly assembled to the inner synchronizer ring (IR). In an embodiment, the controller unit (114) is an electronic control unit (ECU). The presence detecting sensor (116) is adapted to detect the presence of the gear (G) and synchronizer ring assembly (R) which is mounted on the gear and synchronizer locating means (110) and accordingly the presence detecting sensor (116) sends signal to the controller unit (114) which in turn switches on the sensor (112). The controller unit (114) will not switch on the sensor (112) until the controller unit (114) receives signal from the presence detecting sensor (116). The presence detecting sensor (116) is at least an inductive sensor. However, it is also within the scope of embodiments herein to provide any other type of sensors for detecting the presence of the gear (G) and synchronizer ring assembly (R) without otherwise deterring the intended function of the presence detecting sensor (116) as can be deduced from the description and corresponding drawings.
[0029] The presence sensor mounting bracket (117) is adapted to mount the presence detecting sensor (116) onto the platform (102P) of the base structure (102). In an embodiment, the analog to digital converter (118) is adapted to convert the analog signal from the sensor (112) into digital signal which is sent to the controller unit (114).
[0030] The indicating element (120) is adapted to receive signal from the controller unit (114) and accordingly indicate the assembly status of the synchronizer ring assembly (R). For example, the indicating element (120) is a display screen which displays ‘OK’ if the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR), and displays ‘NOT OK’ if the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR). In another embodiment, the indicating element (120) is adapted to receive signal from the controller unit and accordingly indicate at least one of alarm and flashes light to alert the user regarding the assembly status of the synchronizer ring assembly (R). For example, the indicating means (120) flashes green light when the outer synchronizer ring (UR) is correctly assembled to the inner synchronizer ring (IR). Further, the indicating means (120) flashes red light when the outer synchronizer ring (UR) is not correctly assembled to the inner synchronizer ring (IR). In another example, the indicating means (120) is a buzzer which produces alarm to indicate the assembly status of the synchronizer ring assembly (R). The indicating means (120) is at least one of a flash light and a buzzer. However, it is also within the scope of embodiments herein to provide any other means for indicating the assembly status of the synchronizer ring assembly (R) without otherwise deterring the intended function of the indicating means (120) as can be deduced from the description and corresponding drawings.
[0031] The stopper (122) is adapted to stop the plunger assembly (104) therein to restrict a movement of the plunger assembly (104) when the plunger assembly (104) is moved beyond a predefined position. The stopper mounting assembly (124) is adapted to mount the stopper (122) onto the frame (102F) of the base structure (102). The stopper mounting assembly (124) includes a stopper mounting bracket (124M) and a support member (124S). The stopper mounting bracket (124M) is adapted to mount the stopper (122). The support member (124S) is connected to the frame (102F) of the base structure (102). The support member (124S) is adapted to support the stopper mounting bracket (124M).
[0032] The system (100) includes any of a distance measuring sensor and a camera (as disclosed below in this description) instead of the sensor (114) for detecting the assembly error of the synchronizer ring assembly (R). The system (100) includes a sensor for measuring a distance between the lugs (108L) of the synchronizer ring matching element (108) and the synchronizer ring assembly (R) and accordingly the sensor sends the information to the controller unit (114). The controller unit (114) compares the measured value with a reference value and provides an output signal to the indicating means (120) which in turn indicate correct assembly status to user if the measured value is matching with the reference value and when the outer synchronizer ring (UR) is correctly assembled to the inner synchronizer ring (IR). The controller unit (114) compares another measured value with the reference value and provides an output signal to the indicating means (120) which in turn indicate assembly error status to user if the measured value is not matching with the reference value and when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR). In another embodiment, the system (100) includes a camera adapted to capture a media input (picture/ image) of the position of the synchronizer ring matching element (108) with respect to the synchronizer ring assembly (R) and accordingly the camera sends the media input (picture/ image) to the controller unit (114). The controller unit (114) compares the captured picture with a reference picture and provides an output signal to the indicating means (120) which in turn indicate correct assembly status to user if the captured picture is matching with the reference picture and when the outer synchronizer ring (UR) is correctly assembled to the inner synchronizer ring (IR). The controller unit (114) compares another captured picture with the reference picture and provides an output signal to the indicating means (120) which in turn indicate assembly error status to user if the captured picture is not matching with the reference picture and when the outer synchronizer ring (UR) is not correctly assembled with the inner synchronizer ring (IR).
[0033] Fig. 5 depict a flowchart indicating a method (200) for detecting and notifying assembly error in the synchronizer ring assembly (R) of the power transmission unit, according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (200) is explained herein below with reference to detecting and notifying assembly error in in a triple cone synchronizer ring assembly (R) of power transmission unit provided in a vehicle. However, it is also within the scope of this invention to practice/implement the entire steps of the method (200) in a same manner or in a different manner or with omission of at least one step to the method (200) or with any addition of at least one step to the method (200) for detecting and notifying the assembly error in a single cone or double cone synchronizer ring assembly or any other type of synchronizer assembly of power transmission unit provided in the vehicle or a machine or any other applications without otherwise without otherwise deterring the intended function of the method (200) as can be deduced from the description and corresponding drawings. In an embodiment, at step (201A), the method (200) includes, locating a gear (G) onto a gear and synchronizer locating means (110), and assembling an inner synchronizer ring (IR) with the gear (G), and assembling an intermediate synchronizer ring (MR) with the inner synchronizer ring (IR) by engaging the lugs ((ML as shown in fig. 2)) of the intermediate synchronizer ring (MR) with corresponding slots (GS, as shown in fig. 2) in the gear (G), and assembling an outer synchronizer ring (UR) with the inner ring synchronizer ring (IR) by engaging the lugs ((UL as shown in fig. 2)) of the outer synchronizer ring (UR) with corresponding slots ((IS as shown in fig. 2)) in the inner synchronizer ring (IR).
[0034] At step (201B), the method (200) includes sensing and communicating, by a presence detecting sensor (116), presence of the gear (G) and the synchronizer ring assembly (R) to a controller unit (114) and accordingly the controller unit (114) switches on a sensor (112).
[0035] At step (202), the method (200) includes moving, by a pushing assembly (104), a synchronizer ring matching element (108) in a direction towards the synchronizer ring assembly (R).
[0036] At step (204), the method (200) includes moving a movable member of the sensor (112) on engagement of the synchronizer ring matching element (108) with the movable member of the sensor (112).
[0037] At step (206), the method (200) includes providing, by the sensor (112), at least one measured value to the controller unit (114) in response to moving the movable member of the sensor (112) by the synchronizer ring matching element (108). Further, at step (208), the method (200) includes comparing, by the controller unit (114), a measured value of the sensor (112) with a reference value.
[0038] At step (210), the method (200) includes indicating, by an indicating means (120), about assembly error status if the measured value is not matching with the reference value and when the outer synchronizer ring (UR) is not correctly assembled with an inner synchronizer ring (IR).
[0039] Further, at step (212), the method (200) includes, indicating, by the indicating means (120), about correct assembly status if the measured value is matching with the reference value and when the outer synchronizer ring (UR) is correctly assembled with the inner synchronizer ring (IR).
[0040] Therefore, a system (100) for detecting and notifying assembly error in a synchronizer ring assembly (R) of a power transmission unit, which is precise and incurs less cost, is provided. Further, a method (200) for detecting and notifying assembly error in the synchronizer ring assembly (R) of the power transmission unit is provided.
[0041] The technical advantages of the system (100) for detecting and notifying assembly error in the synchronizer ring assembly (R) of the power transmission unit are as follows. The system is used for checking orientation of an outer synchronizer ring with respect to an inner synchronizer ring in the synchronizer ring assembly of the power transmission unit The system is user friendly especially for a novice to easily detect assembly error in the synchronizer ring assembly of the power transmission unit. The system facilitates assembly of the synchronizer ring assembly with the gear of the power transmission unit.
[0042] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.