US008424405B2

(12) United States Patent

(10) Patent No.:

Moore et a].

(45) Date of Patent:

(54)

GEARBOX

(75)

Inventors. Adraln Paul Moore, Cold~Ash (GB),

5,178,250 A *
5,301,565 A *

7,428,854 B2*

Andrew MD0l1galLWOk1ngham(GB);

Assignee: Xtrac Limited, Berkshire (GB)

(*)

Notice:

1/1993 Ashikawa et al. ............ .. 192/38

4/1994 Weismann et al.
. 74/336 R
9/2008

Moore et al. .................. .. 74/339

700% Maguire et 31

2007/0034032 A1

2/2007 Moore et al.

Foster, Reading (GB)

(73)

Apr. 23, 2013

2006/0150760 A1

Anthony Tremlett, Abingdon (GB); Ian

FOREIGN PATENT DOCUMENTS

DE

1 131958

DE

10 2006 000 778

EP

12/1962

7/2006

0 391 604

10/1990

patent
Subject'1stoextended
any disclaimer,~
or adjusted
the term
under
of this
35

Ep

1 736 678 A3
A2

12/2006

U.S.C. 154(b) by 858 days.

GB

2 426 302

11/2006

SU

1237824

6/1986

WO01/11272

2/2001

(21) APPL No: 12565417

(22) Filed:

US 8,424,405 B2

WO

OTHER PUBLICATIONS

Sep. 23, 2009

British Search Report dated Jan. 12, 2009 for Application No. GB

(65)

Prior Publication Data

US 2010/0101345 A1

(30)

08174129
European Search Report completed Jan. 14, 2010 for Application No.
EP 09 25 1969.

Apr. 29, 2010

Foreign Application Priority Data

Sep. 23, 2008

* cited by examiner

(GB) ................................. .. 08174120

Primary Examiner * Troy Chambers

Assistant Examiner * Michael Gonzalez

(51) gllttigl/os

(2006 01)

(74) Attorney, Agent, or Firm * Fay Sharpe LLP

F16D 47/04

(2006.01)

(57)

F16D 41/04

(2006.01)

(52) U 5 Cl
58

U'sc '
F, 1d

( )

1e

7:73sl29ca3gn36e9ar3c703;

92/48 6
1 92/48 91 4 8 2

1. t.
?l f
1 t
h h.

ee app lea Ion e or Comp 6 e Seam 15 Dry

(56)

Amarnshaft assembly for a gearbox 1ncludes amarnshaft (44)

74668 74625 192/48 6_ 192/48 92

t, s
h
' 74/3'25

ABSTRACT
,

'

References Cited

and drive gears (31, 36) carried for rotation about the main
shaft. First and second hubs (50, 50') are associated With

respective drive gears, each hub being operable to selectively

couple or uncouple With the drive gear causing it to rotate With
the hub or With respect to the hub. A drive connection mecha
nism (42, 64, 66) associated With each hub selectively con

nects the hub to the mainshaft. Upon connection of the hubs

to the drive gears, the drive connection operates to connect

Us PATENT DOCUMENTS

one or other of the hubs to the mainshaft When torque is

2 015 096 A *

9/1935 And

74/337

applied to the mainshaft in a ?rst direction or an opposite

4093049 A
41113288 A *

@1978 Wags); """""""""" "

9/1978 Fogelberg ..................... .. 192/38

direction. This enables a gear ratio to be selected by reversing

the torqu? being handled by the gearbox

4,817,451
5,131,285 A *

4/1989
7/1992 Weismann et.....
al... ..

23 Claims, 7 Drawing Sheets

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21

Apr. 23, 2013

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Sheet 1 of7

24 23

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25 27

4+1 C3

66

31

38 36 32 54 34 33

Fig 1

35

80

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US 8,424,405 B2

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US 8,424,405 B2

DIRECTiON OF ROTATION

sermon B-B

US. Patent

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Fig 7

Sheet 5 of7

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Sheet 7 of7

US 8,424,405 B2

5
@

mo
ww
mm
cm
ow

US 8,424,405 B2
1

GEARBOX

a ?rst and a second hub, each hub being associated With a

respective drive gear, each hub having engagement

means operable to selectively couple With the drive gear
causing it to rotate With the hub or uncouple from the

FIELD OF INVENTION

This invention relates to a gearbox. It has particular, but not

exclusive, application for use in a high-performance motor

drive gear to alloW the drive gear to rotate With respect to

the hub;

vehicle such as a sports car or a racing car.

respective drive connection means associated With each

hub being operative to connect the hub to the mainshaft
for rotation With it or to alloW rotation With respect to it,
the connection means including connection elements

BACKGROUND

A conventional manual automotive gearbox has one par

ticular disadvantage When applied to a vehicle from Which
maximum performance is to be extracted: it is necessary to
remove engine torque from the input to the gearbox When the

having a deployed position in Which they prevent rela

tive movement betWeen the hub and the mainshaft and a

WithdraWn position in Which such relative movement is

alloWed;

gear ratio is to be changed, typically by interrupting drive

in Which, upon connection of both ?rst and second hub by

their respective engagement means to each correspond

through a friction clutch. This results in the acceleration of the

vehicle being interrupted during the period for Which the

clutch is open. In a conventional gearbox, it is necessary to
remove torque from immediately before a currently-selected
gear is disengaged until a neW gear is selected.
The most common arrangement in general automotive use
mounts a gear onto a hub using a bearing or bush arrange
ment. The hub is joined to the gear shaft through a splined or

20

applied to the hub through the mainshaft; Wherein

the drive connection means includes control means Which,
in an engaged condition, causes the connection elements

similar coupling. Mounted on the hub is a sliding ring system

Which can slide on the hub to engage a gear in order to couple

25

to adopt their deployed position, and in a disengaged

30

condition, alloWs the connection elements to be moved

against a biasing force to their WithdraWn position.
The presence of the biasing force ensures rapid engage
ment of the drive connection means When they are required to
transmit drive.

that gear to the hub for rotation, thus permitting drive to pass
from the gear to the shaft. In some instances the hub may be

integral With the gear shaft. The sliding ring system can be
either a dog clutch ring or a synchroniZer ring assembly;
many different siZes and types are available. In a sequential

Each connection element is typically a generally cylindri

gearbox, the sliding ring system is actuated by a selector fork,

cal paWl.

Which in turn is actuated by the rotation of a gearchange barrel

In a typical embodiment, in the WithdraWn position, each

upon Which is a cam pro?le. As the barrel is rotated the cam

pro?le causes the correct selector fork to move at the correct

time.
In operation of such a system, to effect a gearchange, one
gear is de-selected, and then the subsequent gear selected. In

ing drive gear, the drive connection means operates to

connect one of the hubs to the mainshaft When torque is
applied to the mainshaft through the hub and to connect
the other one of the hubs to the mainshaft When torque is

35

connection element can be received Within a respective recess

in one of the mainshaft and the hub.

At least part of the biasing force may be provided by one or

more springs Within the hub. For example, each spring may be

order for the sliding ring system to engage and disengage With

generally C-shaped and extend circumferentially partly

the gear the drive torque needs to be cut, this is typically done
through the engine to gearbox clutch and/or an electronic
engine cut. A cut in the engine torque for the required time to
alloW the gear to disengage results in the rate of vehicle

around the mainshaft. Preferably, each spring is prevented

40

force may be provided by a helper assembly located Within

the mainshaft. The helper assembly may comprise a resil
iently biased plunger that acts upon a paWl.

acceleration being reduced. In certain applications, for

example in motor sport, it is not desirable for the vehicle
acceleration rate to reduce during a gear change.
A gearbox that alloWs a driver to make a gear change
Without the requirement to remove drive torque Was disclosed

by the present applicant in EP-A-1 736 678. Such a gearbox

alloWs a driver to perform gear changes Without interrupting
drive poWer by arranging for drive hubs to be selectively

45

50

connected to and disconnected from a drive gear in accor

dance With the rotational direction of torque betWeen the hub

and the gear: in other Words, in accordance With Whether the
gear is tending to drive the hub or the gear is overrunning the
hub.

55

SUMMARY

An aim of this invention is to improve the operation of the

gearbox disclosed in EP-A-1 736 678.
To this end, from a ?rst aspect, this invention provides a
mainshaft for a gearbox assembly, the mainshaft assembly

60

about the mainshaft, each drive gear having a different

number of teeth;

The control means may comprise a holloW cylindrical cage

that surrounds the mainshaft and Which extends betWeen the
hubs and the mainshaft. The cage typically includes slots
Within each of Which a connection element is located. The
cage may be formed of tWo coaxial components intercon
nected such that limited backlash movement can take place
betWeen them. In such embodiments, the slots may have a
circumferential extent that is marginally greater than the
diameter of the connection elements. Alternatively, the cage
may formed of tWo coaxial components interconnected such
that minimal backlash movement can take place betWeen
them or of a single coaxial component. In such embodiments,
the slots may have a circumferential extent that is greater than
the diameter of the connection elements to alloW backlash
movement betWeen the cage and the connection elements.
Each engagement means typically includes a dog clutch
that can engage With or disengage from dogs on a drive gear.
From a second embodiment, the invention provides a gear

comprising:
a mainshaft;
a ?rst and a second drive gear, each carried for rotation

from rotating about the mainshaft by one of the connection

elements. Alternatively or additionally, at least part of biasing

box that includes a mainshaft assembly embodying the ?rst

aspect of the invention.
65

In such a gearbox, the drive gears of the mainshaft assem

bly may be in mesh With a respective laygear. The laygears are

typically constrained to rotate together on a layshaft.

US 8,424,405 B2
3

BRIEF DESCRIPTION OF DRAWINGS

35 provide 3rd and 5 gears respectively. The requirement in

general is that adjacent speeds should not share a hub so that
a speed change can be effected by changing which one of two
hubs is transmitting drive to the mainshaft.

Embodiments of the invention will now be described in

detail, by way of example, and with reference to the accom

panying drawings, in which:

Note that, in this embodiment, the pair of gears 31, 36 that

provide the l and 6 speeds are connected to the mainshaft

FIG. 1 is a longitudinal cross-section of layshaft and main

shaft assemblies of a six-speed gearbox being a ?rst embodi
ment of the invention;
FIG. 2 is an exploded view of the mainshaft assembly
shown in FIG. 1;
FIG. 3 is an exploded view of a hub assembly shown in

44 using a conventional selector hub 38, and do not make use

of the change system provided by this invention; nor does the

reverse gear 37. Therefore, the following description will
describe the operation of the odd-speed pair and the even
speed pair, which do bene?t from the arrangement of the
present invention.

FIG. 2;
FIG. 4 is a section on B-B of FIG. 1, showing the odd-speed
hub of the ?rst embodiment in a drive condition;
FIG. 5 is a section on C-C of FIG. 1, showing the even
speed hub of the ?rst embodiment in a ratchet condition;
FIGS. 6 and 7 show cage assemblies being two alternative

Each spur gear 32 . . . 35 is supported on a respective

bearing 40, 40' which in turn is mounted on a two-component

cage 42, 42' that extends under all four gears. The cage 42 is

carried on the rotatable mainshaft 44. (The bearings 40, 40'

could be bushes rather than rotating element bearings, as in
this embodiment.) The components 42, 42' of the cage are

components of the embodiment of FIG. 1;

FIG. 8 shows a helper assembly for use in embodiments of

the invention; and

20

carried on bearings 46 mounted on the mainshaft 44 such that

they can rotate upon the mainshaft 44. In alternative embodi

FIG. 9 shows the helper assembly of FIG. 8 installed in a

mainshaft.

ments, bushes might replace the bearings, or the cage may be

carried directly upon the mainshaft 44.

DETAILED DESCRIPTION

the gears of the odd-speed pair and the even-speed pair, con

Mounted on each component 42, 42' of the cage between

25

The embodiments described are ?ve-speed or six-speed

gearboxes intended for competition use. However, it will be

seen that the principles of its construction could be extended
in a straightforward manner to a gearbox having a smaller or

larger number of speeds and different applications. The

30

embodiments described may also provide some forward

speeds in a gearbox in which further forward speeds are

provided using conventional means.
With reference ?rst to FIGS. 1 to 3, the gearbox comprises
two principal shaft assembliesia mainshaft assembly 10 and
a layshaft assembly 12. Drive from the engine passes through

is spaced axially from both of the corresponding spur gears,

35

When in a drive position, the dog ring 54, 54' engages with
dog formations on the corresponding spur gear to lock that
gear to the corresponding hub 50, 50' upon which it is carried
such that the hub and the gear rotate together. This sliding
movement is effected by selector forks of the selector assem

40

The layshaft assembly 12 comprises six differently-siZed

bly.
Each hub 50, 50' has a series of internal axially-aligned
grooves 58 and is mounted on a respective component of the
cage 42, 42'. In this example, there are ?ve such grooves, but

forward-speed spur laygears 21 . . . 26 and a reverse spur

laygear 27 carried upon a rotatable shaft 80 for rotation about

other embodiments may have more or fewer. Each cage com

an axis within the gearbox. The spur gears 21 . . . 27 and the

layshaft 80 are coupled by splines so that they rotate together;

spline drive. Thus, the dog rings 54, 54' can slide axially with
respective to the corresponding hub 50, 50', but cannot rotate
with respect to it. Each dog ring 54, 54' can slide between
three operative positions: a central neutral position in which it
or displaced from the central position in one or other direction
to a respective drive position to engage one or other spur gear.

the clutch and enters the gearbox to drive the layshaft assem

bly 12. The output of the gearbox is taken from the mainshaft
assembly 10. Ratio selection is performed on the mainshaft
and is controlled by a selector assembly.

centric to the mainshaft 44, is a respective hub 50, 50'.

Mounted on each hub 50, 50' is a respective dog ring 54, 54'
which, in this embodiment, is connected to the hub through a

45

ponent 42, 42' has a series of rectangular slots 60, each slot 60

that is to say, relative rotation between the spur gears is

being disposed approximately radially inwardly from a

prevented.

respective one of the grooves 58. Likewise, the mainshaft 44

The mainshaft assembly 10 has six forward-speed spur

has a series of grooves 62, eachbeing disposed approximately

gears 31 . . . 36 each of which is in mesh with a respective spur

radially inwardly from a respective one of the slots 60. Thus,
laygear 21 . . . 26 of the layshaft assembly 12, and a reverse 50 a space is enclosed between the internal grooves 58 of the

speed spur gear 37 that can be brought into mesh with the
reverse spur laygear 27 through an idler gear (not shown)

hubs 50, 50', the slots 60 and the grooves 62 of the mainshaft
44 and located within each space is a respective pawl 64, 66 of

when reverse gear is selected. The siZes of the spur gears

generally cylindrical outer shape.

31 . . . 37 are such that they are arranged along the straight axis

of a mainshaft 44 that is parallel to the axis of the layshaft 80.

The mainshaft assembly is central to the operation of this
embodiment, so it will now be described in detail with refer

55

tions at 74 that couple them together. In the ?rst arrangement,

shown in FIG. 6, the slots 60 have a width just greater than the
diameter of the pawls 64, 66. Thus, the pawls 64, 66 are

ence to FIGS. 2 and 3.

The six forward-speed spur gears 31 . . . 36 of the mainshaft

assembly provide 1 to 6 speeds, the six speeds being each

incrementally higher in ratio than the previous gear, i.e., 6th is

60

higher than 5th, and so forth. The gears are not arranged in
ratio-order as is common in most gearboxes. Rather, they are

1 and 6 gears, a second adjacent pair of gears (referred to as

constrained to rotate about the mainshaft 44 along with the

cage component 42, 42' in which they are located. The cas
tellated formations 74 are con?gured to allow some limited

arranged such that a ?rst adjacent pair of gears 31, 36 provide

the even-speed pair) 32, 34 provide 4 and 2' gears respec

tively, while a third pair (referred to as the odd-speed pair) 33,

The cage may be in several con?gurations, two of which

are shown in FIGS. 6 and 7 respectively. Proximal end faces
of the components 42, 42' of the cage have castellated forma

65

rotational backlash movement between the components 42,

42' of the cage. In the second arrangement, shown in FIG. 7,
the slots 60 have a width somewhat greater than the diameter
of the pawls 64, 66. Thus, the pawls 64, 66 are caused to rotate
about the mainshaft 44 along with the cage component 42, 42'

US 8,424,405 B2
5

in Which they are located, With some backlash as the paWls 64,

If the vehicle is accelerating, it may be necessary to change

up a gear, for example from 3rd gear to 4th gear. Initially, the
3rd gear 33 Will be engaged through the odd-speed hub 50. To
perform the gearchange, the 4th spur gear 34 is engaged on

66 move from one side of their slots 60 to the other. The

castellated formations 74 are con?gured to minimise rota

tional backlash movement betWeen the components 42, 42' of

the cage.
The grooves 58 of the hubs 50, 50' are curved such that each
pawl 64, 66 ?ts closely to the base of its groove 58. The bases

drive by dog ring 54' of the even-speed pair. Note that 3rd gear
36 is also still engaged by the dog ring 54 of the odd-speed
pair. Section B-B through the even speed hub 50' shoWs that
as the 4th gear is engaged the drive torque is taken through the
even-speed hub 50' and paWls 64, 66 to the mainshaft 44. The
paWls 64, 66 have rotated the cage 42, 42' fully in the direction
of the drive torque due to the drive torque. Section C-C in FIG.
5 through the odd-speed hub 50 shoWs that, due to the fact that
the mainshaft 44 is noW rotating faster than 3rd gear (Which is
still engaged) the odd-speed hub 50 is noW rotating sloWer
than the even-speed hub 50'. As the cage 42 is forced fully in
the direction of the drive torque by the even-speed hub 50' and
paWls 64, 66 there is noW su?icient space for the 3rd gear
paWls 64, 66 to be forced into the grooves in the mainshaft 44
against the action of the springs 68. This alloWs the odd-speed

of the grooves 62 of the mainshaft 44 are also curved With a

radius similar to that of the paWls 64, 66. HoWever, each of the
grooves 62 of the mainshaft 44 has sloping sideWalls upon
Which the paWls 64, 66 can slide, thus alloWing the paWls
64,66 a small amount of angular rotation around the main
shaft. The Width of each slot 60 is slightly greater than the
diameter ofa paWl 64, 66. When a paWl is located in the base
of its mainshaft groove 62, its radially outermost extent does
not project beyond the radially outer surface of the compo
nents 42, 42' of the cage.
Each paWl 64, 66 is generally cylindrical, and has a trans
verse slot 90,92 formed in it. TWo of the paWls 66 have a slot
90 that is of Width approximately a quarter of the length of the
paWl 66, and offset such that one transverse edge of the slot 90

20

hub 50 to rotate sloWer than even-speed hub 50' and therefore

25

not transmit drive. Thus, 4 gear has been engaged Without

the need to disengage 3rd gear.
Once 4th gear has been engaged, as described above, the
dog ring 54 of the odd-speed pair is WithdraWn from engage
ment With the 3rd forWard-speed spur gear 33 to its central

is approximately at the mid-point of the length of the paWl 66.

These are referred to as anti-rotation paWls. The remaining
paWls 64 have a slot 92 that is of Width approximately a half

of the length of the paWl 64, and is substantially mid-Way

neutral position. The even-speed hub dog ring 54' remains in

along of the length of the paWl 64. These are referred to as

locking paWls. When assembled, the anti-rotation paWls 66

engagement With the 4th spur gear 34. The 3rd spur gear 33 is

are separated from one another by at least one locking paWl

64, and the slots 90 of the anti-rotation paWls are offset in

noW free to rotate on its bearing 40 as it is no longer joined to

axially opposite directions along the mainshaft 44.

A pair of C-shaped springs 68 surrounds the mainshaft 44.
The natural diameter of the springs 68 is somewhat larger than
that of the mainshaft 44. When compressed to closely sur
round the mainshaft 44, the free ends of the springs 68 are
spaced from one another by a distance greater than the diam
eter of the paWls 64, 66. Both springs 68 pass Within the slots
92 of all of the locking paWls 64. HoWever, the slots 90 of the
anti-rotation paWls 66 are Wide enough to receive just one

the odd-speed hub 50 by dog ring 54ithis is essential

30

odd-speed hub 52 and mainshaft 44.

The sequence of operation to accomplish doWnchanges,

With the example being from 4th to 3rd speeds, Will noW be
35

40

opposite sides of the other anti-rotation paWl 66. This pre

vents rotation of the springs 68 about the mainshaft 44.

drive torque is removed, the even-speed hub Will move rota

tionally in the opposite direction to the direction of rotation
relative to the mainshaft 44, and this Will also rotate the paWls
64, 66 in the same relative direction. The paWls 64, 66 are

urged radially outWardly by the springs 68, ready to transmit

drive. The coast torque is transmitted from the mainshaft 44

The slots 60 in the components 42, 42' of the cage are siZed
to alloW the paWls 64,66 to disengage from the hubs 50, 50' as

required during operation. The cage ensures that all of the

described.
Before a doWnchange, engine torque is reduced such that it
is noW imposing a drag on the vehicleithat is, the direction

of torque being transmitted by the gearbox is reversed. Once

spring 68. Thus, each spring 68 passes through the slot 90 of

one anti-rotation paWl 66, and its free ends are disposed on

because there is no relative rotational motion betWeen the

45

through the paWls 64, 66 into the even-speed hub 50' and
thence to the even-speed dog ring 54' and the 4 speed spur

paWls 64 under any one hub 50, 50' are aligned on the same

gear 34. The change in torque direction also forces the cage 42

side of the grooves 62 in the mainshaft 44 as required during

operation of the system. The purpose of the paWls 64, 66 is to
alloW the hubs 50, 50' to be coupled to or uncoupled from the
mainshaft 44, Whereby When coupled, a hub 50, 50' is caused

to move to a coast position. The coast torque is noW being

taken by the sloWer gear, the torque path being from 3rd gear

33, through the odd-speed dog ring 54, the odd-speed hub 50
50

noW be described.

Consider ?rst the state of the mainshaft assembly 10 as

shoWn in FIG. 1. Both dog rings 54, 54' are in their central

55

positions, so all of the spur gears 31 . . . 36 are free to rotate

With respect to the mainshaft 44, and the cage components 42,
42' and paWls 64, 66 are free. Thus, the gearbox is in neutral,
no drive being transmitted from the layshaft assembly 12 to
the mainshaft assembly 10.

by the odd-speed hub 50. The cage 42 is already in the coast

position because of the drive direction. The even-speed hub
50' is rotating faster than the odd-speed hub 50 and therefore
forces the paWls 64, 66 into the grooves 62 in mainshaft 44
against the action of the springs 68 Which alloWs the hub to
rotate With respect to the mainshaft 44, as shoWn in section
C-C.

60

When driving in 4th gear, the dog ring 54' of the even-speed
pair is located in its drive position With respect to the 4th spur
gear 34. Section B-B through 4th gear in FIG. 4 shoWs the
drive Where the torque is taken through the even-speed hub
50' and the paWls 64, 66 into the mainshaft 44. The cage 42 is
rotated fully in the direction of the drive torque by the paWls
64, 66.

and the paWls 64, 66 into the mainshaft 44. The paWls 64, 66
are forced in the opposite direction to the direction of rotation

to rotate With the mainshaft 44 and When uncoupled can rotate

With respect to it. The mechanism by Which this occurs Will

A helper assembly 70 that can be incorporated into the

mainshaft 44 is shoWn in FIGS. 8 and 9. This helper assembly
70 serves to apply a radial force to the paWls 64, 66 additional
to that of the springs 68.

The helper assembly 70 comprises a tubular casing 72 that

65

has an axial through bore and that is symmetrical about a

centre plane normal to the axis. The bore has a central region

of reduced diameter, and its end portions are internally

threaded. The casing has an external diameter that is a close ?t

US 8,424,405 B2
8

7
Within the mainshaft 44. A ball-spring plunger 92 is located

disengaged condition, alloWs the connection elements to

be moved against the biasing force to their WithdraWn

centrally in the casing 72, projecting radially outwardly from

position.

it. The ball-spring plunger cooperates With an internal groove

of the mainshaft 44 to resist axial movement of the helper
assembly 70 Within the bore of the mainshaft 44.
At positions that are radially inWard of the paWls 64,66
When the helper assembly is installed for use, radial apertures
76 are formed through the casing 72 to communicate With the
bore. A respective plunger 80 is located Within each radial
aperture 76. Each plunger 80 has a tapered portion that is
directed into the bore of the mainshaft 44.
Each plunger 80 is acted upon by tWo expander elements

2. A mainshaft assembly according to claim 1 in Which

each connection element comprises a generally cylindrical

paWl.
3. A mainshaft assembly according to claim 1 in Which in
the WithdraWn position, each connection element is received
Within a respective recess in one of the mainshaft and the hub.

4. A mainshaft assembly according to claim 1 in Which at

least part of the biasing force is provided by one or more

springs Within the hub.

5. A mainshaft assembly according to claim 4 in Which

84 that are located to slide Within the bore of the casing 72.
Each of the tWo expander elements 84 has a chamfered axial
face that face one another and Which bear upon the tapered

each spring is generally C-shaped.

6. A mainshaft assembly according to claim 5 in Which

portions of the plungers 80. Each expander element 84 is

acted upon by a pair of coaxial helical springs or a series of

each spring extends circumferentially partly around the main

Belleville compression springs 86, 88, Whereby the tWo

shaft.
7. A mainshaft assembly according to claim 6 in Which

expander elements 84 that are associated With each plunger

80 are urged toWards one another. The compression springs
86, 88 that are associated With the expander elements 84
closest to the centre plane of the casing 72 bear upon the

20

one of the connection elements.

8. A mainshaft assembly according to claim 1 in Which the

central region of reduced diameter. The compression springs

86, 88 that are associated With the expander elements 84
furthest from the centre plane of the casing 72 are retained by
plugs 90 secured Within the threaded end portions of the bore
of the casing 72. Alternatively, the bore might have a groove
Within Which a circlip can be located to retain the springs. The
action of the expander elements 84 acting on the plungers 80

causes the plungers 80 to be urged radially outWardly from

the housing to bear upon the paWls 64, 66, thereby urging the
paWls radially outwardly to supplement the action of the
springs 68.
The invention claimed is:
1. A mainshaft assembly for a gearbox, the mainshaft

at least part of biasing force is provided by a helper assembly

25

acts upon a paWl.

10.A mainshaft assembly according to claim 1 in Which the

control means comprises a holloW cylindrical cage that sur
30

35

a mainshaft;
a ?rst and a second drive gear, each carried for rotation

about the mainshaft;

40

respective drive gear, each hub including engagement

means operable to selectively couple the hub With the
drive gear causing the drive gear to rotate With the hub or
uncouple the hub from the drive gear to alloW the drive
gear to rotate With respect to the hub;
respective drive connection means associated With each
hub being operative to connect the hub to the mainshaft

45

for rotation With the mainshaft or to alloW rotation With

respect to the mainshaft, the connection means includ

ing connection elements having a deployed position in

rounds the mainshaft and extends betWeen the hubs and the
mainshaft, and that includes slots Within each of Which a
connection element is located.
11. A mainshaft assembly according to claim 10 in Which
the cage is formed of tWo coaxial components interconnected
such that limited backlash movement can take place betWeen
them.
12. A mainshaft assembly according to claim 11 in Which
the slots have a circumferential extent that is marginally
greater than the diameter of the connection elements.
13. A mainshaft assembly according to claim 10 in Which
the cage is formed of tWo coaxial components interconnected
such that minimal backlash movement can take place
betWeen them.
14. A mainshaft assembly according to claim 10 in Which
the cage is formed of a single coaxial component.
15. A mainshaft assembly according to claim 13 in Which
the slots have a circumferential extent that is greater than the
diameter of the connection elements to alloW backlash move
ment betWeen the cage and the connection elements.

50

Which the connection elements prevent relative move

ment betWeen the hub and the mainshaft and a With
draWn position in Which such relative movement is

16. A mainshaft assembly according to claim 1 in Which

each engagement means includes a dog clutch that can engage
With or disengage from dogs on a drive gear.

alloWed;
in Which, upon connection of both the ?rst and second hubs
by their respective engagement means to each corre
sponding drive gear, the drive connection means oper

located Within the mainshaft.

9. A mainshaft assembly according to claim 8 in Which the

helper assembly comprises a resiliently biased plunger that

assembly comprising:

a ?rst and a second hub, each hub being associated With a

each spring is prevented from rotation about the mainshaft by

55

ates to connect one of the hubs to the mainshaft When

torque is applied to the mainshaft through the hub and to

17. A mainshaft assembly according to claim 1, Wherein

said mainshaft assembly is installed in a gearbox.
18. A mainshaft assembly according to claim 17 in Which
each of the drive gears of the mainshaft assembly is in mesh
With a respective laygear in the gearbox.
19. A mainshaft assembly according to claim 18 in Which
the laygears are constrained to rotate together on a layshaft.

torque is applied to the other one of the hubs through the

20. A mainshaft assembly according to claim 17, Wherein

said gearbox comprises a selector assembly operable to

mainshaft; Wherein

engage or disengage the engagement means.

connect the other one of the hubs to the mainshaft When

60

means Which, in an engaged condition, retains the con

21. A mainshaft assembly according to claim 20 in Which

the selector assembly is a sequential selector.
22. A mainshaft assembly according to claim 19 in Which
the layshaft is an input to said gearbox and the mainshaft is an

nection elements in their deployed position, and in a

output from said gearbox.

the drive connection means includes biasing means pro

viding a biasing force that causes the connection ele

ments to adopt their deployed position, and control

65

US 8,424,405 B2
9

10

23. A gearbox comprising:

a mainshaft assembly, said mainshaft assembly compris

betWeen the respective hub and the mainshaft and a

WithdraWn position in Which such relative movement is

ing:
a mainshaft;
a ?rst drive gear and a second drive gear, each carried for

alloWed;
Wherein, upon connection of the ?rst and second hubs by
5

rotation about the mainshaft;

and second drive gears, respectively, the respective drive

a ?rst hub and a second hub, each hub being associated

With a respective one of said ?rst and second drive gears,

each hub including engagement means selectively oper

able to couple the hub With its associated drive gear

connection means operate to connect one of the ?rst and

second hubs to the mainshaft When torque is applied to

10

causing the associated drive gear to rotate With the hub

or to uncouple the hub from its associated drive gear to
alloW the associated drive gear to rotate With respect to

shaft; and,
each drive connection means comprising biasing means
providing a biasing force that causes the connection

the hub;

elements to adopt their deployed position, and compris

tively With the ?rst and second hubs, each drive connec
tion means being operative to connect the respective hub
to the mainshaft for rotation With the mainshaft or to

alloW rotation of the respective hub With respect to the

nection elements having a deployed position in Which

the connection elements prevent relative movement

the mainshaft through said one hub and to connect the

other of the ?rst and second hubs to the mainshaft When

torque is applied to said other hub through the main

?rst and second drive connection means associated respec

mainshaft, each drive connection means including con

their respective engagement means to the associated ?rst

20

ing control means Which, in an engaged condition,

retains the connection elements in their deployed posi
tion, and in a disengaged condition, alloWs the connec
tion elements to be moved against the biasing force to

their WithdraWn position.

*