MAK 4058E
Power Transmission in Vehicles
Part #4
Asst. Prof. Dr. Osman Taha Şen
İstanbul Technical University
Department of Mechanical Engineering
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Manual Gearboxes
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Drivetrain – Driveline – Powertrain
• drivetrain
the power train of an automotive vehicle consisting of all the components
between the engine and driving wheels and including the clutch and axle, as
well as the components of the driveline.
• driveline
the components of the power train of an automotive vehicle that are between
the transmission and the differential, and generally consisting of the drive
shaft and universal joint.
• power train (more general)
a train of gears and shafting transmitting power from an engine, motor,
etc., to a mechanism being driven.
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Automotive Transmissions
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Automotive Transmission Types
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Effect of the Transmission
on Basic Attributes of a Vehicle
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Industrial and Automotive Transmissions
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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BURADAN ATLADI
Examples of Fundamental Innovations in
Automotive and Automotive Transmissions
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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A Chronology of Important Developments in Vehicles and Drive Units
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Examples of important stages
in the development of
vehicle transmission
1/3
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Examples of important stages
in the development of
vehicle transmission
2/3
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Examples of important stages
in the development of
vehicle transmission
3/3
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Some Independent Manufacturers of
Automotive Transmissions
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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BURAYA
Losses in Vehicle Gearboxes
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Distribution and Size of Power Losses
of a Coaxial 6-speed Manual Gearbox
in 4th Gear at 50% Part Load
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Driver Type in Terms of Powertrain
Loading in a Passenger Car
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Service Life of
Passenger Car and Commercial Vehicle Transmissions
under Different Operating Conditions
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Trends in the Use of Passenger Car
Transmissions in Europe
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Passenger Car Transmission Designs: Market Shares and
Prediction
2000 2010
2015
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Overall Gear Ratio
The overall gear ratio of the transmission, often referred to as the range of
ratios, is the ratio between the largest and the smallest ratio.
iG,max i1
iG,tot = =
iG,min iz
The overall gear ratio depends on:
• the specific power output of the vehicle (Pmax / (mF + mpayload) in kW/t),
• the engine speed spread and
• the intended use.
Vehicles with a low specific power output, such as commercial vehicles, need a
larger overall gear ratio. The same applies for vehicles with diesel engines,
which have a small engine speed spread.
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Overall Gear Ratios for Various Types of Vehicle
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Velocity/engine-speed Diagram, Overall Gear Ratio
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Gear-Speed Plot of a Gearbox
Reference : Jazar, R.N., Vehicle Dynamics, Springer, 2008.
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Gearbox Design Considerations
• We may design the differential transmission ratio nd and the final gear nn
such that the final gear nn is a direct gear, nn = 1, when the vehicle is moving
at the moderate highway speed. Using nn = 1 implies that the input and
output of the gearbox are directly connected with each other. Direct
engagement maximizes the mechanical efficiency of the gearbox.
• We may design the differential transmission ratio nd and the final gear nn
such that the final gear nn is a direct gear, nn = 1 , when the vehicle is moving
at the maximum attainable speed.
• The first gear n1 may be designed by the maximum desired torque at driving
wheels. Maximum torque is determined by the slope of a desired climbing
road.
Reference : Jazar, R.N., Vehicle Dynamics, Springer, 2008.
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Gearbox Design Considerations
• We can find the intermediate gears using the gear stability condition.
Stability condition provides that the engine speed must not exceed the
maximum permissible speed if we gear down from ni to ni−1, when the
engine is working at the maximum torque in ni.
• The value of cg for relative gear ratios can be chosen in the following range:
1 ≤ cg ≤ 2
ni−1
cg =
ni
Reference : Jazar, R.N., Vehicle Dynamics, Springer, 2008.
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Geometric Ratio Gearbox Design
When the jump of
engine speed in any
two successive gears is
constant at a vehicle
speed, we call the
gearbox geometric .
φth = z−1 iG,tot
in = izφth( z−n)
Reference : Jazar, R.N., Vehicle Dynamics, Springer, 2008.
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Progressive Ratio Gearbox Design
When the speed span of
a vehicle in any two
successive gears is kept
constant, we call the
gearbox progressive .
ϕ1 = 1.1 – 1.7
ϕ2 = 1.0 – 1.2
1
φ1 = z−1 i
0.5( z−1)( z−2 ) G,tot in = izφ1( z−n)φ20.5( z−n)( z−n−1)
φ2
Reference : Jazar, R.N., Vehicle Dynamics, Springer, 2008.
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Gear Steps
Geometrical Gear Steps Progressive Gear Steps
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Geometric Ratio Gearbox Design
Ratio : 1
Ratio : 1 Constant Ratios!
Ratio : 1
Tractive Force
Vehicle Speed Engine Speed
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011. Vehicle Speed
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Progressive Ratio Gearbox Design
Oran : 1.087 Constant
Oran : 1.103 Ratios of ratios!
Oran : 1.098
Tractive Force
Vehicle Speed Engine Speed
Vehicle Speed
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5 Speed Manual Passenger Car Transmission
(VW Golf)
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Effect of Vehicle Load on Max. Speed
laden
empty
Reference: Mitschke, M., Dynamik der Kraftfahrzeuge, Springer Verlag, 2004.
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Selecting the Smallest Powertrain Ratio
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Selecting Underrevving Powertrain Ratios
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Geared Transmissions
a) Gears
b) Syncronizer mechanisms a
c) Gear shifting mechanisms
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4 Speed Gearbox
a) b) c)
a. Sliding gears, 4 3 2 1 4 3 2 1 4 3 2 1
coaxial, two
reductions
b. Sliding
synchronizer,
coaxial, two
reductions
4 4 4
c. Sliding 3 3 3
synchronizer, 2 2 2
one reduction 1 1 1
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6 Speed Gearbox
Transmission
Ratio
Max. Engine
Speed
Reverse Gear
Vehicle Speed
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Two-Range and Three-Range Gearboxes
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.
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Two Range Gearboxes
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Two-Range, 12-Speed Gearbox
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Three Range Gearbox
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Three- Range, 18 Speed Gearbox
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Gear Shifting
Sliding Gears – Spur Gears
a) Gear Shifting must be done while the clutch is disengaged.
=> Engine and gearbox must be separated while gear shifting.
b) Gears to be connected must be brought to equal speeds.
Very difficult for the driver!
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Gear Synchronizers - Helical Gears
Helical gears are always in contact
(constant mesh), they cannot be
slid into each other.
G2 G1
Sleeve gear as internal spur gear is
sliding to the direction of main
gear.
S
Sleeve gear bearing axially free,
rotates with the same speed like
shaft S.
Gearbox shaft S and Gear G1 (or
G2) is running with the same speed
after synchronizing.
https://www.youtube.com/watch?v=wCu9W9xNwtI
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Gear Synchronizers - Helical Gears
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Gear Shifting Mechanisms
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Gearbox Acoustics
R.
Input Shaft
Free
Free
Free
Free
5.
Output shaft
Free
Free
6. 3. 4. 2. 1. 2. Shaft
Main Causes :
1) Gears under Load
2) Shifting
3) Bearings
4) Free Gears (torsional vibrations)
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Gearbox Acoustics – Gearbox Noise
Measuring
(IfF – TU Braunschweig Germany)
Shaft with two cardan joints Rpm measurement
E-machine Disc Brake
Gearbox
e-Machine mount
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Manual Gearbox Ford MTX 75 / VXT
5
4
3
2
1 R
Ford Focus, Mondeo, Galaxy
• FWD
• Transverse engine & gearbox
• 130 - 300 Nm
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Manual Gearbox Audi B80
5
4
3
2
1 R
Audi A4, A6, A8
• FWD
• Longitudinal engine & gearbox
• 140 - 280 Nm
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Videos – Manual Transmissions
How a car transmission system works.
http://www.youtube.com/watch?v=QPaUJfA1KsY
How a Dog Box Works. For race transmissions.
http://www.youtube.com/watch?feature=player_embedded&v=gMsufD2
fMyI
Manual transmission operation.
Synchronizer mechanisms. See minutes 5 to 13.
http://www.youtube.com/watch?v=vOo3TLgL0kM&list=
TLlB76N_mgbLqilJ7F2V16SXtJo_QfrF2R
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