Automotive Transmission System

Module 1 (Contd..)

Types of Transmission Gears

Transmission Gear Tooth action

Evolving History of Automotive Transmission

Development sequence of passenger and commercial vehicle transmissions. a Transmission with sliding gear engagement; b Transmission with constant-mesh engagement; c Synchromesh transmission; d Torque converter clutch transmission; e Add-On-automated manual gearbox; f countershaft-type automatic transmission; g conventional automatic transmission; h dual clutch transmission; i hydrostatic continuously variable transmission with power-split; j mechanical continuously variable transmission with taper discs; k friction gear, toroidal; l 1-E machine hybrid with z-speed transmission; m 2-E machine hybrid with summarising gear (power-split)

Torque/Speed characteristic curve of I.C Engine

Functions of Transmission system

The four main functions of a vehicle transmission are Enable the vehicle to move-off from rest. Adapt power flow. Convert output torque T2 and output speed n2. Enable reverse motion. Enable permanent power transmission. Positive or force locking engine power transmission with minimal loss. Control power matching.

Relative Advantage and Disadvantage of I.C Engine

In addition to the many advantages of the internal combustion engine, such as high power-to-weight ratio, relatively good efficiency and relatively compact energy storage, It has three fundamental disadvantages: unlike steam engines or electric motors, the combustion engine is incapable of producing torque from rest (zero engine speed) an internal combustion engine only produces maximum power at a certain engine speed and fuel consumption is strongly dependent on the operating point in the engines performance map

Theoretical Traction curve for Maximum Power Transmission

a : Secondary map of an internal combustion engine without a gearbox; b : Secondary map of an internal combustion engine with rearmounted 4-speed gearbox: traction diagram

Other requirements of Transmission system

The ancillary requirements of vehicle transmissions can be broken down as follows: operational reliability gearbox costs ease of repair ease of operation power matching efficiency installation dimensions and weight customisability and emissions (noise, oil etc.).

Transmission loss

Composition of losses in vehicle gearboxes

Typical Transmission loss Range for various Transmission System

Reference values for the efficiency ranges of gearwheels and vehicle gearboxes Type of gearbox (%) Gear pair Spur gear 99.099.8 Bevel gear 9093 Mechanical transmission Passenger car 9297 with splash lubrication Commercial vehicle 9097 Automatic transmission with various gear ratios (AT, DCT) 9095 Mechanical continuously variable transmission 8793 Hydrostatic continuously variable transmission without power-split and mechanical part 8086

Comparison of Torque/Speed of I.C Engine vs. Electric Motors

Characteristic curves of torque and performance for electric motors and internal combustion engines

Simple and Compound Gears

Sliding Mesh Gear

Constant Mesh Gear

Power flow diagram of 4-speed Constant Mesh Gears

Synchronizer Ring action

Detail view of Synchromesh Gear

4-speed Manual Transmission

Cut-view of 5-speed Manual Transmission

Power Flow diagram of 5-speed Manual Transmission

Gear shift Levers

Overdrive Gears
Definition of Overdrive

Advantages of Overdrive

Engine power vs. Engine speed for Overdrive operation

Overdrive gear set in a Gear Box

Impeller and Turbine Blade profile

Torque Converter Action

Basic Construction of Torque Converter

4 Stage Operation of Torque Converter

Drive Lines

Basic Driveshaft layout

Two piece Driveshaft

Front wheel Drive line

Single Hookes joint

Double Hookes joint

Construction of Hookes Joint

Constant Velocity Joints

Schematic of CV Joint

Types of CV Rzeppa joint

Drive Line systems (contd..)

Final Drive Gear Unit Dead Axle Live Axle Differential Gear Unit

Purpose of Final Drive Gears

Different Layouts of Final Drive Gears

Basic Geometry of spiral bevel gears

Types of Final Drive Gears

Rear Axle Casing functions

De Dion axle (Dead Axle)

Dead Axle Types

Live Axle (Semi-floating type)

Live Axle (Three-quarter floating type)

Live Axle (Full-floating type)

End view of Semi-floating Axle hub

End view of Three quarter-floating Axle hubs

Rear Drive axle layout

Need of Differential unit in Final Drive

Differential Action

Basic parts of Differential Gear

Dismantled view of Rear Axle Unit

Non-slip Differential Unit

Dismantled view of Non-slip Differential unit

Trouble shoot and Remedies