Download - Ppt Auto 5sem ATE
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Automotive Transmissio
U5AUA11 By. B.HARISH BABU
asst.prof ,vtu.
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UNIT I
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Contents Introduction
Transmission Systems Manua
Automated Manua
Automatic
Continuousy varia!e
"ua Cutc#
$ropeer S#aft
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Contents
Universa &oints
"i'erentia Re(uirements of t#e Transmission "esi)n $roc
$roduct *ife Cyce
Sta)es in t#e "esi)n $rocess
• $ro&ect Set Up
• Concept "esi)n
• "etaied "esi)n• +n)ineerin) "rain)s and Toerancin)
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Transmission System
• unction of transmission/
- It is used to transmit en)ine tor(ue to t#e dri#ees to drive t#e ve#ice on t#e road.
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Re(uirement of Transmission Sys
• To provide for disconnectin) t#e en)ine fr
drivin) #ees
• #en en)ine is runnin) , connect t#e drivi#ees to en)ine smoot#y it#out s#oc2
• *evera)e !eteen en)ine and drivin) #e!e varied
• +na!e t#e drivin) #ees to rotate at di' speeds.
• $rovide reative movement !eteen en)idrivin) #ees
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Transmission System 3 *ayou
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Transmission Types
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Cutc#
unction of cutc#• Cutc# is used to disen)a)e and en)a)e
en)ine it# rest of t#e transmission systems
• To disen)a)e #ie startin) t#e en)ine
#ie c#an)in) )ear ratio.
• To en)a)e after startin) of t#e en)ine and
s#ift operation.
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Cutc#Re(uirement of Cutc#
• Transmit ma7imum tor(ue of t#e en)ine.
• +n)a)e )raduay to avoid sudden &er2s.
• "issipate ma7imum amount of #eat.• "amp t#e vi!rations and noise.
• "ynamicay !aanced.
• As sma as possi!e.
• +asy to operate.
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Cutc# Unit• y#ee aso acts as a drivin)
mem!er
• $ressure pate is connected tocutc# cover assem!y.
• Cutc# Cover assem!y is !oted to
t#e 9y#ee.
• Cutc# sprin)s paced !eteen$ressure pate : Cover pate, presst#e $ressure pate a)ainst t#e
cutc# pate.
• T#us Cutc# pate is s(uee;ed!eteen y#ee : $ressure pate.
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Cassi
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Cutc# +n)a)ed : "isen)a)• Cutc# is aays is in
en)a)ed state.• It can !e disen)a)ed
pressin) of Cutc# peda
"isen)a)ement is e'ect!y non 3 contact of Cutcpate !ot# it# y#
face : $ressure pate fa
• rictiona #eat is
dissipated !y openin)
present in Cutc# #ousin: Cover
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Cutc# Materia
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=eed of @ear Bo7
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@ear Bo7• @ear !o7 varies t#e evera)e
>speed ratio : #ence tor(ue
ratio? !eteen t#e en)ine :drivin) #ees.
• It is ocated !eteen Cutc# :
$ropeer s#aft.
• It is provided it# eit#er 0speed or 5 speed ratios or moredependin) on desi)n.
• @ear ratio is varied !y @ears#ift ever.
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Manua Transmission 3 Type
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UNIT II
S # i
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Sync#roni;ers• A device used to bring two adjacent members to
the same speed before allowing the sleeve to
engage them.• The two elements are friction clutch and toothed
clutch.
• Loc the positive engagement until speeds ares!nchroni"ed .
• #stablish the positive engagement and power flow.
• $!nchroni"er is splined on the shaft %one on thegear &blue' fits into cone-shaped area in the collar.
• (riction between the cone and collar s!nchroni"ethe collar ) gear.
• The outer portion of the collar &sleeve' then slidesso that the dogteeth engage the gear.
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Sync#romes# @ear!o7
1.I speed )ear
%.II speed )ear-.main s#aft
0.outer en)a)in) unit5.inner en)a)in) unit4.top )ear en)a)in) teet#
.main drive )ear6.top )ear sync#roni;in) con8.counter s#aft
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Ho Manua Transmission or2
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Ho Manua Transmission or2 • #en a driver ants to c#an)e from one )ear to a
in a standard stic23s#ift car, #e
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Manua Transmission• C#eap to ma2e
• "ura!e, ecient
• +asy to insta
• +sta!is#ed in mar2etpace and it#manufacturin) infrastructure
• @ives contro to t#e driver
• But driver comfort an issue it# increasin)density
Hence automation must !e considered
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Automated Manua Transmission >
• Automation of
Cutc# and @ears#iftin) operations
• +imination of Cutc
$eda
• Modi
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AMT eatures• Automation of Cutc# operation and @
s#iftin).
• Cutc# sip contro durin) startin)
• Hi start aid system #ic# i assist t#e dr#od and move t#e ve#ice in #i sope
• =ecessary fai safe systems suc# as suds#iftin) from #i)#er )ear to oest )ear and
versa
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System Boc2 "ia)ram
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Cutc# Actuation Contro• +n)ine Start
- Starter s#oud !e operated ony #en t#e )eain neutra position
- #en en)ine is not runnin) and in poer on,i disen)a)e cutc#
- #en en)ine speed e7ceeds a speci
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Cutc# Actuation Contro• @ear C#an)e
- #ie en)a)in) t#e cutc# after )eas#ift, t#e +CU determines cutc# actuato
trave !ased on s#ifted )ear position aacceerator peda stro2e
• Cutc# disen)a)ement- #ie )ear s#iftin) and #en acceeratpeda is reeased,
- if t#e ve#ice speed is oer t#an a setspeed for seect )ear position, t#e +disen)a)es cutc#
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Advanta)es of AMT• Reduced driver e'ort
• Improved Cutc# ife
• Utii;ation of e7istin) manufacturin) facii
for manua transmission
• *oer production cost t#an automatictransmissions
• Hi)#er eciency t#an automatictransmissions
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Automatic Transmission >AT?Conventiona "e
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uid Coupin)• Converts or transmits rotatin)
mec#anica ener)y or poer.
• Basic components.
- outer s#e or #ousin),
- impeer or pump and tur!ine or runner
• Bot# of t#ese units are contained it#in t#e#ousin) via oi3ti)#t seas.
• T#e input tur!ine is connected to t#e poersuppy, typicay an eectric or IC+.
• T#e output tur!ine is connected to t#e drive trainof t#e ve#ice or t#e drive system of a mac#ine.
• Minera oi is used
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uid Coupin)/ or2in)• Standsti
- T#e entire operatin) 9uid in t#ecoupin) is at rest
• Idin)- In sucient centrifu)a force for t#e
oi to turn t#e tur!ine
• *o to medium speed/- Centrifu)a force pus#es oi into
tur!ine and some turnin) e'ort istransmitted. *ar)e de)ree of sip int#e unit. Fp s#aft is rotatin) soy
t#an input s#aft.• Medium to Hi)# Speed
- i force is sucient to transmit fupoer. Fp s#aft rotatin) at a!out86G of speed of IFp s#aft >%G sip?.
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UNIT III
Tor(ue Convertor
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Tor(ue Convertor
• $erves as automatic clutch which transmits
engine tor*ue to the transmission input shaft
• +ultiplies tor*ue generated b! the engine
• Absorbs torsional vibration of engine
• Acts as a fl!wheel and smoothes out engine
rotation
• ,rives oil pump
• A tor*ue converter consists of
- Impeller - Turbine
- $tator
- and transmission fluid
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Tor(ue Convertor 3 Sectiona
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Impeer
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Tur!ine
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Stator
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or2in) of Tor(ue Converto
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or2in) of Tor(ue ConvertoEe#ice acceerates
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$anetary @ear System
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$anetary @ear System/ Construc
• Input shaft is connected to ing gear&lue'
• /utput shaft is connected to 0lane carrier&1reen' which is alsoconnected to +ulti-dis clutch
• $un gear is connected to a ,rum&2ellow'3 which can be loced
b! brae band &ed'. It is also connected to the other half of
%lutch
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$anetary @ear System/ pera• In =eutra
• Bot# !and and cutc# sets are reeased
• $anets assem!ed to carrier it# =RB
• Rin) )ear ony drive panet )ear not t#e panet
>utput s#aft?
• T#e panet )ears drive t#e sun )ears to spin fre
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$anetary @ear System/ perat
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$anetary @ear System/ perat
• In *o @ear >forard reduction?
• Band oc2s t#e sun )ear !y oc2in) t#e drum• $anets a2 around t#e sun )ear
• $anet carrier to spin in same direction as rin) )ear
• @ear ratio sun : rin) teet#Fno of teet# of rin) )ear
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$anetary @ear System/ per
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$anetary @ear System/ per
• In Hi)# @ear >"irect drive?
• Band is reeased.• *oc2 any to mem!ers• Cutc# is en)a)ed so t#at t#e sun )ear and pan
carrier is oc2ed to act as a ri)id mem!er• $anets #as to a2 around t#e rin) )ear,• Rin) @ear >Input s#aft? i spin at t#e same spe
t#e $anet Carrier >utput s#aft?
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$anetary @ear System/ perati
• Reverse @ear• $anet carrier is oc2ed
• Rin) )ear >Input s#aft? i cause t#e sun )ea>utput S#aft? to turn in t#e opposite direction
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UNIT I4
Automatic Transmission >AT
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Automatic Transmission >ATAdvanta)es
T#e ony option for comforta!e automatic s#iftin)
Cost issue miti)ated !y #i)# voume manufacturin)
"isadvanta)es
Cost for deveopment and manufacturin)
ue economy due to tor(ue converter
*ac2 of contro !y t#e driver
Modern improvements
Better contro a)orit#ms
Tor(ue converter oc2 up
Most usea!e transmissions !ased on a coupe of standard arran)ements
Ravi)neau7
*epeetier
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Continuousy Earia!e Transmissi
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Continuousy Earia!e Transmissi
>CET?
• CET provides in!eteen a minimum : ama7imum?.
• S#ifts automaticay it# anin
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CET/ Construction
Uses a pair of a7iay
ad&usta!e sets of puey #aves>Eariators?
Bot# pueys #ave one
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CET/ unctionin)• T#e transmission ratio is varied !y
ad&ustin) t#e spacin) !eteen t#epueys in ine it# t#e circumferenceof t#e tapered puey #aves.
• T#e variators are ad&usted
#ydrauicay.
• #en one puey is varied, t#e ot#erpuey must adapt itsef inversey sincet#e en)t# of t#e !et is
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"ua Cutc# Transmission >"C
04
"CT C t ti
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"CT/ Construction
B i " t C t #
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Basic "ua et Cutc#
Ho "CT or2s
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Ho "CT or2s In a conventional manual transmission3 there is not a
continuous flow of power from the engine to the wheels.
Instead3 power deliver! changes from /N to /(( to /N during
gearshift3 causing a phenomenon nown as 5shift shoc5 or
5tor*ue interrupt
A dual-clutch transmission uses two clutches3 but has no clutchpedal.
$ophisticated electronics and h!draulics control theclutches3 just as the! do in a standard automatic transmission.
In a ,%T3 however3 the clutches operate independentl!
/ne clutch controls the odd gears&first3 third3 fifth and
reverse'3 while the other controls the even gears&second3 fourth and si6th'
Using this arrangement3 gears can be changed without
interrupting the power flow from the engine to the transmission
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$ S# ft
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$ropeer S#aft
Sin)e piece
To piece ront en)ine rear #ee drive Reduction in car #ei)#t
>oerin) of !ody?
Cras# ener)y mana)ement Materia Auminum
stee
Composite >5G car!on, %5G)ass3
Cod roed and seameded
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$ S# ft
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$ropeer S#aft
It propels the vehicle forward3 so called propeller shaft A 0ropeller $haft connects a gearbo6 to a ,ifferential.
It is used to transmit the drive force generated b! the engine
to the a6les.
It is strong enough to handle ma6imum low gear tor*ue
It is provided with two U-joints to maintain constant velocit!
and positioning of differential at different plane.
It is provided with a slip joint to tae care of the change in
length.
$haft diameter and its thicness decides the tor*ue carr!ingcapacit! and angle of operation.
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$ S# ft
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$ropeer S#aft
• "esi)n re(uirements
• Critica speed is at east 15G a!ove tospeed
• Tor(ue carryin) capacity re(uirements
• $un)e re(uirements >suspension trav
• Assem!y re(uirements
5%
Uni ersa &oints
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Universa &oints• "esi)ned to eiminate
tor(ue and speed9uctuations >constant
veocity &oints?
• If ony one universa &oint isused, speed 9uctuationsi not !e neutrai;ed.
• To maintain uniform
motion, to universa &ointsare used it# yo2e u)s inp#ase.
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Universa &oints
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Universa &oints
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Hoo2eLs oint
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Hoo2eLs oint
Condition for Constant veocity drive it# to H
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"i'erentia
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"i'erentia• To transfer t#e
en)ine poer to t#e
#ees
• To act as t#e
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"i'erentia/ In Strai)#t A#ead
Input tor(ue is appied to
t#e rin) )ear, #ic# turnst#e entire
carrier, providin) tor(ueto !ot# side )ears, #ic#
in turn may drive t#e eftand ri)#t #ees.
If t#e resistance at !ot#
#ees is e(ua, t#epinion )ear does not
rotate, and !ot# #eesturn at t#e same rate.
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"i'erentia/ In a Turn
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"i'erentia/ In a Turn
• If t#e eft side )ear>red? encounters
resistance, t#e pinion)ear>)reen? rotates
a!out t#e eft side)ear, in turn appyin)e7tra rotation to t#eri)#t side )ear
>yeo?.
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A7e
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Transmits rotary motion and tor(ue froen)ine3transmission3drives#aft to t#e #ee
C#an)es torsiona direction from on)ituditransverse
$rovides speed reduction and tor(
mutipication $rovides a di'erentia action to permitcornerin)
$rovides mountin) points for suspensio!ra2es
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Transmission Trou!es#ootin
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Transmission Trou!es#ootin
• *ea2in) Transmission uid
• Sippin) of Transmission
• "ama)ed Transmission uid
• Sur)in) of Transmission
• @ear $ro!ems
• uid *ea2in)
• Spiin) out of uid
• +rratic @ear S#iftin)
• ver#eatin) of Transmission
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Transmission Trend
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$assen)er Car Transmission in Indi Manua transmission is more dominant in India as compare
transmissions. Ma&ority of t#e MT are usin) 5speed @B as compared to 4 s But many of t#e u7urious car manufactures are no usin)
Source: Mahr GmbH, Germany
@o!a Transmission Trend
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@o!a Transmission Trend+stimated )o!a mar2et s#are >G? for passen)er car trans
1%
46%
1% 2%
6%
MT
AT
50% CVT
4%2%
47%
MT
AT
CVT
CT 41% CT
AMT AMT
2005 2010
!%
7% 10%
4!%
!7%
MT
AT
CVT
CT
AMT
2015
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Re(uirements of t#e Transmissi
"esi)n $rocess
$roduct *ife Cyce
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$roduct *ife Cyce
• $roduct *ife Cyce must !e deveoped to deiCompany )oas
=e $roduct Introduction
easi!iity StudiesF
=e Concepts
$rototypeTransmission $roduction Ready
"esi)n "eveopment Transmission
Manufacturi$roduct sup
anddeveopme
Mar2et feed!ac2, Mar2et researc#,Tec#nica "eveopment, Appication e7perience
Researc#
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Sta)es in t#e "esi)n $roces
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Sta)es in t#e "esi)n $roces
• Timeine
$ro&ect set up
Concept desi)n
"etai desi)n
Toerancin) :
drain)s
$rototype testin)
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UNIT 4
$ro&ect Set Up
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o&ec Se Up- T#e
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& pTo !e incuded in t#e $roduct "esi)n Speci
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$ro&ect Set Up• To !e incuded in t#e $roduct "esi)n Speciappro7imate
• $ac2a)in) it#in t#e ve#ice
• Assem!e3a!iity
• "ura!iity
• Ratio
• ei)#t
• Cost• @ear s#ift (uaity
• =oise
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$ro&ect Set Up
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$ro&ect Set UpTo !e incuded in t#e $roduct "esi)n Speci
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$ro&ect Set Up/ "uty Cyce• A 2ey component of t#e tar)etsJ is t#e "uty Cyc
• #at is a "uty Cyce
- Cacuation of Component Reia!iity 3 sin)e o
Materia$roperties
peratin)
Conditions Seect
Re(uired
Reia!iity
Component
@eometry
Appied*oads >"uty
Cyce?
Anaysis topredictstress
peratin) Anaysis to
Stresses predict ife
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$ro&ect Set Up/ "uty Cyce
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$ro&ect Set Up/ "uty Cyce• A "uty Cyce is a coection of oadcases
- A automotive transmissions are oaded it# muoadcases
- Mutipe ratios
- "i'erent tor(ue eves for eac# ratio
• 1DG, %DG, -DG P 1DDG tor(ue
• Accountin) for Mutipe3oadcases 3 "ama)e
- MinerLs RueJ >*inear "ama)e Hypot#esis?
• To com!ine t#e e'ect of di'erent oadcases
• "ama)e raction : $ercenta)e
• e need to account for t#e e'ect of t#ese many oadca
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$ro&ect Set Up/ "uty Cyce
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& p y y
• In3service *oads must !e converted into a
cyce for desi)n and testin)"ura!iity
In3Service *oadsTimeFtor(ue
#istory for t#e 85t#
centie
CacuationTo derive t#e
dama)e for eac#
component in t#etransmission
"esi)n "uty Cyce+(uivaent duty cyce
appropriate for
transmission desi)n
Test "uty Cyce+(uivaent duty
cyce appropriatefor ri) testin)
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Concept "esi)n
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Concept "esi)n
• Activities it#in Concept "esi)n >part A?
Inputs from$"S/
3@ear ratios3+n)inetor(ue andduty cyce3-"pac2a)in)space
"esi)n )earteet# and!an2s anddo) teet#
Createinitia)ear!o7
concept
Sync#roniserdesi)n, si;in)and
pac2a)in)
Iterative "esi)nof t#e @ear!o7Concept
Spine
desi)nandratin)
Can
ratiosand
pac2a)in) !e
ac#ieved
=o
Qes utput/$roposedconceptayout
"e
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Concept "esi)n
• @eneration of "esi)n ptions >*ayoutsF Topoo)y?
- Create as many di'erent desi)n ayouts as posto meet t#e ratio and pac2a)in) re(uirements
ption A ption B ption C
ption " ption + ption
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Concept "esi)n
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Concept "esi)nIterative "esi)n, Anaysis and ptimisation, !y
- @ears• Toot# num!ers
• Ratin) to IS 4--4
• Contact Ratio tar)ets
• Misai)nment tar)ets
- S#aft
• "ura!iity
• "e9ection
- Sync#roni;ers• S#ift force
• Cone to inde7 tor(ueratio
- Bearin)s
• "ura!iity
• Misai)nment tar)ets
- Spine
• Stress
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Concept "esi)n
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p )• Activities it#in Concept "esi)n >part B?
Casin)"esi)n and
"i'erentia
$roposed Concept *ayoutS#ift
Mec#anismC#ec2 forcompati!iity
it# ot#er componentsand it# ve#icepac2a)in) C#ec2 for
Assem!y
Iterate on items de
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p
• +vauation criteria
• *ist a t#e re(uirements for t#e desi)n frospecie.). 135?
• "etermine #at o!&ective measures can !efrom concept mode
• ei)#t• =um!er of parts
• Safety factors
Concept Seection
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p
• Concept scorin)
• Assi)n a score to eac# concept accordin) te7tent to #ic# it meets eac# re(uirement
• Mutipy eac# score !y t#e appropriate ei
factor
• T#e !est scorin) concept i t#en form t#e !at#e detai desi)n
6
"etaied "esi)n
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"etaied "esi)n
Activities it#in "etaied "esi)n
• ocus on system de9ections and )ear micro3)eodesi)n
"i'erentia"etaiin)
@ear Micro3)eometry "esi)n
Competed
Competed Concept "esi)n Casin) "etaiin)
"etaied "esi)n andAnaysis of t#er
Components*u!rication system
+, System "e9ectionand @ear Toot#
Contact "etaiedAnaysis
C#ec2 forcompati!iity it#ot#er components
"etaied"esi)n, a=omina
"imensionsCompete
Iterate on Concept "esi)n$arts A and B if necessary
8
"etaied "esi)n
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• Cacuation of System "e9ections
*oaddistri!ution
S#aft
de9ection
*oad distri!utiofactor
ContactStress
Stress
• Cacuation of "ura!iity
6D
"etaied "esi)n
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)• Accurate anaysis is re(uired to determine #
tar)ets are met
• Simpe met#ods do not )ive accurate resuts- Increased ris2 of pro!ems ater in product ife cyce
- *ac2 of cear direction for optimisation
• "etaied anaysis met#ods #ave t#eir on issues- Many desi)n options- "o e #ave to cacuate everyt#in) !efore e ma2e a de
- Ho do e mana)e t#ese met#ods in t#e desi)n process
61
Anaysis Met#ods
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Anaysis Met#ods
• $rincipes
- Hierarc#y of desi)n parameters
• Understand #o desi)n parametersot#er desi)n parameters and transmiperformance
• Understand t#e O#ierarc#yL of desi
parameters
• "e
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Anaysis Met#ods
• Hierarc#y of "esi)n $arameters
- Some parameters #ave a !i) e'ect on )earperformance
- Some parameters are needed to de
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Anaysis Met#ods
• Hierarc#y of "esi)n $arameters
- t#er parameters #ave a smaer e'ect on )eperformance
- T#ey are dependent on precedin) parametersde
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a ys s e ods
• Hierarc#y of "esi)n $arameters- t#er parameters #ave itte e'ect on t#e)ear!o7 performance
- T#ey can !e estimated
- e.). sea desi)n
S#aft desi)n
Seadesi)n
@ear!o7 pac2a)i
+n)ineerin) "rain)s and Toeranc
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• Activities it#in +n)ineerin) "rain)s and Toeran
- Ma&or issues s#oud !e resoved
Compete "rain)s
Competed "etaied "esi)n
Con
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) ) )
• Appyin) Manufacturin) Toerances
- Toerances appied to components !ased o2noed)e of manufacturin) process
• e.). turnin), )rindin) etc
- unctionay critica features identi
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• Toerance Stac2sIdentify
c#ec2s re(uired
Create masterdimension s#eet
Create toerancestac2s for eac#
s#aft assem!y
C#ec2 resut =o
Qes
Create toerance
stac2s for s#aft to
s#aft cearances
@ear and s#aftde9ections from
anaysis
Revise dimensionson master o
dimension s#eet
o
C#ec2 resut Qes
ina desi)n
Qes
C#ec2 resut
Create #ousin)toerance stac2s
66
+n)ineerin) "rain)s and Toeranc
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$otentia $ro!ems
• orm and functionaity at toerance e7tre
- Symptom >e7ampe?/
At toerance e7tremes, transmission does n
assem!e or t#ere is a fou >at ;ero oad?
- Action/
Sma iteration/ Rede
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$otentia $ro!ems• orm and functionaity at toerance, temp
e7tremes, under oad
- Symptom >e7ampe?/ Transmission does not as
or t#ere is a fou at/
• Toerance e7tremes• Temperature e7tremes
• *oad >i.e. de9ected s#apes?
- +7ampe/ @ears cas# due to t#erma e7pansio
a7ia movement due to compiance of
!earin)s, #ousin) etc.
- Action >as !efore?
8D
utput of "esi)n $rocess
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p )• A ayout t#at satis
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THA