Ppt Auto 5sem ATE

8/20/2019 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.

0


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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

5


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Transmission System 3 *ayou

4


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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.

6


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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.

8


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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

1%


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Cutc# Materia

1-


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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

14


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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.

1


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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

16

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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d f


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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

-D


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Tor(ue Convertor 3 Sectiona

-1


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Impeer

-%


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Tur!ine

--


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Stator

-0

or2in) of Tor(ue Converto


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or2in) of Tor(ue ConvertoEe#ice acceerates

-5


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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

-

$ t @ S t


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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

-6

$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

-8

$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

01


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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

0%

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

08

$ 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

5D

$ 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.

5-

Universa &oints


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Universa &oints

50

Hoo2eLs oint


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Hoo2eLs oint

Condition for Constant veocity drive it# to H

55

"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.

5

"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?.

56

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

58

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

4D

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

i f # i i


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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#

40

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)

45


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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

46

$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

D

$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

1

$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)

%

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

0

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

5

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


82/97

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


83/97

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


96/97

p )• A ayout t#at satis


97/97

THA

Date post:	07-Aug-2018
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