Automotive Transmissions: Fundamentals, Selection, Design and Application
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Abstract:
Introduction.- Overview of the Traffic-Vehicle-Transmission System.- Mediating the Power Flow.- Power Conversion: Selecting the Ratios.- Matching Engine and Transmission.- Vehicle Transmission Systems: Basic Design Principles.- Design of Gearwheel Transmisions for Vehicles.- Specification and Design of Shafts.- Gearshifting Mechanisms.- Moving-Off Elements.- Design and Configuration of Further Design Elements.- Typical Designs of Vehicle Transmissions.- Electronic Transmission Control.- Computer-Aided Transmission Development.- The Automotive Transmission Development Process.- Transmission Manufacturing Technology.- Reliability and Testing of Automotive Transmissions.- References.- Index of Companies/Transmissions.- Index of Names.- Subject Index.Keywords:
Power transmission
Automatic transmission
Transmission system
Design flow
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A model is presented which makes it possible to predict power losses in a six-speed manual gearbox. The following sources of dissipation, i.e., power inputs in the model, are considered: (i) tooth friction; (ii) rolling element bearings; (iii) oil shearing in the synchronizers and at the shaft-free pinion interfaces; and (iv) oil churning. Based upon the first principle of Thermodynamics for transient conditions, the entire gearbox is divided into lumped elements with a uniform temperature connected by thermal resistances which account for conduction, convection, and radiation. The numerical predictions compare favorably with the efficiency measurements from the actual gearbox at different speeds and torques. The results also reveal that, at lower temperatures (about 40°C), power loss estimations cannot be disassociated from the accurate prediction of temperature distributions.
Pinion
Shearing (physics)
Churning
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Electric vehicle powertrains traditionally consist of a central electric motor drive, a single-speed transmission and a differential. This electric powertrain layout, for use in either fully electric vehicles or through-the-road parallel hybrid electric vehicles, will be extensively adopted in the next few years, despite the ongoing research in electric vehicles with individually controlled motors. However, current research suggests that electric powertrains with a central electric motor drive can still be widely improved. For example, the installation of a seamless multiple-speed transmission instead of a single-speed transmission can cause an increase in the vehicle performance, together with an enhancement in the overall efficiency of the electric powertrain. These novel transmission systems for electric powertrains require a specific design, in order to be efficient, compact, easy and robust to control and cheap to manufacture. This article presents the mechanical layout and the control system of a novel two-speed transmission system designed by the present authors, with particular focus on the achievement of optimal gearshift dynamics. The torque characteristics of typical electric motor drives require a different actuation of the seamless gearshifts, in comparison with the equivalent operation for a dual-clutch transmission within a powertrain driven by an internal combustion engine.
Powertrain
Automatic transmission
Manual transmission
Continuously variable transmission
Transmission system
Torque converter
Electric machine
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Slippage
Throttle
Manual transmission
Powertrain
Automatic transmission
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The world's first six-speed automatic transmission for passenger cars was introduced to the market by ZF in 2001. The 6HP-family is based on a Lepelletier planetary gear set. An advanced version of these transmissions was launched in 2006. The 2nd generation offers significantly improved customer-relevant features such as reduced fuel consumption, response time and shifting speed. With regard to the increasing requirements especially in reduction of CO2 emissions, a new eight-speed transmission is now under development. The main targets for this transmission family are a further significant reduction in fuel consumption and emissions, good driving performance and state of the art driving comfort. The paper describes the transmission 8HP70, the schematic, main features and major design components. Key figures like transmission weight and size, fuel efficiency benefits and driving performance are shown compared to the 6-speed transmission of the 2nd generation. The 8HP70 transmission offers the possibility of implementing several start-up devices and of integrating different all-wheel drive configurations. Based on a modular system, the 8-speed transmission can be equipped with a variety of hybrid functions. Micro, mild and full hybrid solutions can be implemented without the need of additional installation space. The described technical features meet the demands of future requirements. The new 8HP-family shows that the technology of "conventional" automatic transmissions with torque converter and planetary gear sets still contain a lot of potential. In combination with the known advantages such as market acceptance, cost-benefit ratio, and comfort, this new transmission generation of ZF will mark a milestone in the history of automatic transmission technology for cars, which will serve as a benchmark for other transmission systems.
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Continuously variable transmission
Control variable
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Based on a detailed dynamic model of an automotive powertrain containing a twin-clutch transmission, an integrated powertrain control for gearshifts is developed. The operation of this controller is demonstrated on the basis of simulation results for upshifts, downshifts, and multiple gearshifts taking place within the same half of the transmission. The control algorithm makes use of closed-loop control of clutch slip for a smooth transfer of engine torque with the aim of reproducing the operation of a one-way clutch. Further elements are a closed-loop control of engine speed through a combination of a manipulation of engine controls and clutch pressure. In addition, it is demonstrated that the control of transmission output torque during gearshifts can add robustness to the control and provides a means to manipulate directly the gearshift character. Finally, the dynamic effects of gear preselection through conventional hydraulically actuated cone-type synchronizers on the overall shift quality are discussed.
Powertrain
Torque converter
Automatic transmission
Manual transmission
Robustness
Trimming
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Citations (156)
The research presented in this paper focuses on the effects of downsizing the electric motor drive of a fully electric vehicle through the adoption of a multiple-speed transmission system. The activity is based on the implementation of a simulation framework in Matlab / Simulink. The paper considers a rear wheel drive case study vehicle, with a baseline drivetrain configuration consisting of a single-speed transmission, which is compared with drivetrains adopting motors with identical peak power but higher base speeds and lower peak torques coupled with multiple-speed transmissions (double and three-speed), to analyze the benefits in terms of energy efficiency and performance. The gear ratios and gearshift maps for each multiple-speed case study are optimized through a procedure developed by the authors consisting of cost functions considering energy efficiency and performance evaluation. The cost functions are explained in the paper along with the models adopted for the research. Copyright © 2012 SAE International.
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Citations (63)
Manual transmission
Powertrain
Automatic transmission
Synchronizer
Robustness
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Citations (124)
Powertrain
Torque converter
Throttle
Fluid coupling
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Citations (130)