ON
“TRANSMISSIONS”
To
• ACKNOWLEDGEMENT
• ABSTRACT
• GEAR BOX WORKING PRINCIPLE
• TYPES OF GEAR BOX
• MANUAL TRANSMISSION
• CVT TRANSMISSION
• AMT TRANSMISSION
• DUAL CLUTCH TRANSMISSION
• CONCLUSION
• BIBLIOGRAPHY
ACKNOWLEDGEMENT
A Gear Box is an assembly consisting of various gears, synchronizing sleeves and gear-
shifting mechanism fitted in a metal housing. The metal housing usually made of
aluminium/iron casting accommodates all the gears in it. Gearbox is a part of the
‘transmission’ system as the gears play an important role in transmitting the engine power to
the wheels.
What is Transmission?
All the components of the drive-train that help to transmit the engine power to the wheels are
a part of the ‘Transmission’ system. Of which, the gearbox is an integral part. These
components include the clutch, gearbox, couplings, propeller shaft, axle shafts, and
differential. In general, the term 'Transmission' usually refers to the car’s gear box. Some car
designs integrate the gear box and differential assembly into a single unit called
‘Transmission’ or 'Trans-Axle'.
The gear ratio is the ratio between the input and output gears. The driving gear and driven
gears in a gear box define the gear ratios. The input gears get the drive from the engine and
they rotate the output gears which, in turn, drive the wheels. The ratio of the number of
rotations of output gear to the number of rotations of input gear is called the gear ratio.
Gear Ratio = No. of teeth of output gear / no. of teeth of the input gear
For e.g., If no. of gears on input (driving) gear = 30, no. of gears on output (driven) gear =
105
Then the Gear ratio = 105 / 30 = 3.5: 1 because to rotate the output (driven) gear by 1
rotation, you need to rotate the input (driving) gear by 3.5 rotations.
GEAR RATIO
The gear ratios vary from vehicle to vehicle. In trucks, the gear ratios are typically higher
than cars as they have to carry the heavy load.
A gear box contains gears of different sizes. This is mainly because of the varying demands
of the vehicle in terms of the torque required at the wheels depending upon the road, terrain
& load. For e.g., if a vehicle is climbing a slope, it needs higher torque as compared to while
cruising on a straight road.
In a gear box, the first gear is biggest in size and provides maximum torque output while
producing minimum speed. Hence, it is used when climbing slopes. All the gears between
1st and last gear vary in size; in a decreasing ratio. Thus, it provides a varying combination in
terms of pulling ability and speed. So, the vehicle could be driven smoothly without any drop
in its acceleration. The gear box basically improves the vehicle's driveability in all conditions.
What is an Overdrive?
In contrast, the last gear or the top gear, at times an Overdrive, is smallest in size. However, it
provides minimum traction but maximum speed. A gearbox with an Overdrive means its
output is higher than its input that connects to the engine. In other words, the overdrive gear
rotates faster than the engine speed. Thus, it provides higher speed and better efficiency as
the engine runs at a lower rpm in relation to vehicle speed.
In some advanced designs, there are more than one 'Overdrive' gears; usually two. Thus, Dual
Overdrive (aka 'Double Top') provides even higher speed and better efficiency in a vehicle.
Gearbox Operation:
Generally, there are two sets of gears in a conventional gear box – the input & the output. The
input gears are fixed on the countershaft making it a single unit. It drives the individual gears
on the main shaft which rotate freely on the bearings. Thus, the gearbox passes the drive to
the wheels depending upon the gear which engages on the main shaft. When you push the
shifter-sleeve towards the desired gear, that gear locks onto the main shaft and rotates it.
Thus, the main shaft rotates at the speed of the engaged gear and provides the output as per
the engaged gear’s ratio.
Gearbox: Speed vs Traction
You need both the speed as well as the traction while driving an automobile. The
gears in the gearbox help you choose either of them depending on the driving
conditions. The lower gear i.e. 2nd and 1st gear will give you greatest traction while
the higher gears i.e. 5th and 6th (if available) will give you the highest speed. The
number of gears in the gearbox provides the perfect combination of traction and
speed. Thus, it helps the driver/rider choose the most appropriate combination to
enhance efficiency at all times. Hence, choosing the right gear according to road and
load conditions is very important. With short gearing, you get better acceleration or
pick-up while with tall gearing you achieve higher top speed.
So by now, you should have a basic understanding of a transmission’s purpose: it ensures that
your engine spins at an optimal rate (neither too slow nor too fast) while simultaneously
providing your wheels with the right amount of power they need to move and stop the car, no
matter the situation you find yourself in.
Input shaft- The input shaft comes from the engine. This spins at the same speed and power
of the engine.
Countershaft- The countershaft (aka layshaft) sits just below the output shafts. The
countershaft connects directly to the input shaft via a fixed speed gear. Whenever the input
shaft spins, so does the countershaft, and at the same speed as the input shaft.
In addition to the gear that takes power from the input shaft, the countershaft also has several
gears on it, one for each of the car’s “gears” (1st-5th), including reverse.
Output shaft-The output shaft runs parallel above the countershaft. This is the shaft that
delivers power to the rest of the drivetrain. The amount of power the output shaft delivers all
depends on which gears are engaged on it. The output shaft has freely rotating gears that are
mounted on it by ball bearings. The speed of the output shaft is determined by which of the
five gears are in “gear,” or engaged.
1st-5th gears- These are the gears that are mounted on the output shaft by bearings and
determine which “gear” your car is in. Each of these gears is constantly enmeshed with one
of the gears on the countershaft and are constantly spinning. This constantly enmeshed
arrangement is what you see in synchronized transmissions or constant mesh transmissions,
which most modern vehicles use. (We’ll go into how all the gears can always be
spinning while only one of them is actually delivering power to the drivetrain here in a bit.)
First gear is the largest gear, and the gears get progressively smaller as you get to fifth gear.
Remember, gear ratios. Because first gear is bigger than the countershaft gear it’s connected
to, it can spin slower than the input shaft (remember, the countershaft moves at the same
speed as the input shaft), but deliver more power to the output shaft. As you move up in
gears, the gear ratio decreases until you reach the point that the input and output shafts are
moving at the same speed and delivering the same amount of power.
Idler gear- The idler gear (sometimes called “reverse idler gear”) sits between the reverse
gear on the output shaft and a gear on the countershaft. The idler gear is what allows your car
to go in reverse. The reverse gear is the only gear in a synchronized transmission that isn’t
always enmeshed or spinning with a countershaft gear. It only moves whenever you actually
shift the vehicle into reverse.
Synchronizer collars/sleeves-Most modern vehicles have a synchronized transmission,
meaning the gears that deliver power on the output shaft are constantly enmeshed with gears
on the countershaft and are constantly spinning. But you might be thinking, “How can all five
gears be constantly enmeshed and constantly spinning, but only one of those gears is actually
delivering power to the output shaft?”
The other issue that comes up with the gears always spinning is that the drive gear is often
rotating at a different speed than the output shaft that the gear is connected to. How do you
sync up a gear spinning at a different rate as the output shaft, and in a smooth way that
doesn’t cause a lot of grinding?
The answer to both questions: synchronizer collars.
As mentioned above, gears 1-5 are mounted on the output shaft via ball bearings. This allows
all of the gears to freely spin at the same time while the engine is running. To engage one of
these gears, we need to firmly connect it to the output shaft, so power is delivered to the
output shaft and then to the rest of the drivetrain.
Between each of the gears are rings called synchronizer collars. On a five-speed transmission,
there’s a collar between the 1st and 2nd gears, between the 3rd and 4th gears, and between
the 5th and reverse gear.
Whenever you shift a car into a gear, the synchronizer collar shifts over to the moving gear
you’re looking to engage. On the outside of the gear are a series of cone-shaped teeth. The
synchronizer collar has grooves to accept those teeth. Thanks to some excellent mechanical
engineering, the synchronizer collar can connect to a gear with very little noise or friction
even while the gear is moving, and sync the gear’s speed with the input shaft. Once the
synchronizer collar is enmeshed with the driving gear, that driving gear is delivering power to
the output shaft.
Whenever a car is “neutral” none of the synchronizer collars are enmeshed with a driving
gear.
Synchronizer collars are also something that’s easier to understand visually. Here’s a short
little clip that does a great job explaining what’s going on (starts at about 1:59 mark):
Gearshift- The gearshift is what you move to put a car into gear.
Shift rod- The shift rods are what move the synchronizer collars towards the gear you want
to engage. On most five-speed vehicles, there are three shift rods. One end of a shift rod is
connected to the gearshift. At the other end of the shift rod is a shift fork that holds the
synchronizer collar.
Shift fork- The shift fork holds the synchronizer collar.
Clutch- The clutch sits between the engine and gearbox of the transmission. When the clutch
is disengaged, it disconnects power flow between the engine and transmission gearbox. This
disconnection of power allows the engine to continue running even though the rest of the
car’s drivetrain isn’t getting any power. With engine power disconnected from the
transmission, shifting gears is much easier and prevents damage to the transmission gears.
This is why whenever you shift gears, you push the clutch pedal and disengage the clutch.
When the clutch is engaged — your foot comes off the pedal — power between the engine
and transmission is restored.
CVT-TRANSMISSION
CVT! Most of you would have heard of this term when you wanted to buy a gearless
scooter or an automatic car. It stands for Continuous Variable Transmission, one of the
forms of automatic transmission on a two-wheeler and four-wheelers as well.
The gear shift pattern is pre-programmed from the factory and that data is stored by the ECU.
So whenever the RPM climbs to a certain level, the ECU automatically controls the actuators
to operate both the clutch and gearbox in synchronisation.
This functions exactly like an automatic gearbox as there is no clutch pedal and in some
cases, there isn’t even a gear lever inside the cabin (as seen in the Renault Kwid). Although
in most cases, there is a gear lever with the three drive modes, R (Reverse), N (Neutral) and
D (Drive). There is also an option of shifting into manual mode just parallel to the Drive
mode.
In the manual mode, the gear operation is significantly simple, move the lever forward to
shift into a higher gear and move it backwards to shift into a lower gear, no clutch and no
multi-directional shift paths.
Most people know that cars come with two basic transmission types: manuals, which require
that the driver change gears by depressing a clutch pedal and using a stick shift,
and automatics, which do all of the shifting work for drivers using clutches, a torque
converter and sets of planetary gears. But there's also something in between that offers the
best of both worlds -- the dual-clutch transmission, also called the semi-automatic
transmission, the "clutchless" manual transmission and the automated manual transmission.
So, in a conventional manual transmission, there is not a continuous flow of power from the
engine to the wheels. Instead, power delivery changes from on to off to on during gearshift,
causing a phenomenon known as "shift shock" or "torque interrupt." For an unskilled driver,
this can result in passengers being thrown forward and back again as gears are changed.
A dual-clutch gearbox, by contrast, uses two clutches, but has no clutch pedal. Sophisticated
electronics and hydraulics control the clutches, just as they do in a standard automatic
transmission. In a DCT, however, the clutches operate independently. One clutch controls the
odd gears (first, third, fifth and reverse), while the other controls the even gears (second,
fourth and sixth). Using this arrangement, gears can be changed without interrupting the
power flow from the engine to the transmission. Sequentially, it works like this:
The diagram below shows this arrangement for a typical five-speed DCT. Notice that one
clutch controls second and fourth gears, while another, independent clutch controls first, third
and fifth gears. That's the trick that allows lightning-fast gear changes and keeps power
delivery constant. A standard manual transmission can't do this because it must use one
clutch for all odd and even gears.
Multi-plate Clutches
Because a dual-clutch transmission is similar to an automatic, you might think that it requires
a torque converter, which is how an automatic transfers engine torque from the engine to the
transmission. DCTs, however, don't require torque converters. Instead, DCTs currently on the
market use wet multi-plate clutches. A "wet" clutch is one that bathes the clutch components
in lubricating fluid to reduce friction and limit the production of heat. Several manufacturers
are developing DCTs that use dry clutches, like those usually associated with manual
transmissions, but all production vehicles equipped with DCTs today use the wet version.
Many motorcycles have single multi-plate clutches.
Like torque converters, wet multi-plate clutches use hydraulic pressure to drive the gears. The
fluid does its work inside the clutch piston, seen in the diagram above. When the clutch is
engaged, hydraulic pressure inside the piston forces a set of coil springs part, which pushes a
series of stacked clutch plates and friction discs against a fixed pressure plate. The friction
discs have internal teeth that are sized and shaped to mesh with splines on the clutch drum. In
turn, the drum is connected to the gearset that will receive the transfer force. Audi's dual-
clutch transmission has both a small coil spring and a large diaphragm spring in its wet multi-
plate clutches.
To disengage the clutch, fluid pressure inside the piston is reduced. This allows the piston
springs to relax, which eases pressure on the clutch pack and pressure plate.
Hopefully it's becoming clear why the DCT is classified as an automated manual
transmission. In principle, the DCT behaves just like a standard manual transmission: It's got
input and auxiliary shafts to house gears, synchronizers and a clutch. What it doesn't have is a
clutch pedal, because computers, solenoids and hydraulics do the actual shifting. Even
without a clutch pedal, the driver can still "tell" the computer when to take action through
paddles, buttons or a gearshift.
Driver experience, then, is just one of the many advantages of a DCT. With upshifts taking a
mere 8 milliseconds, many feel that the DCT offers the most dynamic acceleration of any
vehicle on the market. It certainly offers smooth acceleration by eliminating the shift shock
that accompanies gearshifts in manual transmissions and even some automatics. Best of all, it
affords drivers the luxury of choosing whether they prefer to control the shifting or let the
computer do all of the work.
Perhaps the most compelling advantage of a DCT is improved fuel economy. Because power
flow from the engine to the transmission is not interrupted, fuel efficiency increases
dramatically. Some experts say that a six-speed DCT can deliver up to a 10 percent increase
in relative fuel efficiency when compared to a conventional five-speed automatic.
Many car manufacturers are interested in DCT technology. However, some automakers are
wary of the additional costs associated with modifying production lines to accommodate a
new type of transmission. This could initially drive up the costs of cars outfitted with DCTs,
which might discourage cost-conscious consumers.
DCTs don't have such issues and are ideal for high-performance vehicles. In Europe, where
manual transmissions are preferred because of their performance and fuel efficiency, some
predict that DCTs will capture 25 percent of the market. Just one percent of cars produced in
Western Europe will be fitted with a CVT by 2012.
Next, we'll look at the history of the DCT and see what the future holds.
The man who invented the dual-clutch gearbox was a pioneer in automotive engineering.
Adolphe Kégresse is best known for developing the half-track, a type of vehicle equipped
with endless rubber treads allowing it to drive off-road over various forms of terrain. In 1939,
Kégresse conceived the idea for a dual-clutch gearbox, which he hoped to use on the
legendary Citroën "Traction" vehicle. Unfortunately, adverse business circumstances
prevented further development.
Both Audi and Porsche picked up on the dual-clutch concept, although its use was limited at
first to racecars. The 956 and 962C racecars included the Porsche Dual Klutch, or PDK. In
1986, a Porsche 962 won the Monza 1000 Kilometer World Sports Prototype Championship
race -- the first win for a car equipped with the PDK semi-automatic paddle-shifted
transmission. Audi also made history in 1985 when a Sport quattro S1 rally car equipped with
dual-clutch transmission won the Pikes Peak hill climb, a race up the 4,300-meter-high
mountain.
Commercialization of the dual-clutch transmission, however, has not been feasible until
recently. Volkswagen has been a pioneer in dual-clutch transmissions, licensing
BorgWarner's DualTronic technology. European automobiles equipped with DCTs include
the Volkswagen Beetle, Golf, Touran, and Jetta as well as the Audi TT and A3; the Skoda
Octavia; and the Seat Altea, Toledo and Leon.
Ford is the second major manufacturer to commit to dual-clutch transmissions, made by Ford
of Europe and its 50/50 joint venture transmission manufacturer, GETRAG-Ford. It
demonstrated the Powershift System, a six-speed dual-clutch transmission, at the 2005
Frankfurt International Motor Show. However, production vehicles using a first generation
Powershift are approximately two years away.
CONCLUSION
From the above report we can conclude that transmission plays a vital role in the performance
and efficiency of a car . In manual transmission we can take full control whereas in automatic
transmission there is more comfort. We also have varieties of automatic transmissions like
CVT which is more efficient, Dual clutch which gives more performance by eliminating lag
in gear shifting and AMT which is more simple and easy to use. We also get to know about
the difference between in their workings and mechanisms.
BIBLIOGRAPHY
• https://auto.howstuffworks.com/dual-clutch-transmission.htm
• https://www.cars24.com/blog/amt-gearbox-automated-manual-transmission/
• https://auto.ndtv.com/news/what-is-a-continuous-variable-transmission-and-how-
does-it-work-1449575
• https://www.howacarworks.com/basics/how-manual-gearboxes-work
• https://en.wikipedia.org/wiki/Manual_transmission