Automotive Transmissions

UNIT I
1. OVERVIEW OF VEHICLE POWERTRAIN SYSTEM
LAYOUT OF AUTOMOBILE POWER TRANSMISSION SYSTEM

REQUIREMENTS OF TRANSMISSION SYSTEM

1. To provide for disconnecting the engine from the driving wheels.
2. When the engine is running, to enable the connection to the driving wheels to be made
smoothly and without shock.
3. To enable the leverage between the engine and driving wheels to be varied.
4. It must reduce the drive-line speed from that of the engine to that of the driving wheels in a ratio of
somewhere between about 3:1 and 10:1 or more, according to the relative size of engine and
weight of vehicle.
5. Turn the drive, if necessary, through 90° or perhaps otherwise re-align it.
6. Enable the driving wheels to rotate at different speeds.
7. Provide for relative movement between the engine and driving wheels.
REQUIREMENTS OF CLUTCH
 Torque transmission: The clutch should be able to transmit the maximum torque of the engine
under all condition. It is usually designed to transmit 125 to 150 per cent of the maximum engine
torque. As the clutch slips during engagement, the clutch facing is heated. Clutch temperature is the
major factor limiting the clutch capacity. This requires that the clutch facing must maintain a
reasonable coefficient of friction with the mating surfaces under all working conditions. Moreover
the friction material should not crush at high temperatures and clamping loads.
 Gradual engagement: The clutch should positively take the drive gradually without the occurrence
of sudden jerks.
 Heat dissipation: During clutch application, large amounts of heat are generated. The rubbing
surfaces should have sufficient area and mass to absorb the heat generated. The proper design of the
clutch should ensure proper ventilation or cooling for adequate dissipation of the heat.
 Dynamic balancing: This is necessary particularly in the high speed clutches.
 Vibration damping: Suitable mechanism should be incorporated with in the clutch, to eliminate
noise produced in the transmission.
 Size: The size of the clutch must be smallest possible so that it should occupy minimum amount of
space.
 Inertia: The clutch rotating parts should have minimum inertia. Otherwise, when the clutch is
released for gear changing, the clutch plate will keep on spinning, causing hard shifting and gear
clashing in spite of synchronizer.
 Clutch free pedal play: To reduce effective damping load on the carbon thrust bearing and wear
thereof, sufficient clutch free pedal play must be provided in the clutch.
 Ease of operation: For higher torque transmissions the operation of disengaging the clutch must not
be tiresome to the driver.

Table 2.6 Internal and External factors affecting the development of vehicle transmissions
 Table 2.7: Transmission-oriented classification of motor vehicles by type of vehicle and type of use;
GVW: Gross Vehicle Weight *) another feature is the number of seats

Why do Vehicles Need Gearboxes?

In addition to many advantages of the I C 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 I C Engine only produces maximum power at a certain engine speed

– The efficiency of the engine, i.e. its fuel consumption, is very much dependent on
operating point in the engine’s performance map