AUTOMOTIVE TRANSMISSIONS:FUNDAMENTALSPDF|Epub|txt|kindle电子书版本网盘下载

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1 Introduction1

1.1 Preface1

1.2 History of Vehicle Transmissions6

1.2.1 Fundamental Innovations6

1.2.2 Development of Vehicles and Drive Units8

1.2.3 Stages in the Development of Vehicle Transmissions9

1.2.4 Development of Gear-Tooth Systemsand other Transmission Components17

1.2.5 Development of Torque Converters and Clutches19

1.2.6 Investigation of Phenomena: Transmission Losses and Effiiciency20

1.2.7 Overview21

2 Overview of the Traffic - Vehicle - Transmission System23

2.1 Fundamental Principles of Traffiic and Vehicle Engineering23

2.1.1 The Signifiicance of Motor Vehicles in our Mobile World24

2.1.2 Trends in Transport Engineering28

2.1.3 Passenger and Goods Transport Systems30

2.1.4 Alternative Transport Concepts33

2.2 The Market and Development Situation for Vehicles,Gearboxes and Components35

2.2.1 Market Situation and Production Figures36

2.2.2 Development Situation39

2.3 Basic Elements of Vehicle and Transmission Engineering41

2.3.1 Systematic Classifiication of Vehicles and Vehicle Use41

2.3.2 Why do Vehicles Need Gearboxes?42

2.3.3 Main and Auxiliary Functions of Vehicle Transmissions,Requirements Profile44

2.3.4 Interrelations: Direction of Rotation, Transmission Ratio, Torque45

2.3.5 Road Profiiles, Load Profiiles, Typical Vehicle Useand Driver Types49

2.4 Fundamental Performance Features of Vehicle Transmissions49

2.4.1 Service Life and Reliability of Transmissions50

2.4.2 Centre Distance Characteristic Value51

2.4.3 Gearbox Mass Characteristic Value52

2.4.4 Gearbox Cost Characteristic Value53

2.4.5 Transmission Noise54

2.4.6 Gearbox Losses and Efficiency54

2.5 Transmission Design Trends56

3 Mediating the Power Flow58

3.1 Power Requirement58

3.1.1 Wheel Resistance58

3.1.2 Adhesion, Dynamic Wheel Radius and Slip60

3.1.3 Air Resistance61

3.1.4 Gradient Resistance63

3.1.5 Acceleration Resistance63

3.1.6 Total Driving Resistance64

3.1.7 Efficiency Map65

3.2 Diversity of Prime Movers68

3.2.1 Overview68

3.2.2 Electric Drive69

3.2.3 Hybrid Drive70

3.3 Power Output, Combustion Engine Characteristic71

3.3.1 Torque/Engine Speed Characteristic72

3.3.2 Engine Spread, Throttle Map74

3.3.3 Consumption Map75

4 Power Conversion: Selecting the Ratios77

4.1 Power Train78

4.2 Speed Converter for Moving Off79

4.3 Total Ratio and Overall Gear Ratio81

4.3.1 Overall Gear Ratio82

4.3.2 Selecting the Largest Power-Train Ratio83

4.3.3 Selecting the Smallest Power-Train Ratio84

4.3.4 Final Ratio87

4.4 Selecting the Intermediate Gears87

4.4.1 Saw Profile Diagram88

4.4.2 Geometrical Gear Steps88

4.4.3 Progressive Gear Steps89

4.5 Continuously Variable Transmissions90

5 Matching Engine and Transmission92

5.1 Traction Diagram94

5.1.1 Deriving a Traction Diagram （Example）95

5.1.2 Engine Braking Force97

5.1.3 Geared Transmission with Dry Clutch98

5.1.4 Geared Transmission with Trilok Converter98

5.2 Vehicle Performance101

5.2.1 Maximum Speed102

5.2.2 Climbing Performance103

5.2.3 Acceleration Performance103

5.3 Fuel Consumption104

5.3.1 Calculating Fuel Consumption （Example）104

5.3.2 Determining Fuel Consumption by Measurement106

5.3.3 Reducing Fuel Consumption107

5.3.4 Continuously Variable Transmissions107

5.4 Emissions108

5.5 Dynamic Behaviour of the Power Train, Comfort109

6 Vehicle Transmission Systems: Basic Design Principles111

6.1 Arrangement of the Transmission in the Vehicle111

6.1.1 Passenger Cars111

6.1.2 Trucks and Buses114

6.1.3 Four-Wheel Drive Passenger Cars114

6.1.4 Transverse and Longitudinal Dynamics with All-Wheel Drive119

6.2 Transmission Formats and Designs120

6.2.1 Transmission Format120

6.2.2 Transmission Design121

6.3 Basic Gearbox Construction123

6.3.1 Shifting with Power Interruption124

6.3.2 Shifting without Power Interruption124

6.3.3 Continuously Variable Transmissions without Power Interruption125

6.4 Gear-Sets with Fixed Axles, Countershaft Transmissionsand Epicyclic Gears126

6.5 Fundamental Approaches for Part Functions, Evaluation128

6.5.1 Reverse Gear129

6.6 Passenger Car Transmissions130

6.6.1 Manual Passenger Car Transmissions130

6.6.2 Semi-Automatic Manual Passenger Car Transmissions133

6.6.3 Fully Automatic Passenger Car Transmissions134

6.6.4 Continuously Variable Passenger Car Transmissions141

6.7 Commercial Vehicle Transmissions145

6.7.1 Single-Range Transmissions146

6.7.2 Multi-Range Transmissions147

6.7.3 Practical Design of Two- and Three-Range Transmissions154

6.7.4 Semi-Automatic Manual Commercial Vehicle Transmissions157

6.7.5 Fully Automatic Commercial Vehicle Transmissions158

6.7.6 Continuously Variable Transmissions for Commercial Vehicles159

6.8 Transfer Gearboxes and Power Take-Offs160

6.9 Final Drives: Formats, Performance Limits, Transmission Ratios162

6.9.1 Final Drive Systems for Passenger Cars163

6.9.2 Final Drive Systems for Commercial Vehicles164

6.10 Differential Gears, Differential Locks and Locking Differentials167

6.10.1 Principles of Differential Gears168

6.10.2 The Need for Locking169

6.10.3 The Interlock Value170

6.10.4 Alternatives to Self-Locking Differentials171

7 Design of Gearwheel Transmissions for Vehicles173

7.1 Gearwheel Performance Limits173

7.1.1 Causes and Types of Damage174

7.1.2 Calculating the “Tooth Failure” Performance Limit178

7.1.3 Calculating the “Pitting” Performance Limit178

7.1.4 Calculating the “Gear Scuffing” Performance Limit180

7.2 Estimating Centre Distance180

7.3 Estimating Face Widths183

7.4 Operational Integrity and Service Life184

7.4.1 The Wohler Curve185

7.4.2 Load Profiile and Enumeration187

7.4.3 Damage Accumulation Hypothesis189

7.5 Developing Low-Noise Transmissions195

7.5.1 Transmission Noise and Its Causes195

7.5.2 How Noise Reaches the Ear199

7.5.3 Assessment Criteria199

7.5.4 Countermeasures202

8 Specification and Design of Shafts204

8.1 Typical Problems in Vehicle Transmissions204

8.1.1 Configuration of Shafts in Vehicle Transmissions204

8.1.2 Designing for Stress and Strength204

8.1.3 Deflection206

8.1.4 Vibration Problems206

8.2 General Design Guidelines207

8.3 Transmission Drive-Shaft Strength Design208

8.3.1 Loading208

8.3.2 Bearing Reactions211

8.3.3 Spatial Beam Deflection211

8.3.4 Power and Torque Profiiles212

8.3.5 Critical Cross-Section214

8.3.6 Stresses215

8.3.7 Preliminary Specification of the Shaft Diameter218

8.3.8 Designing for Fatigue Strength218

8.3.9 Designing for Operational Integrity219

8.3.10 Normal Shaft Materials220

8.4 Calculating Deformation220

8.5 Flow Chart for Designing Transmission Shafts221

9 Gear Shifting Mechanisms, Layout and Design of Synchronisers224

9.1 Systematic Classification of Shifting Elements226

9.1.1 Shifting Elements for Geared Transmissionswith Power Interruption226

9.1.2 Shifting Elements for Geared Transmissionswithout Power Interruption229

9.1.3 Parking Lock230

9.2 Synchroniser Functional Requirements231

9.2.1 Changing Gear233

9.2.2 Main Functions and Ancillary Functions234

9.2.3 Speed Synchronisation with Slipping Clutch234

9.2.4 Synchroniser Dimensions236

9.3 The Synchronising Process237

9.3.1 Ease of Use239

9.4 Design of Synchronisers241

9.4.1 Synchroniser Performance Limits241

9.4.2 Basis for Design Calculation244

9.4.3 Practical Design for Acceptable Thermal Stress245

9.4.4 Designing Locking Toothing for Locking Effect249

9.5 The Tribological System253

9.5.1 Materials253

9.6 Engineering Designs254

9.6.1 Detail Questions258

9.7 Alternative Transmission Synchronisers259

10 Hydrodynamic Clutches and Torque Converters261

10.1 Principles262

10.2 Hydrodynamic Clutches and their Characteristic Curves265

10.3 Torque Converters and their Characteristic Curves266

10.3.1 The Trilok Converter267

10.4 Engine and Torque Converter Working Together268

10.4.1 Torque Converter Test Diagram, Interaction of Engine and Trilok Converter270

10.5 Practical Design of Torque Converters272

10.6 Engineering Designs272

10.7 Design Principles for Increasing Efficiency274

10.7.1 Torque Converter Lock-Up Clutch274

10.7.2 Power Split Transmission275

11 Notes on the Design and Configuration of Further VehicleTransmission Design Elements279

11.1 Bearings279

11.1.1 Selecting Bearings280

11.1.2 Bearing Design280

11.1.3 Design of Roller Bearings284

11.2 Lubrication of Gearboxes, Gearbox Lubricants286

11.2.1 Bearing Lubrication287

11.2.2 Principles of Lubricating Gearwheel Mechanisms287

11.2.3 Selecting the Lubricant290

11.2.4 Selecting Lubricant Characteristics290

11.2.5 Lifetime Lubrication in Vehicle Gearboxes293

11.2.6 Testing the Scuffing Resistance of Gearbox Lubricants294

11.3 Gearbox Housing295

11.3.1 Gearbox Housing Design295

11.3.2 Venting Gearboxes297

11.4 Gearbox Sealing301

11.4.1 Seals for Static Components301

11.4.2 Seals for Rotating Components304

11.4.3 Seals for Reciprocating Round Components305

11.4.4 Practical Examples306

11.5 Vehicle Continuous Service Brakes307

11.5.1 Definitions308

11.5.2 Engine Braking Systems309

11.5.3 Retarders309

11.5.4 Actuation and Use313

12 Typical Designs of Vehicle Transmissions314

12.1 Manual Gearboxes315

12.1.1 Manual Passenger Car Gearboxes315

12.1.2 Manual Commercial Vehicle Gearboxes322

12.2 Semi-Automatic Manual Gearboxes326

12.2.1 Semi-Automatic Manual Passenger Car Gearboxes326

12.2.2 Semi-Automatic Manual Commercial Vehicle Gearboxes326

12.3 Fully Automatic Gearboxes328

12.3.1 Fully Automatic Passenger Car Gearboxes329

12.3.2 Fully Automatic Commercial Vehicle Gearboxes332

12.4 Further Examples333

12.5 Final Drives340

12.5.1 Typical Designs, Passenger Cars340

12.5.2 Typical Designs, Commercial Vehicles343

12.6 Differential Gears, Locking Differentials346

12.7 Four-Wheel Drives, Transfer Gearboxes352

13 Engine and Transmission Management, Electronicsand Information Networking359

13.1 Overview of Electronic Systems in Current Use359

13.2 Engine Management361

13.3 Transmission Control361

13.3.1 Automatic Master/Gearshifting Clutch361

13.3.2 Semi-Automatic Manual Transmissions, Automatic Gear Selection362

13.3.3 Fully Automatic Transmissions, Adaptive Gearshift Strategy362

13.3.4 Continuously Variable Transmissions364

13.4 Electronically Controlled Braking and Traction Systems364

13.5 Safety Concepts364

14 Overview of the Development Process, Product Planning and Systematic Engineering Design365

14.1 Product Life Cycles366

14.2 Product Planning368

14.3 The Development Process371

14.4 Systematic Engineering373

14.5 Linking Development and Production380

15 Computer-Aided Transmission Development, Driving Simulation381

15.1 Driving Simulation383

15.1.1 Extraneous Factors384

15.1.2 Route Data Set, Route Data Acquisition385

15.2 Driving Simulation Programs386

15.2.1 Classification386

15.2.2 Modular Construction387

15.3 Applications of Driving Simulation388

16 Reliability and Testing of Vehicle Transmissions391

16.1 Principles of Reliability Theory392

16.1.1 Definition of Reliability392

16.1.2 Statistical Description and Representation of the Failure Behaviour of Components392

16.1.3 Mathematical Description of the Failure Behaviour Using the Weibull Distribution395

16.1.4 Reliability with Systems400

16.1.5 Availability of Systems402

16.2 Reliability Analysis of Vehicle Transmissions403

16.2.1 System Analysis403

16.2.2 Qualitative Reliability Analysis406

16.2.3 Quantitative Reliability Analysis408

16.3 Testing to Ensure Reliability411

16.3.1 Classifying Vehicle Transmission Test Programs412

16.3.2 Test Stands for the Test Programs415

References419

Index of Companies/Transmissions439

Index of Names441

Subject Index442