Car Gearbox Research Articles

The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer

The design and analysis of helical gears with involutes profiles is the primary focus of this study. The most widely utilized gearing system in use today is the involutes gear profile. Power and torque are typically transmitted through them. When compared to other forms of transmission, the efficiency of power transmission via gears is extremely high. Bending and contact stress are the main causes of gear tooth failure. The current study examines helical gear, which has to do with slag transfer in the steel production sector. The most affected stress concentrated location of any set of gears in the slag port transfer car (SPTC) gear box is identified by examining the contact stresses for the current design set of gears. The high stress concentration gear set was redesigned with a constant (45mm) face width at various Helix angles (14, 15, 16, 17, 19^, 20 ̊, 25^, and 30 ̊) and a constant pressure angle (20). To calculate the contact stresses between two gears that are mating. The robust and cutting-edge solid modeling program AUTODESK FUSION 360 creates a three-dimensional solid model. The ANSYS Workbench module was utilized to do the numerical analysis. The outcomes of the workbench module for ANSYS. The current study is helpful in quantifying the previously mentioned factors, which aids in the safe and effective design of the helical gear in the SPTC Gearbox.

Methods of detection and localization of the sources of noise and vibration on car gearboxes: a review

One of the primary sources of noise and vibration in automobiles is gearboxes. Shafts, gears, and bearings are the main causes of noise and vibration in vehicle gearboxes. Various studies have reported that vibrations’ root cause is bearing excitation. Besides bearing fatal defects or extreme structure resonance amplification, gear mesh is the primary source of high-frequency vibration and noise, even in newly built units. Gear damage detection is frequently crucial in automotive gearboxes and vehicle safety. Furthermore, vibrations caused by shaft imbalances, shaft misalignments, and other factors can cause noise and vibrations in the drivetrain's transfer path. In addition, the vibration of an automobile gearbox is closely related to poor design, construction quality, and production accuracy. This paper reviewed previous research and methods on car gearboxes for conventional vehicles. It was obvious that frequency analysis and order analysis were commonly used in noise and vibration analysis on car gearboxes. Envelope analysis is usually used to analyze bearing faults. Finally, rolling-element bearing diagnostic techniques were also reviewed.

Different types of mobile phone use while driving and influencing factors on intention and behavior: Insights from an expanded theory of planned behavior.

Mobile phone use while driving (MPUWD) is a significant concern due to its negative impact on road safety. This cross-sectional study aimed to assess different types of MPUWD and identify factors influencing intention and behavior among drivers in Zahedan. A total of 392 participants provided information on demographic and driving characteristics, as well as constructs derived from the Theory of Planned Behavior (TPB) augmented with moral norms. Findings revealed that a majority of drivers (86.4%) engaged in MPUWD, primarily involving calling, using applications, and texting. However, most participants did not intend to use their phones while driving in the following week. Multiple regression analysis identified age, receiving driving fines, subjective norm, and perceived behavior control as significant predictors of intention for MPUWD. Additionally, factors such as age, receiving driving fines, driving hours, car gearbox type, attitude, perceived behavior control, behavioral intention, and moral norm were significant predictors of actual MPUWD. Older participants demonstrated better behavior in various mobile phone activities while driving. Overall, the study emphasized that the main TPB constructs and moral norms have a greater influence compared to other variables in predicting MPUWD. Perceived behavioral control was the most important predictor of the intention and behavior of MPUWD. Understanding these factors can guide efforts to discourage MPUWD through targeted interventions and strategies to promote safer driving practices.

Study of Temperature Mode of Support Bearing Units of a Car Gearbox

Study of Temperature Mode of Support Bearing Units of a Car Gearbox

Research of the temperature regime of the support bearing units of a car gearbox

The technology for automatic digital thermal diagnostics of mechanical transmission components is presented using the example of gearbox bearings. The diagnostic criterion is substantiated, the problem of indirect determination of the temperature in the friction zone is solved, taking into account the influence of adjacent heat sources. Thermal imaging observation of the gearbox operation confirmed the effectiveness of the proposed diagnostics. Keywords transmission, bearing, testability, automatic diagnostics, thermal diagnostics

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes-A Review.

The aim of this article is to review the application of the finite element method (FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future.

Automation the assembly process of a passenger car gearbox

A stand for automatic assembly and adjustment of gearboxes in the production of passenger cars, which makes it possible to speed up and improve the assembly quality and acceptance of products is developed. When developing the stand, the component base presented on the domestic market is used. Keywords automation, stand, car, gearbox, machine vision

Аналіз конструктивних особливостей різних типів коробок перемикання передач автомобілів

One of the important components of the car design is the gearbox, which is part of the transmission. It is the gearbox that is responsible for changing the direction of the car and its speed. This affects traction and dynamic properties in general. The purpose of this article is to analyze the design features of various types of car gearboxes. The work analyzes the design features of various types of car gearboxes. The purpose of the gearbox, the effect on the traction-speed properties, which are a set of properties that determine the possible speed ranges and the maximum intensity of acceleration when the car is moving in the traction mode in various operating conditions, are given, as well as the main requirements that it should provide. The peculiarities of the construction of mechanical gearboxes, their structure, the principle of operation and the possibility of placement in a car are considered. The structure and main elements of the hydromechanical transmission (HMT) design are presented. It consists of three main parts: a torque converter, a manual gearbox and a control system. The design features of the gearbox with V-belt and toroid variators are considered. The principle of operation of variators, which ensures a stepless change of the gear ratio within the established limits, is presented. The design of the gearbox with a double clutch is considered, which ensures uninterrupted transmission of the power flow to the drive wheels. The gearbox is controlled by an electronic control unit, which receives information from sensors located in the box and is connected by a high-speed bus to the engine's electronic control unit. The main advantages and disadvantages of each type of considered gearboxes are highlighted. The mechanical gearbox has proven itself as a unit that is simple in design and reliable in operation. The prospects for the development of the gearbox are the development of new electronic control systems, the use of modern materials with high performance indicators and the use of high-performance methods of mechanical processing.

Automating the Assembly Process of Passenger Car Gearboxes

Aims: The study aims to identify ways and potential solutions to automate the assembly and production process for passenger car gearboxes.
 Object of Research: Assembly and production process for car gearboxes.
 Subject of Research: Modern and evolutionary automation tools that have the potential to be implemented in the assembly processes of automotive transmission controls.
 Methodology: To achieve this goal, as part of this study, it is planned to apply methods of bibliometric analysis of leading scientometric databases to obtain correlation relationships and analytical conclusions regarding the vector of development of automation means of passenger car gearbox assembly process.
 Results: As a result of the research by means of scientometric analysis and correlation the vector of probabilistic technical solutions of integration and development of automation means of the sequence of production operations during the assembly of the transmission, as well as adaptive framework-design solutions for the implementation of tools of the fourth iteration of industrial-industrial progress in the production processes of assembly of the studied technical control means and logical-technological connection of the elements of the transmission system, which affect the overall process of automotive manufacturization.
 Conclusion: The passenger car gearbox is a multi-component, complex system whose assembly is a complex multi-operational process, and given the high responsibility of this machine element, there is an urgent need to introduce modern automation tools into the assembly and production processes, which will significantly optimize global automatofactoring. The practical results of the present study consist in the formation of a focus scientometric database of profile data, identification of a potential vector of development of means and systems of automation of assembly-production operations, identification and formation of solutions for the implementation of modern means of automated production in the actual global automotive manufacturing, which allows to get the optimum ratio of production costs/quality of products by improving the manufacturability, productivity and flexibility of processes of assembly of multi-element and multi-component automotive systems and structures.

Digitalized manufacturing process sequences – foundations and analysis of the economic and ecological potential

As a consequence of the increasing digitalization of production, the availability of data from individual manufacturing processes and components is rising continuously. Digitalization affects various levels of production, such as the design of manufacturing processes, technology planning, quality monitoring, or logistics control. The contribution of this paper is to present the foundations for digitalized manufacturing process sequences and to develop data-based models and methods for the design of economically and ecologically optimized process sequences. For this purpose, a procedure for cross-process life cycle assessment was developed and carried out in order to evaluate the various ecological effects resulting from manufacturing and, in particular, different process designs. This ecological evaluation was combined with the evaluation of economic efficiency in order to provide an integrated evaluation as the basis for the design of manufacturing process sequences. In addition, the effects of the individual manufacturing process designs or process parameters on component quality were analyzed and an approach was derived for determining cross-process dependencies. The basis for these developments is a process sequence for the manufacture of pinion shafts used in electric car gearboxes. This digitalized process sequence consists of the processes soft cutting, gear hobbing, case-hardening, cylindrical grinding, and gear grinding, and over 100 components were manufactured with various process designs. This enabled an extensive amount of process and quality data to be collected throughout the process sequence. The application of the developed methods to the aforementioned process sequence underlines the high potential for the optimization of the target parameters quality, economy and ecology through cross-process analyses of digitalized manufacturing process sequences. Finally, an outlook on further developments regarding the digitalization of manufacturing process sequences is given.

Failure analysis of overdrive gear of passenger car gearbox fabricated from powder metallurgy

In this paper, investigations into the premature failure of gearbox overdrive gears were done in three passenger car models. The premature failure occurred when a replaced gear model was used instead of the original gear. A series of experiments were carried out on gears made by two manufacturers, including failed gear after an average operation of 100,000 km and gear with partial failure but usable with an average operation of 200,000 km. Numerical and experimental results showed that sharp hardness slope (reduction of 300 HV in 0.15 mm), high porosity, and Hertz stress distribution of about 90% of the allowable contact stress σHa are the factors affecting premature failure. In addition, replacement gear samples with low density compared to original gear have low yield and ultimate strength due to high porosity and interconnected structure of pores. Pores with sharp corners act as the initiation points of the cracks, resulting in final fracture.

Collaborative robot task allocation on an assembly line using the decision support system

ABSTRACT Human-robot collaboration (HRC), as a part of Industry 4.0 strategy, requires a completely new type of robots able to co-work with humans, called collaborative robots or cobots. This kind of collaboration is especially needed in assembly systems, which are known for having a low level of automation. For some assembly tasks human is still an irreplaceable factor. On the other hand, some assembly tasks are monotonous and tiring for humans. Therefore, the different approaches to cope with the challenge of identification and selection of proper task allocation between human worker and cobots are reported by many researchers. It is not an easy task since multiple and often conflicting criteria need to be taken into account. Some kind of artificial decision support is needed, to successfully solve this problem. In this research, task allocation procedure is presented for identification of different improvement options that utilize cobots into the assembly line for different tasks to be performed. The decision support system based on the HUMANT algorithm has been used for selection of the option which represents the best compromise solution. The procedure is experimentally tested on the assembly line with car gearboxes as a real product.

The rational repair and maintenance cycle of the KamAZ car gearbox taking into account the pre-repair operating time

A significant proportion of the costs and downtime for repairs are on transmission units, and especially on the gearbox (GB). Based on the research results presented in the work, up to 76% of all transmission failures fall on the gearbox of a KamAZ 6540 automobile under ordinary operating conditions. The purpose of the study is to justify the repair and maintenance cycle (RMC) of the gearbox of the KamAZ 6540 automobile, taking into account the pre-repair operating time. The proposed methodology for assessing the pre-repair resource allows you to select the resource elements of the gearbox, taking into account the value of their resource and coefficient of variation. The structure of the RMC proposed in the work provides for: the first current repair during running hours - 125940 km; first overhaul during running hours - 251880 km; second current repair during running hours - 377820 km; second overhaul during running hours - 503760 km. Thus, changing the structure of the gearbox REC allows increasing the gearbox resource from 380 to 500 thousand km.

Automation systems in automatic assembling gear shaft output as car gearbox part at PT. Matahari Megah

This study is an observation and analysis about automatic assembling gear shaft output as car gearbox part that made at PT. Matahari Megah as a result of research. That automation product can reduce the assembly time from about 5 minutes to less than 45 seconds. Then the objectives in this case study are to describe assembly processes, how to choose censoring systems properly, and give recommendation in calculating compressive force for servo press mechanism. Automatic assembling gear shaft output has four main assembly stations consists of station OP 10, OP 20, OP 30, and OP 40. One of the most important element at that product is censoring system mounted at station check for checking the workpiece properly. The recommendations given are about the acrylic plate mounted at station check to reduce the amount of photoelectric sensor and equation for calculating compressive force for pressing gear and bearing to the output shaft appropriately.

A Fully Coupled Thermomechanical Damage Analysis of Hot Closed Die Forging Using Finite Element Modeling

Advanced simulations are needed in the industry nowadays for reliable design of various machine parts. A complex computation is presented here to describe the whole manufacturing process, apart from the machining, of forged spur gear for a reverse transmission from a car gearbox. A coupled thermomechanical analysis was realized through the explicit finite element method, while the stress–strain analysis was conducted in all phases of the production with time- and temperature-dependent constitutive law. The influence of process parameters was assessed, and the magnitudes of forging load were compared for selected dimensions of intermediate product (blank) and its initial temperature (preheating). The numerical simulation was finished with the flash trimming along the circumference, so the temperature-dependent ductile failure criterion proposed by Johnson and Cook was accounted for as well.

Diagnostic Signal Informativeness Increase

Modern requirements for the operation of cars lead to the need to improve the efficiency of their maintenance. Diagnosis as an element of the maintenance process allows you to provide information about the technical condition of a particular element, which allows you to respond in a timely manner to the technical condition change of a diagnostic object with minimal resources. In this paper, we consider the way improving the diagnostic signal quality. It is known that a diagnostic signal must meet several requirements. The most important requirement is informativeness, which shows the decrease of uncertainty about the technical condition of an object, represented by a priori entropy after information application from this diagnostic signal, measured during the diagnosis. There are the methods for a diagnostic signal conversion, which allow to get rid of the noise entering it to a different degree or present it in such a way to facilitate the signal analysis process. Three methods are considered in the work: direct spectrum obtaining, signal envelope spectrum obtaining, and adaptive filtering. The analysis of these methods led to the conclusion that adaptive filtering has the greatest efficiency potential. We have proposed the method that is based on adaptive filtering, but with additional operations. In the course of the diagnostic signal studies and the adaptive filtering algorithm, we found that it is possible to set the function to be detected as a variable, as well as several parameters that affect the result quality. Based on this, a new method for a useful signal extraction was proposed. The results of the work were checked on a signal simulating a car gearbox signal. The results show that the method allows you to obtain the necessary knowledge about a defect, which can be used in the diagnosis. The developed method allows to increase the information content of the diagnostic signal by suppressing its other components. The results of the proposed method correlate with the results of other methods for general cases, i.e., when the ratio of the useful signal to noise is such that high sensitivity of the method is not required to identify the useful signal.

Effects of sputtering gas on microstructure and tribological properties of titanium nitride films

Abstract Titanium nitride (TiN) films can be utilized as hard and protective coatings for synchronizer ring, which is the key components of the car gearbox. The tribological properties of synchronizer ring play a key role in the safety and reliability of the car shifting system. The aim of the present work is to improve tribological properties of synchronizer ring and investigate effects of depositing gas on preferred orientation, surface morphology, surface roughness and tribological properties of TiN thin films. The as-prepared films are deposited on copper alloy (TL084) and Si (100) substrates by a closed field unbalanced magnetron sputtering system. The different sputtering gas with the volume ratio of argon to nitrogen of 1:3, 1:2 and 1:1 is employed. Results indicated that the increasing argon concentration in the gas mixture promotes the growth of TiN nanocrystallines and reduces its surface roughness, friction coefficient and wear rate. TiN films have the (200) preferred orientation at low argon concentration, while the (111) preferred orientation dominates at high argon concentration. TiN thin films deposited with the ratio of argon to nitrogen of 1:1 has the best tribological properties, which are the best sputtering condition as an ideal functional coating for synchronizer ring.

Comparison of beta-kurtosis and kurtosis methods for troubleshooting the performance of a transmission vehicle using vibrating frequencies

One of the main methods in maintenance and repair is a preventive maintenance method that is often more effective. The requirements of this method are to monitor the performance of machinery during operation. One of the car's functions that is monitored in this way is its vibra-tions. In this paper, a mathematical model of vibration analysis of a passenger car gearbox is presented based on Beta-Kurtosis and Kurtosis methods. In the next step, the data and test settings for the gearbox are based on the accelerometer installation to record the vibrations of the gearbox. To verify the accuracy of the proposed method, the results of the vibrational analysis of the car gearbox in four modes of a healthy gearbox, defective gearbox in the shaft end bearing, gear shaft failure on the gear shaft, simultaneous failure of the bearing and gearbox on the gear shaft were compared. Also, the results are compared for both Kurtosis and Beta-Kurtosis methods. The results show that both of the proposed methods are very accurate in identifying faults in the gearbox and determining the type of fault.

ИСТОРИЧЕСКИЙ ОБЗОР РАЗВИТИЯ КОНСТРУКЦИИ КОРОБОК ПЕРЕМЕНЫ ПЕРЕДАЧ ЛЕГКОВЫХ АВТОМОБИЛЕЙ

The paper reports the review in the development of motor car gearbox design. The main task consists in the detection of the reasons for changes in gearbox design for the definition of the field for gearbox substantiated application in motor car design.
 In the main part the advantages and shortcomings of manual, automated, infinitely variable and automatic gearboxes are under consideration. There are shown and analyzed functional diagrams of gearbox designs considered.
 In the conclusion it is pointed out that the most promising design of a gearbox is a robot gearbox with two clutches allowing the assurance of the absence of power flow break; the smoothness of gear shifts and smoothness of motion; comfort of control; high fuel efficiency; high tractiondynamic characteristics.

Simultaneous Analysis of Noise and Vibration of Machines in Vibroacoustic Diagnostics

Abstract The article is a continuation of the authors’ elaboration (Dąbrowski, Dziurdź, 2016). The aim of this continuation is to prove that a proposed way of modelling and using the coherent analysis to filter nonlinear disturbances is a useful technique in vibroacoustic diagnostics. The thesis was proved by solving the task of diagnosing the damage of the gear of the car gearbox on the basis of the measurement of mechanical vibrations and the noise in the engine chamber.