Manual Gearbox Research Articles

3D DESIGN OF A AUTOMOTIVE 5 SPEED SYNCHROMESH GEARBOX IN AUTODESK INVENTOR

The gearbox is a rotary assembly that provides speed and torque conversions from one rotary power supply (crankshaft) to another device (drive wheels) due to internal combustion engine limitations and also facilitates the shaft steering output.Autodesk Inventor is a computer aided design (CAD) application for creating 3D digital prototypes used in mechanical design, visualization, tooling creation and product simulation. It allows the user to create prototype products that accurately simulate the weight, stress, friction, driving loads, and many more properties of the products and their components in a simulated 3D environment.This paper contains all the graphic knowledge and operations required to create a 3D model of a manual gearbox by using the Autodesk Inventor software, and step by step, procedure for generating a 3D model of an synchromesh gearbox, starting from the initial calculus in Mathconnex.

Development of a Volkswagen Jetta MK5 Hybrid Vehicle for Optimized System Efficiency Based on a Genetic Algorithm

Hybrid electric vehicles (HEVs) have emerged as a trendy technology for reducing over-dependence on fossil fuels and a global concern of gas emissions across transportation networks. This research aims to design the hybridized drivetrain of a Volkswagen (VW) Jetta MK5 vehicle on the basis of its mathematical background description and a computer-aided simulation (MATLAB/Simulink/Simscape, MATLAB R2023b). The conventional car operates through a five-speed manual gearbox, and a 2.0 TDI internal combustion engine (ICE) is first assessed. A comparative study evaluates the optimal fuel economy between the conventional and the hybrid versions based on a proportional-integral-derivative (PID) controller, whose optimal set-point is predicted and computed by a genetic algorithm (GA). For realistic hybridization, this research integrated a Parker electric motor and the diesel engine of a VW Crafter hybrid vehicle from the faculty of engineering to reduce fuel consumption and optimize the system performance of the proposed car. Moreover, a VCDS measurement unit is developed to collect vehicle data based on real-world driving scenarios. The simulation results are compared with experimental data to validate the model’s accuracy. The simulation results prove the effectiveness of the proposed energy management strategy (EMS), with an approximately 89.46% reduction in fuel consumption for the hybrid powertrain compared to the gas-powered traditional vehicle, and 90.05% energy efficiency is achieved.

Analysis of KIA’s Intelligent Manual Transmission

Abstract: It is difficult to decide that the new Intelligent Manual Transmission in the KIA motor’s vehicle is an automatic or a manual transmission from the point of view of user. In general, iMT is a manual gearbox, but talking about it’s mechanism it has gears with mechanism that looks precisely like any other manual transmission. The iMT transmission does not have clutch, it contains only a break and throttle. To be noticed, it’s not totally automated. iMT is the next generation gearbox technology in Indian automobiles ater the AMT (automated manual transmission) that Maruti Suzuki popularized. It is now available in the KIA Seltos, Carens etc.

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.

Fuzzy Logic Controlled Two Speed Electromagnetic Gearbox for Electric Vehicle
 

Epicyclic transmission (ET), five-speed manual gearbox (5-SMT), automatic transmission (AT), and continuously variable transmission (CVT) are all possible transmission options for electric vehicles (EVs). The ET is so complex that motorists may be unaware that they are in gear. As the 5-SMT, AT, and CVT transistors are heavier, they consume more energy. Although a single-speed gearbox is lighter, it is not capable of developing enough torque for acceleration. Therefore, this study presents a fuzzy-logic-controlled electromagnetic two-speed gearbox (AEM-2SGB) model for EVs. The electromagnetic actuator is modelled in terms of electromagnet size, number of coil turns, supply current, and electromagnetic force needed to shift gears. The parametric analysis of AEM-2SGB is conducted using Matlab Simulink and a fuzzy simulation model. According to the results, the AEM-2SGB has a first-gear shift time of 110 ms at 300 Nm motor torque and a second-gear shift time of 116 ms at 110 km/h vehicle speed, with a maximum current supply of 16 A using a 24 V lithium ion battery. The AEM-2SGB reduces weight by 37%-66%, transmission losses by 40%–90%, and battery life by 5%.

Considerations on implementing Industry 4.0 in a manufacturing process

An industrial manufacturing company must adapt to the market all the time. If not, there is a high risk of losing money and the business can fail (for example in 2020, due to COVID 19 situation, more than 40% of businesses have temporary close their business and 60% of them have remained permanently closed). Wouldn’t be wonderful if the manufacturing process can be flexible and adapted in function of the customer demand? Industry 4.0 does that – in the function of orders, software can tell us with how many people or machines can work, what will be the rooting/flow, how much energy is needed for that manufacturing process, etc. and most important – when the goods will be on the market. Industry 4.0 is playing a role more and more important in all the fields, as everybody is looking for performance and efficiency. This article is showing a study on an assembly line for the gear shifter of a manual gearbox. People might be taking wrong decisions when there is a tight situation regarding breakdowns or capacity crisis, but a good system in place can guide the humans to apply the best solution to avoid losses and increase productivity. In this article you will find an example of how Industry 4.0 can influence an assembly line, for a simple product, by increasing the productivity at 133% versus a traditional line who lost 40% in productivity due to a machinery breakdown.

Mechatronic module design of the control system for the tractor gearbox

This article describes the mechatronic control device for the manual gearbox system and points out disadvantages of the transmission controls located in the operator’s cab. The block diagram of the gearbox control unit is presented. The choice of the device elements is proved. PETG plastic part models of the mechatronic module printed on a 3D printer are proposed. The technical characteristics of the mechatronic module of the gearbox control system for the transport and technological vehicle are described.

Vibro-acoustic analysis of metal and non-metal gears used in a powertrain

Gearbox (Powertrain) is one of the prime sources of noise in any Automobile. The noise can be broadly divided into two types. First is the one that occurs due to meshing of gears and second due to the inefficient design of the gearbox casing. This paper focuses majorly on the former problem and compares the results for analytical methods of vibration measurement. Modal analysis is carried out on a 5-speed synchromesh manual gearbox using ANSYS to find out modes of vibrations. The amplitude of noise is then calculated for one specific modal frequency (the one showing maximum deflection) using Acoustics module of COMSOL Multiphysics Software for 4 different gear materials.

Excess Fuel Consumption Due to Selection of a Lower Than Optimal Gear—Case Study Based on Data Obtained in Real Traffic Conditions

Appropriate driving technique, in compliance with eco-driving principles, remains an effective method to reduce fuel consumption. The selection of the correct gear is one of the pertinent factors when driving a car with a manual gearbox. In this study we have analyzed fuel overconsumption based on data recorded in real traffic conditions for vehicles driven by experienced drivers, using a black-box model. It was found that the total share of trip time with a lower than optimal gear selected amounted to from c.a. 3% for motorway driving up to 28% on rural roads. The mean fuel consumption reduction factor (following selection of the next gear up) amounted to from c.a. 2% up to 20%, depending on the selected gear and type of driving. Unfortunately, the potential for reduction of fuel consumption is not evenly distributed over the entire operating area of the engine. Thus, the cumulative reduction of fuel consumption, due to selection of the optimal gear, amounted to from c.a. 0.2% for motorway driving up to 3–6%, for urban and rural driving. It was shown that due to the selection of the appropriate gear, there still exists a real possibility of reduction of fuel consumption, even in the case of experienced drivers.

Experimental validation for the employment of shifting strategies optimized via i-AWGA in a gear shift indicator system for manual transmission vehicles

In the present work, a computational routine was developed in order to optimize the shifting strategies implemented in a Gear Shift Indicator to assist the driver of manual transmission vehicles according to a desired driving style. In order to achieve this goal, a simulation algorithm was developed to estimate the fuel consumption and acceleration performance of a vehicle equipped with a 5-speed manual gearbox propelled by a 1.4 L engine when submitted to the FTP-72 driving cycle. A multi-objective Genetic Algorithm was then employed to solve the optimization problem for both fuel consumption and performance. Among the set of optimized solutions, 3 shifting strategies were selected for experimental evaluation on a chassis dynamometer. The experiments showed that the strategy with focus on fuel economy was able to save 10.7% of fuel, being the best performance strategy responsible for enhancing the vehicle acceleration in 8.33%, when compared to the standard strategy provided by the vehicle manufacturer. Finally, the best-compromised solution presented 6.4% fuel-savings with an acceleration performance similar to the best performance strategy.

Drivability improvements obtained using a mild hybrid electrical system on a vehicle equipped with a manual gearbox

In order to fulfil the latest and future emission standards, all vehicles will need to be equipped with hybrid powertrains or advanced depollution systems. For low cost and entry level range of vehicles, in order to keep the production costs low, the simplest choice of hybridization is the mild-hybrid system with integrated starter-generator (ISG). This paper contains a model of a mild-hybrid electric vehicle equipped with a manual gearbox with focus on the drivability performance of the powertrain. The goal of this paper is to find out the drivability performances of a hybrid vehicle by simulation and to show the improvements compared to a similar vehicle equipped with a conventional powertrain.

Fuel consumption and emission improvements obtained using a mild hybrid electrical system on a vehicle equipped with a manual gearbox

The latest emission requirements for vehicles requires major improvement in vehicles fuel consumption and emission performance. For entry level range of vehicles, in order to keep the production costs low, the simplest choice of hybridization is the mild-hybrid system with integrated starter-generator (ISG). This paper contains a model of a mild-hybrid electric vehicle equipped with a manual gearbox and a model of conventional vehicle with focus on the emission performance. The goal of this paper is to find out the fuel consumption and emission of a mild hybrid electric vehicle by simulation and to show the improvements compared to a similar vehicle equipped with a conventional powertrain.

Optimal Remanufacturing Service Resource Allocation for Generalized Growth of Retired Mechanical Products: Maximizing Matching Efficiency

Maximizing the residual value of retired products and reducing process consumption and resource waste are vital for Generalized Growth-oriented Remanufacturing Services (GGRMS). Under the GGRMS, the traditional product-oriented remanufacturing methods to be changed: the products in GGRMS should be divided into multiple parts for maximizing residual value of different parts. However, this increases the difficulty of resource matching for service activities. To improve the efficiency of resource matching, we first used rough-fuzzy number and structural entropy weighting method to perform a coupling analysis on all service activities in the generalized growth scheme set, and to merge redundant service activities. We then considered the interests of both the service providers and integrators and added flexible impact factors to establish a service resource optimization configuration model, and solved it with the Non-Dominated Sorting Genetic Algorithm (NSGA-II). Finally, we, using a retired manual gearbox an experiment, optimized the service resource allocation for its generalized growth scheme set. The experimental results shown that the overall matching efficiency was increased by 74.56% after merging redundant service activities, showing that the proposed method is suitable for the resource allocation of the generalized growth for complex single mechanical products, and can offer guidelines to the development of RMS.

Kinematic and Dynamic Analysis of a Classic, Three-Axis Manual Gearbox, Without a Direct Socket

Fixed axis mechanical transmissions today have the largest spread on the entire planet, being practically used in almost all areas. From the gearboxes of the vehicles to the stationary reducers, used in the electrical, electronic and electrotechnical equipment, in the heavy industry but also in the light industry, in energy and in transport, practically the transmissions with fixed axes meet today everywhere, being part of our daily life. For this reason, we want to present the kinematic and dynamic analysis at a classic, manual, three-axis gearbox, with six speeds, without a direct socket. With the help of the presented method, one can analyze the dynamics of such a gearbox in order to design it optimally, so as to achieve the highest yields in operation, especially in the most used speeds, so that the transmission losses are limited to up.

Going Green with Manual Gearbox

Volkswagen to cut carbon with new transmission

Reverse rotation stator of torque converter in automotive powertrain system

Global economy demonstrates a steady elevated demand for heavy mobile equipment for construction and mining enterprises. At the same time wheel loaders, the total annual world output of which is about 160-170 thousand units are in high demand. Many wheel buckets and forklifts are equipped with hydro-mechanical transmissions containing a torque converter and a manual gearbox with hydraulic control. The positive properties of self-regulating torque converters are particularly favorable for equipment operating under stress. The transmission is equipped with a gear due to insufficient transforming properties of the torque converter. In order to improve the dynamic properties of self-propelled machines, designers increase the number of stages in gearboxes. However, multi-stage boxes complicate the hydro-mechanical transmission and its control system. One of the ways to improve the hydro-mechanical gears of mobile machines is to fully utilize the motor and tractor torque converters by using the opposite rotation of the torque converter reactor in the forward and reverse modes of the transmission. The article discusses circuit solutions for a hydro-mechanical transmission with a single-stage torque converter without a multi-stage gearbox, intended for use in transmissions of wheeled transport and loading and other self-propelled machines.

Combined hydraulic power vehicle transmission modes

Achieving high efficiency is a key objective of optimal vehicle drive train design. Hydraulic power transmissions with hydraulic torque converters are commonly used in wheeled and tracked self-propelled vehicles. Hydraulic torque converters are self-adjusting, and have a relatively low efficiency. The study investigates design options for self-propelled vehicle combined hydraulic power transmission. In order to improve their average efficiency, the engine power is transferred in two combined modes: single-and double-flow. We propose hydraulic power transmission layouts where the hydraulic torque converter operates with regular or summing differentials. Screw and free wheel clutches are used as drive train controls. They enable automated switchover of the torque transmissions modes. The proposed drive trains with switchable hydraulic torque converters are designed for both road and off-road self-propelled vehicles. They can be combined with robotic fixed-ratio gearboxes or as a part of a vehicle drive train consisting of a conventional clutch, and a manual gearbox.

Computational modelling and measurement of vibration of power train mountings of a passenger car

The paper presents tools for vibration evaluation of power train mounting system of a passenger car to meet demands for passenger’s comfort. The computational model is based on the Multi-Body System principles and includes submodules as are engine, clutch, gearbox, final drive, drive shafts and rheological models of all power train mountings. Simulation results are validated on account of measurement of power train vibration at different engine load conditions. Both simulation and measurement are carried out at power train of the European B-segment car with an in-line three-cylinder spark-ignition engine and manual gearbox. Presented methodology can bring time and cost savings particularly during mountings design process.

Dynamic Synthesis of a Classic, Manual Gearbox

Today, various types of gearboxes have been introduced into the vehicles to change the way the classic manual gearboxes work, such as automatic gearboxes, semi-automatic, continuous variable, dual-clutch automatic gearboxes etc. However, most gear shifters for in-service vehicles are still classical manuals, which is why their optimal synthesis based on their dynamics and especially on optimal performance is now more than necessary. The paper presents how to accurately determine the mechanical performance of a gearbox for passenger buses. Based on these relationships, an optimal synthesis of the performance of a classic, mechanical, manual gearshift can be achieved regardless of its operating status.

Effect of multi-parameters interaction on transmission gear rattle based on RBF neural network

This paper proposes a method to analyse multi-parameters interaction on transmission gear rattle. Firstly, a simulation model of manual transmission was established, and the angular velocity of each loose gear as well as the mesh force were obtained. Then the loose gear angular velocity was measured on a manual transmission gearbox to verify the model. The derivative of gear mesh force was taken as the rattle index (jerk index), and was calculated using forward difference method. A radial basis function (RBF) neural network was applied to map the relationships between the selected input parameters and rattle index. The results show that gear backlash has the largest influence on gear rattle, followed by the inertia of the loose gear, the speed fluctuation and the drag torque. This study can be easily extended to other types of transmission systems to control the gear noise and improve sound quality.