AUTOMOTIVE TRANSMISSIONS:FUNDAMENTALSPDF电子书下载

1 Introduction 1

1.1 Preface 1

1.2 History of Vehicle Transmissions 6

1.2.1 Fundamental Innovations 6

1.2.2 Development of Vehicles and Drive Units 8

1.2.3 Stages in the Development of Vehicle Transmissions 9

1.2.4 Development of Gear-Tooth Systemsand other Transmission Components 17

1.2.5 Development of Torque Converters and Clutches 19

1.2.6 Investigation of Phenomena: Transmission Losses and Effiiciency 20

1.2.7 Overview 21

2 Overview of the Traffic - Vehicle - Transmission System 23

2.1 Fundamental Principles of Traffiic and Vehicle Engineering 23

2.1.1 The Signifiicance of Motor Vehicles in our Mobile World 24

2.1.2 Trends in Transport Engineering 28

2.1.3 Passenger and Goods Transport Systems 30

2.1.4 Alternative Transport Concepts 33

2.2 The Market and Development Situation for Vehicles,Gearboxes and Components 35

2.2.1 Market Situation and Production Figures 36

2.2.2 Development Situation 39

2.3 Basic Elements of Vehicle and Transmission Engineering 41

2.3.1 Systematic Classifiication of Vehicles and Vehicle Use 41

2.3.2 Why do Vehicles Need Gearboxes? 42

2.3.3 Main and Auxiliary Functions of Vehicle Transmissions,Requirements Profile 44

2.3.4 Interrelations: Direction of Rotation, Transmission Ratio, Torque 45

2.3.5 Road Profiiles, Load Profiiles, Typical Vehicle Useand Driver Types 49

2.4 Fundamental Performance Features of Vehicle Transmissions 49

2.4.1 Service Life and Reliability of Transmissions 50

2.4.2 Centre Distance Characteristic Value 51

2.4.3 Gearbox Mass Characteristic Value 52

2.4.4 Gearbox Cost Characteristic Value 53

2.4.5 Transmission Noise 54

2.4.6 Gearbox Losses and Efficiency 54

2.5 Transmission Design Trends 56

3 Mediating the Power Flow 58

3.1 Power Requirement 58

3.1.1 Wheel Resistance 58

3.1.2 Adhesion, Dynamic Wheel Radius and Slip 60

3.1.3 Air Resistance 61

3.1.4 Gradient Resistance 63

3.1.5 Acceleration Resistance 63

3.1.6 Total Driving Resistance 64

3.1.7 Efficiency Map 65

3.2 Diversity of Prime Movers 68

3.2.1 Overview 68

3.2.2 Electric Drive 69

3.2.3 Hybrid Drive 70

3.3 Power Output, Combustion Engine Characteristic 71

3.3.1 Torque/Engine Speed Characteristic 72

3.3.2 Engine Spread, Throttle Map 74

3.3.3 Consumption Map 75

4 Power Conversion: Selecting the Ratios 77

4.1 Power Train 78

4.2 Speed Converter for Moving Off 79

4.3 Total Ratio and Overall Gear Ratio 81

4.3.1 Overall Gear Ratio 82

4.3.2 Selecting the Largest Power-Train Ratio 83

4.3.3 Selecting the Smallest Power-Train Ratio 84

4.3.4 Final Ratio 87

4.4 Selecting the Intermediate Gears 87

4.4.1 Saw Profile Diagram 88

4.4.2 Geometrical Gear Steps 88

4.4.3 Progressive Gear Steps 89

4.5 Continuously Variable Transmissions 90

5 Matching Engine and Transmission 92

5.1 Traction Diagram 94

5.1.1 Deriving a Traction Diagram （Example） 95

5.1.2 Engine Braking Force 97

5.1.3 Geared Transmission with Dry Clutch 98

5.1.4 Geared Transmission with Trilok Converter 98

5.2 Vehicle Performance 101

5.2.1 Maximum Speed 102

5.2.2 Climbing Performance 103

5.2.3 Acceleration Performance 103

5.3 Fuel Consumption 104

5.3.1 Calculating Fuel Consumption （Example） 104

5.3.2 Determining Fuel Consumption by Measurement 106

5.3.3 Reducing Fuel Consumption 107

5.3.4 Continuously Variable Transmissions 107

5.4 Emissions 108

5.5 Dynamic Behaviour of the Power Train, Comfort 109

6 Vehicle Transmission Systems: Basic Design Principles 111

6.1 Arrangement of the Transmission in the Vehicle 111

6.1.1 Passenger Cars 111

6.1.2 Trucks and Buses 114

6.1.3 Four-Wheel Drive Passenger Cars 114

6.1.4 Transverse and Longitudinal Dynamics with All-Wheel Drive 119

6.2 Transmission Formats and Designs 120

6.2.1 Transmission Format 120

6.2.2 Transmission Design 121

6.3 Basic Gearbox Construction 123

6.3.1 Shifting with Power Interruption 124

6.3.2 Shifting without Power Interruption 124

6.3.3 Continuously Variable Transmissions without Power Interruption 125

6.4 Gear-Sets with Fixed Axles, Countershaft Transmissionsand Epicyclic Gears 126

6.5 Fundamental Approaches for Part Functions, Evaluation 128

6.5.1 Reverse Gear 129

6.6 Passenger Car Transmissions 130

6.6.1 Manual Passenger Car Transmissions 130

6.6.2 Semi-Automatic Manual Passenger Car Transmissions 133

6.6.3 Fully Automatic Passenger Car Transmissions 134

6.6.4 Continuously Variable Passenger Car Transmissions 141

6.7 Commercial Vehicle Transmissions 145

6.7.1 Single-Range Transmissions 146

6.7.2 Multi-Range Transmissions 147

6.7.3 Practical Design of Two- and Three-Range Transmissions 154

6.7.4 Semi-Automatic Manual Commercial Vehicle Transmissions 157

6.7.5 Fully Automatic Commercial Vehicle Transmissions 158

6.7.6 Continuously Variable Transmissions for Commercial Vehicles 159

6.8 Transfer Gearboxes and Power Take-Offs 160

6.9 Final Drives: Formats, Performance Limits, Transmission Ratios 162

6.9.1 Final Drive Systems for Passenger Cars 163

6.9.2 Final Drive Systems for Commercial Vehicles 164

6.10 Differential Gears, Differential Locks and Locking Differentials 167

6.10.1 Principles of Differential Gears 168

6.10.2 The Need for Locking 169

6.10.3 The Interlock Value 170

6.10.4 Alternatives to Self-Locking Differentials 171

7 Design of Gearwheel Transmissions for Vehicles 173

7.1 Gearwheel Performance Limits 173

7.1.1 Causes and Types of Damage 174

7.1.2 Calculating the “Tooth Failure” Performance Limit 178

7.1.3 Calculating the “Pitting” Performance Limit 178

7.1.4 Calculating the “Gear Scuffing” Performance Limit 180

7.2 Estimating Centre Distance 180

7.3 Estimating Face Widths 183

7.4 Operational Integrity and Service Life 184

7.4.1 The Wohler Curve 185

7.4.2 Load Profiile and Enumeration 187

7.4.3 Damage Accumulation Hypothesis 189

7.5 Developing Low-Noise Transmissions 195

7.5.1 Transmission Noise and Its Causes 195

7.5.2 How Noise Reaches the Ear 199

7.5.3 Assessment Criteria 199

7.5.4 Countermeasures 202

8 Specification and Design of Shafts 204

8.1 Typical Problems in Vehicle Transmissions 204

8.1.1 Configuration of Shafts in Vehicle Transmissions 204

8.1.2 Designing for Stress and Strength 204

8.1.3 Deflection 206

8.1.4 Vibration Problems 206

8.2 General Design Guidelines 207

8.3 Transmission Drive-Shaft Strength Design 208

8.3.1 Loading 208

8.3.2 Bearing Reactions 211

8.3.3 Spatial Beam Deflection 211

8.3.4 Power and Torque Profiiles 212

8.3.5 Critical Cross-Section 214

8.3.6 Stresses 215

8.3.7 Preliminary Specification of the Shaft Diameter 218

8.3.8 Designing for Fatigue Strength 218

8.3.9 Designing for Operational Integrity 219

8.3.10 Normal Shaft Materials 220

8.4 Calculating Deformation 220

8.5 Flow Chart for Designing Transmission Shafts 221

9 Gear Shifting Mechanisms, Layout and Design of Synchronisers 224

9.1 Systematic Classification of Shifting Elements 226

9.1.1 Shifting Elements for Geared Transmissionswith Power Interruption 226

9.1.2 Shifting Elements for Geared Transmissionswithout Power Interruption 229

9.1.3 Parking Lock 230

9.2 Synchroniser Functional Requirements 231

9.2.1 Changing Gear 233

9.2.2 Main Functions and Ancillary Functions 234

9.2.3 Speed Synchronisation with Slipping Clutch 234

9.2.4 Synchroniser Dimensions 236

9.3 The Synchronising Process 237

9.3.1 Ease of Use 239

9.4 Design of Synchronisers 241

9.4.1 Synchroniser Performance Limits 241

9.4.2 Basis for Design Calculation 244

9.4.3 Practical Design for Acceptable Thermal Stress 245

9.4.4 Designing Locking Toothing for Locking Effect 249

9.5 The Tribological System 253

9.5.1 Materials 253

9.6 Engineering Designs 254

9.6.1 Detail Questions 258

9.7 Alternative Transmission Synchronisers 259

10 Hydrodynamic Clutches and Torque Converters 261

10.1 Principles 262

10.2 Hydrodynamic Clutches and their Characteristic Curves 265

10.3 Torque Converters and their Characteristic Curves 266

10.3.1 The Trilok Converter 267

10.4 Engine and Torque Converter Working Together 268

10.4.1 Torque Converter Test Diagram, Interaction of Engine and Trilok Converter 270

10.5 Practical Design of Torque Converters 272

10.6 Engineering Designs 272

10.7 Design Principles for Increasing Efficiency 274

10.7.1 Torque Converter Lock-Up Clutch 274

10.7.2 Power Split Transmission 275

11 Notes on the Design and Configuration of Further VehicleTransmission Design Elements 279

11.1 Bearings 279

11.1.1 Selecting Bearings 280

11.1.2 Bearing Design 280

11.1.3 Design of Roller Bearings 284

11.2 Lubrication of Gearboxes, Gearbox Lubricants 286

11.2.1 Bearing Lubrication 287

11.2.2 Principles of Lubricating Gearwheel Mechanisms 287

11.2.3 Selecting the Lubricant 290

11.2.4 Selecting Lubricant Characteristics 290

11.2.5 Lifetime Lubrication in Vehicle Gearboxes 293

11.2.6 Testing the Scuffing Resistance of Gearbox Lubricants 294

11.3 Gearbox Housing 295

11.3.1 Gearbox Housing Design 295

11.3.2 Venting Gearboxes 297

11.4 Gearbox Sealing 301

11.4.1 Seals for Static Components 301

11.4.2 Seals for Rotating Components 304

11.4.3 Seals for Reciprocating Round Components 305

11.4.4 Practical Examples 306

11.5 Vehicle Continuous Service Brakes 307

11.5.1 Definitions 308

11.5.2 Engine Braking Systems 309

11.5.3 Retarders 309

11.5.4 Actuation and Use 313

12 Typical Designs of Vehicle Transmissions 314

12.1 Manual Gearboxes 315

12.1.1 Manual Passenger Car Gearboxes 315

12.1.2 Manual Commercial Vehicle Gearboxes 322

12.2 Semi-Automatic Manual Gearboxes 326

12.2.1 Semi-Automatic Manual Passenger Car Gearboxes 326

12.2.2 Semi-Automatic Manual Commercial Vehicle Gearboxes 326

12.3 Fully Automatic Gearboxes 328

12.3.1 Fully Automatic Passenger Car Gearboxes 329

12.3.2 Fully Automatic Commercial Vehicle Gearboxes 332

12.4 Further Examples 333

12.5 Final Drives 340

12.5.1 Typical Designs, Passenger Cars 340

12.5.2 Typical Designs, Commercial Vehicles 343

12.6 Differential Gears, Locking Differentials 346

12.7 Four-Wheel Drives, Transfer Gearboxes 352

13 Engine and Transmission Management, Electronicsand Information Networking 359

13.1 Overview of Electronic Systems in Current Use 359

13.2 Engine Management 361

13.3 Transmission Control 361

13.3.1 Automatic Master/Gearshifting Clutch 361

13.3.2 Semi-Automatic Manual Transmissions, Automatic Gear Selection 362

13.3.3 Fully Automatic Transmissions, Adaptive Gearshift Strategy 362

13.3.4 Continuously Variable Transmissions 364

13.4 Electronically Controlled Braking and Traction Systems 364

13.5 Safety Concepts 364

14 Overview of the Development Process, Product Planning and Systematic Engineering Design 365

14.1 Product Life Cycles 366

14.2 Product Planning 368

14.3 The Development Process 371

14.4 Systematic Engineering 373

14.5 Linking Development and Production 380

15 Computer-Aided Transmission Development, Driving Simulation 381

15.1 Driving Simulation 383

15.1.1 Extraneous Factors 384

15.1.2 Route Data Set, Route Data Acquisition 385

15.2 Driving Simulation Programs 386

15.2.1 Classification 386

15.2.2 Modular Construction 387

15.3 Applications of Driving Simulation 388

16 Reliability and Testing of Vehicle Transmissions 391

16.1 Principles of Reliability Theory 392

16.1.1 Definition of Reliability 392

16.1.2 Statistical Description and Representation of the Failure Behaviour of Components 392

16.1.3 Mathematical Description of the Failure Behaviour Using the Weibull Distribution 395

16.1.4 Reliability with Systems 400

16.1.5 Availability of Systems 402

16.2 Reliability Analysis of Vehicle Transmissions 403

16.2.1 System Analysis 403

16.2.2 Qualitative Reliability Analysis 406

16.2.3 Quantitative Reliability Analysis 408

16.3 Testing to Ensure Reliability 411

16.3.1 Classifying Vehicle Transmission Test Programs 412

16.3.2 Test Stands for the Test Programs 415

References 419

Index of Companies/Transmissions 439

Index of Names 441

Subject Index 442