Automotive Transmission Systems

Function of transmission:
- It is used to transmit engine torque to
the driving wheels to drive the vehicle
on the road.
Requirement of Transmission System
➢ To provide for disconnecting the engine from the driving
wheels

➢ When engine is running , connect the driving wheels to

engine smoothly without shock

➢ Leverage between engine and driving wheels to be varied

➢ Enable the driving wheels to rotate at different speeds.

Transmission System - Layout

Torque Converter
Transmission Types
 Clutch
Function of clutch

• Clutch is used to disengage and engage the

engine with rest of the transmission systems.

• To disengage while starting the engine and

while changing gear ratio.

• To engage after starting of the engine and gear shift

operation.
 Clutch
Requirement of Clutch
• Transmit maximum torque of the engine.

• Engage gradually to avoid sudden jerks.

• Dissipate maximum amount of heat.

• Damp the vibrations and noise.

• Dynamically balanced.

• As small as possible.

• Easy to operate.
 Clutch Unit
• Flywheel also acts as a driving member

• Pressure plate is connected to clutch cover assembly.

• Clutch Cover assembly is bolted to the flywheel.

• Clutch springs placed between Pressure plate & Cover plate, press the
Pressure plate against the clutch plate.

• Thus Clutch plate is squeezed between Flywheel & Pressure plate.

Clutch Unit
 Classification of Clutch
• Cone clutch

• Flat Plate clutch

• Dry or Wet type clutch

• No. of friction plates (Single or

Multiple)

• Actuation mode (Cable or

Hydraulic)

• Actuation spring (Helical or

Diaphragm)

• Centrifugal clutch
Clutch Engaged & Disengaged
• Clutch is always is in engaged
state.

• It cannbe disengaged by pressing

of Clutch pedal.

• Disengagement is effected by non

- contact of Clutch plate both with
Flywheel face & Pressure plate
face.

• Frictional heat is dissipated by

openings present in Clutch
housing & Cover
Clutch Material
 Gear Box
• Gear box varies the leverage (speed
ratio & hence torque ratio) between the
engine & driving wheels.

• It is located between Clutch &

Propeller shaft.

• It is provided with either 4 speed or 5

speed ratios or more depending on
design.

• Gear ratio is varied by Gear shift

Manual Transmission
lever.
Manual Transmission - Types
 Synchronizers
• A device used to bring two adjacent members to the same
speed before allowing the sleeve to engage them.

• The two elements are friction clutch and toothed clutch.

• Lock the positive engagement until speeds are synchronized.

• Establish the positive engagement and power flow.

• Synchronizer is splined on the shaft Cone on the gear (blue) fits into
cone-shaped area in the collar.

• Friction between the cone and collar synchronize the collar & gear.
• The outer portion of the collar (sleeve) then slides so that the
dogteeth engage the gear.
 How Manual Transmission Work?
• When a driver wants to change from one gear to another in a standard stick-shift
car, he first presses down the clutch pedal.

• This operates a single clutch, which disconnects the engine from the gearbox and
interrupts power flow to the transmission.

• Then the driver uses the stick shift to select a new gear, a process that involves
moving a toothed collar from one gear wheel to another gear wheel of a different size.

• Devices called synchronizers match the gears before they are engaged to prevent
grinding.

• Once the new gear is engaged, the driver releases the clutch pedal, which re-
connects the engine to the gearbox and transmits power to the wheels.
 Manual Transmission
➢ Cheap to make
➢ Durable, efficient
➢ Easy to install
➢ Established in marketplace and with manufacturing
infrastructure
➢ Gives control to the driver
➢ But driver comfort an issue with increasing traffic density

Hence automation must be considered

Automated Manual Transmission (AMT)

• Automation of Clutch and

Gear shifting operations

• Elimination of Clutch Pedal

• Modification of Gear Shifting

lever

• Minimum modifications in
manual transmission
 AMT Features

• Clutch slip control during starting

• Automation of clutch operation and gear shifting.

• Hill start aid system which will assist the driver in hold and
move the vehicle in hill slope

• Necessary fail safe systems such as sudden shifting from

higher gear to lowest gear and vice versa
System Block Diagram
 Clutch Actuation Control
• Engine Start
• Starter should be operated only when the gear is in neutral
position

• When engine is not running and in power on, ECU will

disengage clutch

• When engine speed exceeds a specified rpm, ECU engages

clutch gradually

• Vehicle Start
• On pressing the accelerator pedal, ECU controls the clutch

• Actuator travel and clutch engagement

 Clutch Actuation Control
• Gear Change
• While engaging the clutch after gear shift, the ECU determines
clutch actuator travel based on shifted gear position and
accelerator pedal stroke

• Clutch disengagement

• While gear shifting and when accelerator pedal is released,

• If the vehicle speed is lower than a set speed for select gear
position, the ECU disengages clutch
 Advantages of AMT
•Reduced driver effort

•Improved Clutch life

•Utilization of existing manufacturing facilities for

manual transmission

•Lower production cost than automatic transmissions

•Higher efficiency than automatic transmissions

 Fluid Coupling
• Converts or transmits rotating mechanical energy
or power.

• Basic components.
• outer shell or housing,
• impeller or pump and turbine
or runner

• Both units are contained within the housing via

oil-tight seals.

• The input turbine is connected to the power

supply, typically an electric or ICE.

• The output turbine is connected to the drive train

of the vehicle or the drive system of a machine.

• Mineral oil is used

 Fluid Coupling: Working
• Standstill
• The entire operating fluid in the
coupling is at rest

• Idling
• In sufficient centrifugal force for the oil to
turn the turbine
• Low to medium speed:
• Centrifugal force pushes oil into turbine
and some turning effort is transmitted.
Large degree of slip in the unit. O/p shaft is
rotating slowly than input shaft.

• Medium to High Speed

• Oil force is sufficient to transmit full power.
O/p shaft rotating at about 98% of speed of
I/p shaft (2% slip).
 Torque Convertor
• Serves as automatic clutch which transmits engine
torque to the transmission input shaft

• Multiplies torque generated by the engine

• Absorbs torsional vibration of engine

• Acts as a flywheel and smoothes out engine rotation

• Drives oil pump

• A torque converter consists of

- Impeller
- Turbine
- Stator
- and transmission fluid
Torque Convertor - Sectional View
Impeller
Turbine
Stator
Working of Torque Convertor Vehicle accelerates
Planetary Gear System
 Planetary Gear System: Construction
• Input shaft is connected to Ring gear(Blue)

• Output shaft is connected to Plane carrier(Green) which is also connected to

Multi-disk clutch

• Sun gear is connected to a Drum(Yellow), which can be locked by brake band

(Red). It is also connected to the other half of Clutch
 Planetary Gear System: Operation
• In Neutral
• Both band and clutch sets are released

• Ring gear only drive planet gear not the planet carrier (Output shaft)

• The planet gears drive the sun gears to spin freely

Planetary Gear System: Operation
• In Low Gear (forward reduction)
• Band locks the sun gear by locking the drum

• Planets walk around the sun gear

• Planet carrier to spin in same direction as ring gear

 Planetary Gear System: Operation
• In High Gear (Direct drive)
• Band is released.

• Clutch is engaged so that the sun gear and planet carrier is locked to act
as a rigid member

• Planets has to walk around the ring gear,

• Ring Gear (Input shaft) will spin at the same speed as the Planet Carrier
(Output shaft)
 Planetary Gear System: Operation
• Reverse Gear
•Planet carrier is locked

•Ring gear (Input shaft) will cause the sun gear (Output Shaft) to
turn in the opposite direction
 Automatic Transmission (AT)

Advantages
The only option for comfortable automatic shifting Cost issue mitigated
by high volume manufacturing

Disadvantages
Cost for development and manufacturing Fuel economy due
to torque converter
Lack of control by the driver

Modern improvements
Better control algorithms Torque converter
lock up
 Propeller Shaft
• It propels the vehicle forward, so called propeller shaft
• A Propeller Shaft connects a gearbox to a Differential.
• It is used to transmit the drive force generated by the engine to the axles.
• It is strong enough to handle maximum low gear torque
• It is provided with two U-joints to maintain constant velocity and
positioning of differential at different plane.
• It is provided with a slip joint to take care of the change in length.
• Shaft diameter and its thickness decides the torque carrying capacity and
angle of operation.
Universal joints
Universal joints
 Axle

• Transmits rotary motion and torque from the engine-transmission-

driveshaft to the wheels

• Changes torsional direction from longitudinal to transverse

• Provides speed reduction and torque multiplication

• Provides a differential action to permit vehicle cornering

• Provides mounting points for suspension and brakes