Automotive Transmissions
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- Godfrey Rodgers
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1 Automotive Transmissions Fundamentals, Selection, Design and Application Bearbeitet von Harald Naunheimer, Bernd Bertsche, Joachim Ryborz, Wolfgang Novak, Aaron Kuchle 2nd ed Buch. xxiv, 717 S. Hardcover ISBN Format (B x L): 15,5 x 23,5 cm Gewicht: 1274 g Weitere Fachgebiete > Technik > Verkehrstechnologie > Fahrzeugtechnik Zu Leseprobe schnell und portofrei erhältlich bei Die Online-Fachbuchhandlung beck-shop.de ist spezialisiert auf Fachbücher, insbesondere Recht, Steuern und Wirtschaft. Im Sortiment finden Sie alle Medien (Bücher, Zeitschriften, CDs, ebooks, etc.) aller Verlage. Ergänzt wird das Programm durch Services wie Neuerscheinungsdienst oder Zusammenstellungen von Büchern zu Sonderpreisen. Der Shop führt mehr als 8 Millionen Produkte.
2 Contents Terms and Symbols... XVII 1 Introduction Preface History of Automotive Transmissions Basic Innovations Development of Vehicles and Drive Units Stages in the Development of Automotive Transmissions Development of Gear-Tooth Systems and other Transmission Components Development of Torque Converters and Clutches Investigation of Phenomena: Transmission Losses and Efficiency Historical Overview Overview of the Traffic Vehicle Transmission System Fundamental Principles of Traffic and Vehicle Engineering The Significance of Motor Vehicles in our Mobile World Trends in Traffic Engineering Passenger and Goods Transport Systems Alternative Transport Concepts The Market and Development Situation for Vehicles, Gearboxes and Components Market Situation and Production Figures Development Situation Basic Elements of Vehicle and Transmission Engineering Systematic Classification of Vehicles and Vehicle Use Why do Vehicles Need Gearboxes? Main and Auxiliary Functions of Vehicle Transmissions, Requirements Profile Interrelations: Direction of Rotation, Transmission Ratio, Torque Road Profiles, Load Profiles, Typical Vehicle Use and Driver Types Fundamental Performance Features of Vehicle Transmissions Service Life and Reliability of Transmissions Centre Distance Characteristic Value...60
3 X Contents Gearbox Mass Characteristic Value Gearbox Cost Characteristic Value Gearbox Noise Gearbox Losses and Efficiency Trends in Transmission Design Mediating the Power Flow Power Requirement Wheel Resistance Adhesion, Dynamic Wheel Radius and Slip Air Resistance Gradient Resistance Acceleration Resistance Total Driving Resistance Efficiency Map Diversity of Prime Movers Overview Electric Drive with Electric Energy Accumulator Electric Drive with Fuel Cell Hybrid Drive Power Output, Combustion Engine Characteristic Torque/Engine Speed Characteristic Engine Spread, Throttle Map Consumption Map Power Conversion: Selecting the Ratios Powertrain Total Ratio and Overall Gear Ratio Overall Gear Ratio i G,tot Selecting the Largest Powertrain Ratio i A,max Selecting the Smallest Powertrain Ratio i A,min Final Ratio Selecting the Intermediate Gears Velocity/Engine-Speed Diagram Geometrical Gear Steps Progressive Gear Steps Ratio Variation in Continuously Variable Transmissions Matching Engine and Transmission Traction Diagram Deriving a Traction Diagram (Example) Engine Braking Force Geared Transmission with Dry Clutch Geared Transmission with Torque Converter Vehicle Performance Maximum Speed
4 Contents XI Climbing Performance Acceleration Performance Fuel Consumption Calculating Fuel Consumption (Example) Determining Fuel Consumption by Measurement Reducing Fuel Consumption Continuously Variable Transmissions Emissions Dynamic Behaviour of the Powertrain, Comfort Vehicle Transmission Systems: Basic Design Principles Arrangement of the Transmission in the Vehicle Passenger Cars Commercial Vehicles All-Wheel Drive Passenger Cars Transverse and Longitudinal Dynamics with All-Wheel Drive Transmission Formats and Designs Transmission Format Transmission Design Basic Gearbox Concept Shifting with Power Interruption Shifting without Power Interruption Continuously Variable Transmissions without Power Interruption Gear Sets with Fixed Axles, Countershaft Transmissions and Epicyclic Gears Solution Principles for Part Functions, Evaluation Reverse Gear as Example Passenger Car Transmissions Manual Passenger Car Transmissions (MT) Automated Manual Passenger Car Transmissions (AMT) Dual Clutch Passenger Car Transmissions (DCT) Automatic Passenger Car Transmissions (AT) Passenger Car Hybrid Drives Continuously Variable Passenger Car Transmissions (CVT) Commercial Vehicle Transmissions Manual Commercial Vehicle Transmissions (MT) Automated Manual Commercial Vehicle Transmissions (AMT) Commercial Vehicle Torque Converter Clutch Transmissions (TCCT) Automatic Commercial Vehicle Transmissions (AT) Commercial Vehicle Hybrid Drives Continuously Variable Commercial Vehicle Transmissions (CVT)...219
5 XII Contents 6.8 Final Drives Axle Drives for Passenger Cars Axle Drives for Commercial Vehicles Differential Gears and Locking Differentials Hub Drives for Commercial Vehicles Transfer Gearboxes Power Take-Offs Design of Gearwheel Transmissions for Vehicles Gearwheel Performance Limits Causes and Types of Damage Calculating the Tooth Root Load Capacity Calculating the Pitting Load Capacity Calculating the Scuffing Load Capacity Estimating Centre Distance Estimating Face Widths Operational Fatigue Strength and Service Life The Wöhler Curve Load Profile and Counting Procedure Damage Accumulation Hypothesis Developing Low-Noise Transmissions Transmission Noise and Its Causes How Noise Reaches the Ear Assessment Criteria Countermeasures Specification and Design of Shafts Typical Requirements in Vehicle Transmissions Configuration of Shafts in Vehicle Transmissions Designing for Stress and Strength Deflection Vibration Problems General Design Guidelines Transmission Drive Shaft Strength Design Loading Bearing Reactions Spatial Beam Deflection Shear Force and Bending Moment Diagrams Critical Cross-Section Stresses Preliminary Specification of the Shaft Diameter Designing for Endurance Strength Designing for Operational Fatigue Strength Common Shaft Materials Calculating Deformation Flow Chart for Designing Transmission Shafts
6 Contents XIII 9 Gearshifting Mechanisms Systematic Classification of Shifting Elements Shifting Elements for Transmissions with Power Interruption Shifting Elements for Transmissions without Power Interruption Shift-by-Wire Layout and Design of Synchronizers Synchronizer Functional Requirements The Synchronizing Process Design of Synchronizers The Tribological System of Synchronizers Engineering Designs Alternative Transmission Synchronizers Detail Questions Layout and Design of Multi-Plate Clutches Multi-Plate Clutch Requirements The Shifting Process Design of Multi-Plate Clutches Tribological System of Multi-Plate Clutches Engineering Designs Detail Questions Parking Locks Mechanically Activated Parking Locks Electrically Activated Parking Locks Detail questions Moving-Off Elements Dry Clutches Structure of Dry Clutches Design of Dry Clutches Dry Multi-Plate Clutches Wet Clutches Dual Clutches Hydrodynamic Clutches and Torque Converters Principles Hydrodynamic Clutches and their Characteristic Curves Torque Converters and their Characteristic Curves Engine and Torque Converter Working Together Practical Design of Torque Converters Engineering Designs Design Principles for Increasing Efficiency Design and Configuration of Further Design Elements Bearings Selecting Rolling Bearings...421
7 XIV Contents Rolling Bearing Design Design of Rolling Bearings Plain Bearings Bearing Bushes and Thrust Washers Lubrication of Gearboxes, Gearbox Lubricants Bearing Lubrication Principles of Lubricating Gearwheel Mechanisms Selecting the Lubricant Selecting Lubricant Characteristics Lifetime Lubrication in Vehicle Gearboxes Testing the Scuffing Resistance of Gearbox Lubricants Oil Supply and Oil Pumps Oil Supply Oil Pumps Detail Questions Gearbox Housing Gearbox Housing Design Venting Gearboxes Gearbox Sealing Seals for Static Components Seals for Rotating Components Seals for Reciprocating Round Components Practical Examples Final Inspection for Detecting Leakage Vehicle Continuous Service Brakes Definitions Engine Braking Systems Retarders Actuation and Use Typical Designs of Vehicle Transmissions Passenger Car Transmissions Manual Passenger Car Transmissions (MT) Automated Manual Passenger Car Transmissions (AMT) Dual Clutch Passenger Car Transmissions (DCT) Automatic Passenger Car Transmissions (AT) Passenger Car Hybrid Drives Continuously Variable Passenger Car Transmissions (CVT) Commercial Vehicle Transmissions Manual Commercial Vehicle Transmissions (MT) Automated Manual Commercial Vehicle Transmissions (AMT) Commercial Vehicle Torque Converter Clutch Transmissions (TCCT) Automatic Commercial Vehicle Transmissions (AT) Commercial Vehicle Hybrid Drives
8 Contents XV Continuously Variable Commercial Vehicle Transmissions (CVT) Final Drives Axle Drives for Passenger Cars Axle and Hub Drives for Commercial Vehicles Differential Gears and Locking Differentials All-Wheel Drives, Transfer Gearboxes Electronic Transmission Control Networked Systems Electronic Transmission Control Unit (TCU) TCU Structure Operating Conditions and Construction Technologies Control Systems Transmission Actuator Clutch Actuator Transmission Control Functions Software Further Examples of Transmission Control Systems Transmission Calibration with Vehicle-Specific Software Data Input Computer-Aided Transmission Development Principles and Tools Driving Simulation Simulation of Vehicle Longitudinal Dynamics Route Data Set, Route Data Acquisition The Automotive Transmission Development Process Product Life Cycle Product Strategy, Product Planning Release Stages in the Product Development Process The Design Process and Systematic Design Transmission Manufacturing Technology Process Chains for Steel Part Processing Soft Machining Methods Heat Treatment Methods Hard Machining Methods Process Chains for Cast Part Processing Casting Methods Machining Cast Parts Process Chains for Gear Machining Soft Machining Methods Hard Machining Methods Process Chains for Sheet Metal Machining...623
9 XVI Contents Sheet Separation Sheet Forming Manufacturing and Factory Management Work Preparation and Planning Production Systems Statistical Process Control in Manufacture Reliability and Testing of Automotive Transmissions Principles of Reliability Theory Definition of Reliability Statistical Description and Representation of the Failure Behaviour of Components Mathematical Description of Failure Behaviour using the Weibull Distribution Reliability with Systems Availability of Systems Reliability Analysis of Vehicle Transmissions System Analysis Qualitative Reliability Analysis Quantitative Reliability Analysis Testing to Ensure Reliability Classifying Vehicle Transmission Test Programs Test Benches for the Test Programs Simulation during Bench Testing References Index of Companies/Transmissions Index of Names Subject Index About the Authors
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