Sunday, 15 May 2011

Automatic Transmissions.

 This blogs on Automatic Transmissions that we done in practical.



Automatic transmissions purpose depending on how its driven and its load e.g moving from stand still, towing, is to select a suitable gear ratio either a high ratio or low ratio automatically. Gear ratios in automatics can also be driven manually like a manual transmission e.g 1, 2, 3. drive or L, 2, 3, drive.



For an automatic transmissions, there are three major sections,



  1.   Torque Converter: A torque converter is a fluid coupling with a stator that work together for one cause, torque multiplication forward or reverse acceleration. When engine is rotating so is the torque converter. Without stator, torque multiplication wouldn't be achieved and would just be a fluid coupling which has a constant ratio of 1:1 which means impeller and turbine rotating at close to same speed . Torque converter has four major parts. Impeller, turbine, stator and housing. The housing (impeller side) is bolted to the fly wheel of the engine which rotates the torque converter. When engine starts rotating, impeller will rotate and sling with a great force hydraulic fluid from centre to the outside vanes and will enter in the turbine outside vanes. This is done by centrifugal force known as rotary oil flow.Without a stator, the fluid will enter the impeller and hit the front (wrong side) of vanes and slow it down. With a stator and its one way clutch allowing it to rotate one way and lock the other, the fluid flow from the turbine will hit the stator and its job is to redirect fluid flow so that when fluid goes back to impeller it hits the back of the vanes and assists it to rotate to produce a high vortex oil flow for torque multiplication. Maximum vortex oil flow is archived when impeller is rotating at full power and turbine is stationary e.g acceleration from standstill. When both impeller and turbine are rotating at same speed this is coupling point which then the one way clutch will then let stator turn with impeller and turbine. This happens because fluid pressure from the impeller to turbine has lessened  therefore pressure on the one way clutch is no longer and also no torque multiplication.                                                             
  2.  Mechanical gear system: Also known as the gear section is made of one way clutches, shafts, gears, front and rear multi plate clutches, front and rear bands, and  compound planetary gears. The components for automatic transmission of a rear wheel drive is as pictured without valve body. The clutches engage to connect to drive parts of gearing e.g sun gears while bands and one way clutch holds other parts of the planetary system stationary e.g planet/pinion carrier. Gear ratios is archived by the use of different combinations of clutches and bands .  The multi plate clutch  Compound planetary gears are made of four parts, primary sun gear (small), secondary sun gear (large), internal gear and planet carrier or pinion carrier with a long set and short set of  pinions. When either planet carrier, sun gears or ring gear is stationary, the other conponets will rotate/walk around them e.g  for the primary sun gear to rotate, the front clutch would be engaged which in turn will kick in one way clutch to hold stationary the planet carrier. In this example the primary sun gear rotates with the engine direction, as sun gear is meshed to primary pinions they too turn but the one way clutch is engaged which at this point causes the pinion carrier to be held stationary, primary pinions rotate in opposite direction to engine direction and they too are in mesh with secondary pinions which rotate them in the direction with the engine which then turns the ring gear by being in mesh through the ring gears inside helical teeth. As ring gear rotates with engine direction it supplies power  flow through to the output shaft (1st gear). This is shows how a automatic transmission works its mechanical components to select its different gears while in motion.
  3.  Hydraulic systems: The main part of the system consist of a pump, governer, pressure regulator values, manual value, throttle value and shift value.                                                                                                                                                     PUMP: Is usually located in the cover of the transmission which draws oil from the sump which feeds torque converter, hydraulic system and transmission cooler. The inner ring gear connect to the housing of torque conveter so it turns with engine. The outer gear is turned by the inner gear and as it rotates oil is drawn up from the sump which then feeds hydraulic system.                                                                                                                        
GOVERNER: This value tells the transmission how fast the car is traveling and is located on the output shaft. Inside the governer is a spring loaded value that opens up depending on how fast governer is spining, more spin more opening of value. The pump feeds oil to governer through output shaft. The faster the car goes, the faster the governer value opens which then gives higher pressure of fluid it lets through.

MANUAL VALUE: This is whats connected to shift lever, depending on what gear is being selected, this value feeds hydraulic circuits that force certain gears into play for instance if shift lever was in thrid value feeds a circuit so overdrive doesn't kick in.

SHIFT VALUE: This supplies hydraulic pressure to the bands and clutches to engage each gear it also ddetermines when to shift from 1st to 2nd. shift value is pressurized with fliud from the governer on one side and the other from the throttle value and rotate fluid one of two cicuits which controls the gear car runs in. Each shift responds to particular pressure range so if car is traveling fast the 2nd and 3rd shift will take over because the pressure from governer is enough to trigger that value.

PRESSURE REGULATOR VALUE: There are two main pressure values found in the value body Primary value takes fluid under pressure from the pump which supplies sufficient fluid to system to maintain system pressure. beyond this point the fliud is reguulated pressure also known as line pressure which goes to manual value for redistribution to other values and components. Secondary value provides pressure for the torque converter which is converter pressure. Some fluid from secondary value is used for lubricating various parts of transmission.

THROTTLE VALUE: This monitors engine load. As driver accelerates on the pedal the engine will take up load the more pedal is depressed the more engine takes on load. When pedal is depressed, the movement is transmitted to throttle value which increases hydraulic pressure to the opposite end of shift value which moves and cause a downshift in gears.



Manual Transmission

This blogs of the manual transmission done in practical.


The manual transmission in a vehicle allows driver to operate at its most efficient speed range which is around 2000 - 3500 rpm and provides a operating speed of 1500 rpm. It allows suitable gear ratio to be selected for torque multiplication to any increased loads produced. As vehicle travels transmission also allows for driver to select a gear ratio to reduce engine torque multiplication in favour of upping road speed because load in 3rd or 4th gears is alot less than in 1st or 2nd gear. Two other features of transmission is that driver can select neutral which disconnects drive from engine which allows engine to turn e.g standstill at lights and also allows driver to reverse which allows driver to drive vehicle backwards. An automatic and manual  transmission uses gears that have been specially heat treated which gives its characteristics needed for high output. In the picture above shows of two different gears teeth found in transmissions today. The gears with the teeth traveling horizontally are referred to as spur gear which are generally used for reverse and some axle differentials built for high static loads. Spur gears are cheap for manufactures and easily construction but have a poor strength which wouldn't last if used as a driver or driven gear. The gear teeth that are angled are helical gears which are used  in most gearboxes simply because their of strength and durability. Pictured is the mainshaft of the transmission which have two sychromesh clutch sleeves. These sleeves are used to engaged a select gears. When a gear is selected, the selector forks which slide onto the sleeves move the sleeves towards the gear being selected. As gear is being selected the baulk ring will slide towards gear onto gear cone which slows down or synchronises the gear being selected so that baulk teeth on baulk ring can mesh with teeth on gear being selected which is then fully engaged. When selecting gears, the transmission uses a interlock up mechanisms so that driver can never select more than one gear at one time and for the driver to feel that gear is fully engaged the transmission uses detent locks which are a spring loaded ball located in a groove on the selector rods that hold and locate for gear selection. Gear ratios in any transmission is calculated by counting the teeth on each gear off the mainshaft and clustershaft. The mainshaft are the driven gears and clustershaft are the driving gear. Calculation will be as follow: Driven / Driver and this is how you get the ratio for each gear. The shift is normally in a H pattern and must be capable of producing movement horizontaly or transverse for gear stick to move across neutral and  longitudinal for selection of rail for engagement of correct gear needed.

Clutches

This blogs about a clutch that was done in practical.

The clutch is used to transmit engine drive (torque) to  the transmission which drives wheels in a motor vehicle. Motor vehicles using a manual transmissions use a dry single plate clutch which MUST NOT have any oil or grease because this would cause slipping of the clutch friction face against the pressure plate.
A clutch is bolted to the flywheel and splined with the input shaft which rotates with engine due to torque from engine but doesn't turn when clutch is engaged. A clutch is normally located in around the same area as if it were in a in line (north to south) or transaxle (east to west) assembly. A clutch disk is sometimes referred  to as a friction disc. The friction material are riveted to the disk which provide a lining against contact surfaces of flywheel (engine side) and pressure plate (transmission side), while the grooves between each friction face aids in cooling and clutch release. The torsion spring also known as damper spring are there to help absorb shock of selecting gears and also help stop vibration from engine transmitting into transmission.When clutch is engaged the clutch plate is squeezed between the flywheel and pressure plate and when disengaged the release bearing pushes ( by way of fork) onto diaphragm spring which then distorts and pulls back the pressure plate away from the clutch plate which allows flywheel and clutch plate to free spin and gear selection. The friction material will wear after a while and become thinner because the diaphragh spring is natural cone shape it will move closer to flywheel which means these two component's will slip which creates excessive heat that will destroy clutch assembly . For this the release bearing would need to be moved back so there would clearance between the two. To achieve this with out taking the transmission off or putting pressure on release bearing while engaged is by adjusting the clutch rod or cable linkage which can be made by a threading link at the clutch lever or cable mounting on firewall. Clutch adjustments are made to compensate for wear like stated before and linkage between clutch pedal release lever (fork) which means setting the right amount of free play in the release mechanism. Too much play equals clutch to drag while in disengagement and too little play equals cause clutch slippage. In a hydraulic clutch, as pedal depresses and rods contact the master cylinder pistons which then contact with assembly value and closes the inlet value allowing hydraulic pressure to build in the master cylinder which then transmits to slave cylinder and then fork starts pushing on bearings which compress the diaphragm spring