Naunheimer H., Bertsche B., Ryborz J., Novak W. Automotive Transmissions: Fundamentals, Selection, Design and Application

Springer-Verlag Berlin Heidelberg, 1994, 2011. 742 p. — ISBN: 978-3-642-16213-8, e-ISBN: 978-3-642-16214-5.This book gives a full account of the development process for automotive transmissions. Main topics: - Overview of the traffic – vehicle – transmission system - Mediating the power flow in vehicles - Selecting the ratios - Vehicle transmission systems - basic design principles - Typical designs of vehicle transmissions - Layout and design of important components, e.g. gearshifting mechanisms, moving-off elements, pumps, retarders - Transmission control units - Product development process, Manufacturing technology of vehicle transmissions, Reliability and testing The book covers manual, automated manual and automatic transmissions as well as continuously variable transmissions and hybrid drives for passenger cars and commercial vehicles. Furthermore, final drives, power take-offs and transfer gearboxes for 4-WD-vehicles are considered. Since the release of the first edition in 1999 there have been a lot of changes in the field of vehicles and transmissions. About 40% of the second edition’s content is new or revised with new dataHistory 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
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 MoversOverviewElectric 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 iG,tot
Selecting the Largest Powertrain Ratio iA,max
Selecting the Smallest Powertrain Ratio iA,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
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)
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
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
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
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
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 TestingIndex of Companies/Transmissions