arsgi2019 Why do we need gears? ~ x-enginserorg UNDERGRADUATE ENGINEERING ¥ / GRADUATE ENGINEERING ~ AUTOMOTIVE ENGINEERING » QUIZ! | NEWS / PROJECTS HOME > AUTOMOTIVE ENGINEERING > DRIVETRAIN > TRANSMISSIONS » Why Do We Need Gears? | ‘TRANSMISSIONS: Why do we need gears? The vast majority of vehicles sold today are powered by internal combustion engines (ICE). The most common types of ICE are spark- ignition (gasoline / petrol) and compression ignition (diesel) engines. From the traction point of view, regardless of the type of fuel used, the internal combustion engines has some fundamental disadvantages: = itis not capable to produce torque from rest (0 rpm) = the maximum engine power is produced only at a certain engine speed = fuel consumption is directly linked to the operating point of the ‘engine (speed and torque) + itcan only rotate one way + ithas a minimum operating speed (idle speed) From the traction point of view, the maximum vehicle acceleration is obtained when we constantly apply at the wheel the maximum engine power. Power is the product between force and speed: Pras = v () where: Prmax {W] ~ maximum power at the wheel , . Recent Comments Fy IN] traction force at the wheel v [m/s] - vehicle speed (wheel tangential speed) Shakaib on Air-fuel ratio, From (1) we can extract the formula of the traction force at the wheel, lambda and engine function of maximum power and vehicle speed: performance hitps/cengineer.orglautomotive-engineeringidrvetrainransmissionsiwhy-do-we-need-gears! 19arsgi2019 Why do we need gears? ~ x-enginserorg Fi Prue 4 (2) Hynek Pokorny on How to v solve a second order ordinary Let's suppose that the maximum power at the wheel is a constant 80 kW. If differential equation (ODE) in the vehicle speed varies between 10 and 90 kph, applying equation (2), the Seilab traction force atthe wheel will lok lke: Alan Thomas on How to calculate the torque capacity wenginaarorg of aclutch 20 000: Ajay Venkata on Extracting data from a matrix in Scilab Dev on EV design ~ battery 20 000. calculation 3 #13000. 2 atreon § 10 000. £ 5.000 PATREON >. 40 20 30 40 «50 69 70 80 90 100 Vehicle (wheel) speed tkph) Image: Traction force at wheel for maximum power ent Po: Thus, if the maximum engine power could be deployed at the wheel through the whole speed range of the vehicle, the traction hyperbola depicted in the above figure will result. This is called ideal traction How to import table data hyperbola (ITH). In real applications, at low speeds, the traction force is (csv) in Scilab limited by the friction limit of the wheels and at high speed by the road and How to create a multiple y- aerodynamic vehicle losses. axes plot in Scilab Exhaust Gas Recircul (EGR) complete guide ~ architectures ion oe Exhaust Gas Recircul (EGR) complete guide - components Ideal Traction Hyperbola (TH) Exhaust Gas Recircul Road and aerodynamic (EGR) complete guide ~ ene ieaies introduction Traction force at wheel Vehicle speed v [rvs] Image: deal Traction Hyperbola (1H) Assuming that there are no gears (no gearbox, transmission and differential) on the vehicle, the engine torque can be translated into wheel force (traction force) by dividing it with the wheel radius. hitps/cengineer.orglautomotive-engineeringidrvetrainransmissionsiwhy-do-we-need-gears!avisi2018 Why do we need gears? ~ x-enginserorg (3) where: Fo NI ~ engine force (at the wheel) Te Nm] ~ engine torque ry [ml ~ wheel radius With equation (3) we can take the engine's maximum torque line and convert it into engine available traction line at the wheel. If we overlap the traction line of the engine over the ideal traction hyperbola, we get something like this n g Ideal Traction Hyperbola (ITH) ‘Traction force at wheel Ice available traction Vehicle speed v [mvs] Image: deal Traction Hyperbola (ITH) and available engine traction (no gear) As you can see, the engine's traction line can only cover a small area of the required (ideal) traction performance (blue area). Without a way of converting the traction output of the engine, the vehicle will not be able to cover the blue area, beneath the ideal traction hyperbola. This means that Select Category 7% the vehicle will not be able to pull-away and it will have very poor acceleration performance. Pages Here is when the gearbox / transmission comes into play. The multi-step gearbox is a torque and speed converter which adapts the traction output ‘About of the internal combustion engine to match the traction requirement of the Contact Vehicle, Multi-step gearbox means that the gearbox has at least two or more forward gears and one reverse gear. Cookie Policy Privacy Policy Terms and Condi hitps/cengineer.orglautomotive-engineeringidrvetrainransmissionsiwhy-do-we-need-gears!anoror9 Why do we nsed gears? -xengineetorg Ad closec by Google si cing this Why this ad? Given a transmission with 4 gears and a differential, the engine traction force at the wheel will be: = (4) where: ig] is the gear ratio (x = .2,3,4) ig H~ is the final drive (differential) ratio From (4) we can see that, thanks to the gearbox, we now have 4 traction lines of the engine, one for each gear. Overlapping the engine's traction lines (for each gear) with the required (ideal) traction hyperbola of the vehicle, gives: engacocarg z 2 Traction force at whee! ‘Vehicle speed v [mls] Image: Ideal Traction Hyperbola (T}H) and available engine traction (4 gears) ‘As we can see, using a multi-step gearbox, the traction output of the engine approximates better the ideal traction hyperbola. The higher the numbers of gears, the better the approximation. hitps/cengineer.orglautomotive-engineeringidrvetrainransmissionsiwhy-do-we-need-gears! 49arsgi2019 Why do we need gears? ~ x-enginserorg A battery electric vehicle, which is using electric motors for traction, doesn't need a multi-step gearbox because the traction output of the electric motors matches the ideal traction hyperbola and the electric motor can also output torque rotating in opposite direction. Also, a vehicle equipped with an internal combustion engine and continuously variable ‘transmission (CVT) will also have an ideal traction hyperbola, We can summarize the role of a transmission (gearbox) on a vehicle with internal combustion engine as: ‘adapts the traction output torque of the engine to match (approximate) the required (ideal) traction hyperbola of the vehicle (through the forward gears) = allows the vehicle to move in reverse (backwards) with the engine rotating in the same direction (through the reverse gear) = allows the engine to be disconnected from the wheels (through the clutch / torque converter or putting the gearbox in Neutral) OX Example. Plot the traction lines of a vehicle with the following input parameters: Maximum power, Prix KW] 250 Gear rallos 4 an cy 34 is an 4 167 is 128 is 1.00 b 0.84 hitps:i-engineer.orglautomotive-engineeringldrvetrainransmissionsiwhy-do-we-need-gears! 59aniarora Why do we need gears? ~x-enginserorg is 067 Final dive () aa Whoo adv, 0.3865 Maximum sp2ed, Vrae KPH 260 The engine traction force at the wheel will be calculated from the maximum static engine torque line. Engine speed tooo 202029903500 © 0006500, points (full load), Ne rpm] Engine static 306 385439480 480867 torque points (ullloae), Te Nm First, we need to calculate the minimum vehicle speed, which is achieved with the engine at idle and the first gear engaged. The idle speed of the engine is considered to be 1000 rpm. \V_Amin) \text( [kphl} = \frac(1000 \edot \fract\piX30) \edot r_(w) \edot 3.6) {A1) \cdot i {0}} \tag(5) Measurerr Ad Laborate For Your Nee Anton Paar Learn mor (3) With equation (2) welll calculate the ideal traction hyperbola (ITH). Using equations (4) we can calculate the engine wheel force for each gear. For an easier implementation, we are going to use a Scilab script

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