Đồ án DESIGN GEARBOX ON HYUNDAI I10

Tóm tắt nội dung đồ án Tóm tắt nội dung của đồ án tốt nghiệp trong khoảng tối đa 300 chữ. Phần tóm tắt cần nêu được các ý: vấn đề cần thực hiện; phương pháp thực hiện; công cụ sử dụng (phần mềm, phần cứng…); kết quả của đồ án có phù hợp với các vấn đề đã đặt ra hay không; tính thực tế của đồ án, định hướng phát triển mở rộng của đồ án (nếu có); các kiến thức và kỹ năng mà sinh viên đã đạt được. MỤC LỤC CHƯƠNG 1. OVERVIEW 1 1.1 The use of the gearbox 1 1.2 Gearbox requirements 2 1.3 Gearbox classification 2 1.3.1 According to the control method, it is divided into the following types: 2 1.3.2 Classified by the number of levels: 11 1.3.3 According to the dynamic diagram, it is divided into: gearboxes with fixed shafts (2.3 or more axes) and planetary gearboxes (one row, two rows) 12 1.4 Choose design options 13 1.4.1 Gearbox with two shaft and 5 speed 14 1.4.2 Gear box with three shaft and 5 speed 15 1.5 Gearbox on Hyundai i10 16 1.5.1 Working principle of gearbox: 16 1.5.2 Working principle of synchronizer: 17 1.5.3 Working principle of gear shifting: 19 1.5.4 Working principle of interlock mechanism: 19 1.5.5 Components : 21

TRƯỜNG ĐẠI HỌC BÁCH KHOA HÀ NỘI

Chữ ký của GVHD

ĐỀ TÀI

Biểu mẫu của Đề tài/khóa luận tốt nghiệp theo qui định của viện, tuynhiên cần đảm bảo giáo viên giao đề tài ký và ghi rõ họ và tên

Trường hợp có 2 giáo viên hướng dẫn thì sẽ cùng ký tên

Giáo viên hướng dẫn

Ký và ghi rõ họ tên

cụ sử dụng (phần mềm, phần cứng…); kết quả của đồ án có phù hợp với các vấn

đề đã đặt ra hay không; tính thực tế của đồ án, định hướng phát triển mở rộng của

đồ án (nếu có); các kiến thức và kỹ năng mà sinh viên đã đạt được

Sinh viên thực hiện

Ký và ghi rõ họ tên

MỤC LỤC

CHƯƠNG 1 OVERVIEW 1

1.1 The use of the gearbox 1

1.2 Gearbox requirements 2

1.3 Gearbox classification 2

1.3.1 According to the control method, it is divided into the following types: 2 1.3.2 Classified by the number of levels: 11

1.3.3 According to the dynamic diagram, it is divided into: gearboxes with fixed shafts (2.3 or more axes) and planetary gearboxes (one row, two rows) 12 1.4 Choose design options 13

1.4.1 Gearbox with two shaft and 5 speed 14

1.4.2 Gear box with three shaft and 5 speed 15

1.5 Gearbox on Hyundai i10 16

1.5.1 Working principle of gearbox: 16

1.5.2 Working principle of synchronizer: 17

1.5.3 Working principle of gear shifting: 19

1.5.4 Working principle of interlock mechanism: 19

1.5.5 Components : 21

DANH MỤC HÌNH VẼ

Hình 2.1 Đồ thị kiểu bánh 20

Hình 2.2 Đồ thị kiểu thanh ngang 20

Hình 2.3 Đồ thị kiểu cột đứng 21

Hình 2.4 Đồ thị kiểu đường 21

Hình 2.5 Đồ thị kiểu diện tích 22

DANH MỤC HÌNH VẼ

Bảng 1.1 Thống kê các thiết bị và giá thành 8

CHƯƠNG 1 OVERVIEW

1.1 The use of the gearbox

Why we need a gearbox?

A gearbox is necessary for petrol powered cars because petrolengines are very not effecient at very low or very high turnover rates, calledRPMs

The first thing to understand is something called a gear ratio

If a full setup has no gears, meaning the power was somehow applieddirectly to the wheels, the gear ratio would be 1 This means for one turn of theengine, or crank shaft which is the shaft coming out of the engine, there would beone full turn of the wheels

However, in most scenarios it's useful to change the gear ratio depending

on the power and speed you want, and the power output of the engine The higherthe gear ratio the more often the engine has to turn for each turn of wheels Thisincreases power per engine turn but decreases distance traveled per turn, andtherefore speed

Because petrol engines change power and efficiency depending on howfast they are spinning, you want to keep the engine spinning where it's efficient

no matter what speed you're going, or what you're trying to do (engines are morefuel efficient at lower rotations per minute, but more powerful at higher RPMs,for example)

The gearbox is a set of gears that allow you to change the gear ratio whilethe car is moving to try and keep the engine running at its most efficient, and togive you extra power or extra miles per gallon when you want

The gearbox is used to change the number of revolutions and torque of theengine transmitted to the active wheels (both in gear position and direction) tosuit the ever-changing working conditions of cars and tractors The engine itselfcannot meet because:

Low torque adaptation factor (Km= 1.05 ÷1.25)

Relatively high minimum number of stable revolutions (min= 350 ÷400rpm)

The direction of rotation cannot be changed by itself

In addition, the gearbox is also used to

- Long-term separation of the engine from the transmission system whennecessary such as when starting the engine, when stopping the vehicle for theengine to idling, when driving the vehicle under inertia

- Driving working parts on specialized vehicles, such as trucks withwinches, dump trucks, cranes and other equipment

- Working smoothly, shifting gears smoothly, without impact:

When we shifting gear, the gear match together with different rotationspeed, if we do not have mechanism to do it smoothly, gear will wear and tearvery fast

-Has an intermediate position to be able to permanently cut the enginefrom the transmission:

When we shifting gear, we need to cut the engine from the transmission inorder to shifting gears smoothly

-Simple structure, reliable and sustainable work:

Gearbox need to check and maintain easily

- High performance, small volume, low cost:

Gearbox also must have economic efficiency

- High power transmission efficiency:

Save fuel consumption and have protect engine

- Have interlock mechanism: preventing the double meshing of atransmission

- Have signaling structure when on reverse gear: Safety mechanism

1.3 Gearbox classification

There are many type of car are used nowadays so to guaranteed therequirement of these car we also have a lot of type of gearbox and they candivided into many class which mentioned below

1.3.1 According to the control method, it is divided into the following types:

A, Manual transmission

A manual transmission (MT), also known as manual gearbox, standardtransmission (in Canada and the United Kingdom), or stick shift (in the UnitedStates), is a multi-speed motor vehicle transmission system, where gear changesrequire the driver to manually select the gears by operating a gearstick and clutch (which is usually a foot pedal for cars or a hand lever formotorcycles)

Picture 1.1: Diagram of MT

I : Primary shaft , II : intermediate shaft , III : secondary shaft

Manual tranmission are widely used because of their simple structure andhigh efficiency ( 0,96 ÷ 0, 98 ) , low price, small size and weight

ADVANTAGES OF MANUAL TRANSMISSION

1 Better perceive when driving

One of the advantages of manual transmission when compared toautomatic transmission and continuously variable transmission is that it gives adrive a little more control over how hard the engine works and how much powergets to the wheels due to direct gear selection and torque transfer regulation

Most sports cars come with manual transmissions due to better controlover the engine that translates to direct driver involvement In addition, off-roadvehicles and trucks are often equipped with manual transmissions due to directgear selection and more durability in rugged driving conditions

2 Durability and low maintenance

Another benefit of manual transmission is longevity due to durability andlow maintenance When compared to automatic transmission and continuouslyvariable transmission, a manual transmission has simpler mechanicalspecifications and fewer mechanical parts

Also, manual transmission is smaller and more compact than AT although

a CVT has similar compact orientation Nonetheless, the inherent physical andmechanical characteristics of manual transmission translate to resiliency fromwear and tear, lesser maintenance requirements, and easier reparability

3 More Cost-Effective

The price of vehicles equipped with manual transmissions is usually lowerthan similar vehicle models come with an automatic transmission or continuouslyvariable transmission variant Specifically, the price difference ranges from

$1000 to $3000

Furthermore, the durability, lower maintenance frequency, and easierreparability of MT boxes translate to lower maintenance and repair costs It isalso worth mentioning that in a manual gearbox, the engine slows down thevehicle more effectively whenever the driver releases the engine speed control In

an automatic transmission, engine-breaking is less effective, thus resulting inmore usage of breaks and shorter break life

4 Push Starting

Push starting is another advantage of manual transmission Also known asclutch starting or crash starting, push starting is a method of starting a vehiclewhen other starting methods are unavailable due to a low battery or otherhardware failures

DISADVANTAGES OF MANUAL TRANSMISSION

2 Relatively Slower Shifting Speed

Similar to operational complexity, another disadvantage of manualtransmission is a relatively slower shifting speed than automatic transmission orcontinuously variable transmission This drawback stems from the time requiredfor a driver to operate the clutch pedal and move the gearstick to choose theappropriate gear

3 Mechanical Deterioration Due to Improper Use

The clutch is also susceptible to wear and tear under differentcircumstances For example, driving in the first gear or moving the vehicle from

a standstill causes a considerable amount of mechanical stress due to friction

B, Automatic transmission

The automatic transmission is by far the most common transmission onthe road today It uses a highly-complex torque converter to transmit the engine’srotational energy, while gear shifts are controlled by the vehicle’s computer andaccomplished with a planetary gear set and a series of clutches and brakes

and uses sensors to use the ‘in-built’ clutch while the power to change gears

remains in the drivers’ hands

IMT apply in some cars such as: Hyundai i20, Hyundai Venue, Kia Sonet,

Picture 1.3: IMT transmission

AMT:

AMT stands for Automated Manual Transmission It is exactly as its name

suggests – a transmission that automates manual transmission AMT not only

removes the clutch pedal like the IMT but also goes a step further to relieve the driver of the responsibility of shifting gears, thereby reducing user input

to a bare minimum.

The AMT system works with the help of a series of sensors andmechanical parts that are being told what to do by the cars ECU (ElectronicControl Unit), pre-programmed by respective automotive manufacturers Sensorsand actuators work together to engage the clutch and shift gears and therefore,the only true interaction the driver has is with the accelerator and brake pedal

Picture 1.4: AMT transmission

AMT is installed in: Suzuki Alto K10, Toyota Glanza, Tata Punch,…CVT:

A CVT, or continuously variable transmission, seamlessly changesthrough an unending range of effective gear ratios while you drive, whereas otherkinds of mechanical transmissions offer a fixed number of gear ratios and havehard shifts between each as explained by Certified Transmission Repair CVTtransmission systems are also known as single-speed, shiftless, and steplesstransmissions

The shiftless nature of a CVT offers unparalleled flexibility that maintainsconstant angular velocity regardless of output speed Additionally, a continuouslyvariable transmission makes accelerating smooth and offers enhanced fueleconomy

The speed change when we change the volume of 2 pulleys and themoment go from drive pulley à belt à driven pulley

To better understand how a DCT transmission works, it’s best tounderstand how a manual transmission works When using a manualtransmission, the driver needs to frequently disengage the clutch to be able tochange gears The clutch works by disconnecting the engine’s drive from thedriveline briefly so that the gears can be changed smoothly A DCT works byusing two clutches instead of one, and both are computer controlled, so there’s noneed for a clutch pedal.

The dual clutch transmission operates via several in-built computers.These computers eliminate the need for the driver to manually change gears andthe entire process is automated In this respect, a DCT can be looked upon asbeing similar to an automatic transmission The main difference is that the DCToperates the odd and even gear numbers separately, which prevents the enginefrom being disengaged from interrupted power flow when the gears are changed.The core difference between a DCT transmission and an traditional automatictransmission is that the DCT transmission doesn’t use a torque converter

DCT is used in: Audi R8, Nissan GT-R, Porsche 718,….

ADVANTAGES OF VEHICLE WITH AN AUTOMATICTRANSMISSION

EASE

Automatic transmissions are easier to use as compared to manual ones.Most modern vehicles have a hydraulic planetary automatic transmission that iscapable of switching between the gears on its own In a manual transmission, thistask has to be performed by the driver Automatic transmissions use transmissionfluid for increasing or decreasing gear ratios They also have an oil pump thatcontrols the clutches in a planetary gear pattern by pressurizing the fluid Thismakes driving easy and drivers do not have to worry about what gear they aredriving in

SAFETY

Automatic cars are safe to drive as compared to manual cars In a manualcar, your one hand and leg are always engaged while driving This is not the casewhen it comes to automatic cars because the gears are switched on their own.Therefore, you can easily drive with both hands on the steering wheel and you donot even have to worry about changing gears every now and then

ENVIRONMENT FRIENDLY

Although manual transmission cars give you more control over anengine’s exertions, automatic transmission cars are fuel-efficient

DISADVANTAGES OF AUTOMATIC TRANSMISSION

The driver have less perceive when driving

In an automatic transmission, the car loses a certain degree of control.Some drivers prefer manual transmission over automatic one as they have morecontrol of gear

COSTLY REPAIRS

Automatic transmissions are comparatively more expensive than theirmanual counterparts Maintenance of automatic transmission cars costs mainlyfor transmission and fuel However, when it comes to selling your automatic car,you can easily get buyers as these cars have high demand and most people knowhow to drive them

C, Semi-automatic transmission:

A semi-automatic transmission is a multi-speed transmission, where part

of its operation is automatic, but requires a driver’s input to drive the vehiclefrom stop and change gears manually It is a combination of manual andautomatic transmission

It can also provide you with how to control the gears as there is a selection

of both manual and automatic options The kinetic energy produced by theengine helps the wheels spin, while gear ratios control how fast or slow yourwheels spin

Importantly, semi-automatics do not have a clutch pedal Instead, the car’sCPU and sensors operate the clutch when the driver changes gears, as a result,semi-autos are actually easier to drive Semi-automatic transmission is commonlyused in Hyundai cars

Picture 1.7:Semi-automatic transmission

Semi-automatic is used in: Toyota C-HR, Land Rover Defender, SkodaKaroq,…

In Semi-automatic, the way of momen is the same like manual gearboxbut the driver can changes gear more easily than manual gearbox

1.3.2 Classified by the number of levels:

A, There are 3, 4, 5 speed gearbox:

Picture 1.8: 3 speed gearbox

Picture 1.9: 5 speed gear box

B, A gearbox with a gear number greater than 6 is called a multi-speedgearbox:

Picture 1.10: Multi-speed gearbox