Advanced Transmission Systems

Seminar Description: Advanced Transmission Systems
William Mark McVea, Ph.D., P.E.
Advanced Transmission Systems

Seminar Description:
Building on the basic understanding derived from the Fundamentals of Passenger Vehicle and
Light Truck Transmission Systems seminar, attendees will develop a deeper understanding of
many of the functions of the modern automatic transmission. Specifically;
Hydro-Mechanical Shift Events
Shift-to-Shift Sequencing
Controlled Clutch Slipping
Electronic Controls, Theory & Mechatronic Implementation
Adaptive Control Strategies & Implementation
Sensors & Actuators
During the first day the attendee will explore each of these areas to expand their base
knowledge of these modern transmission systems. The second day will be spent exploring the
implementation of these technologies through a systematic approach.
Learning Objectives:
Section I: Shift Control Mechanism
Learning Objective: The attendee should expect to discuss and learn how to identify all major
components in both traditional and modern valve body / shift system; understand the control
logic, how it is implemented, what information is required to make good shift decisions, and
how that information is used in the logic controller.
Completion Criteria: The attendee will de able to definitively explain The Shift Event;
What causes an up-shift to occur
What causes a down-shift to occur

How the transmission control system is commanded to shift

What occurs internal to the shift control mechanism
What the transmission needs the rest of the powertrain to do in order to facilitate a
smooth shift
How to achieve a smooth shift, with maximum power transfer
What sensory and conditional information is required to make the best shift
Section II: Sensors and Instrumentation

Learning Objective: The attendee will develop a deeper understanding of sensor technology as
it applies to modern vehicle transmission systems. They will understand transmission
sensor technology from two points of view: First, they will review the data requirements for
control and smooth, efficient operation of the transmission control system. Second they will
develop and understanding of the operation, design and application considerations of the
typical sensors in use today, as well as the current technology directions within the industry.
Completion Criteria: The attendee will be able to;

Identify all major common sensors on a typical transmission
Explain what data they are designed to acquire
How sensors acquire data, and how they work internally
Finally, how communicated through the controller system and how data is used by the
system to control the operation of the transmission
Section III: Friction Materials

Learning Objective: The attendees will investigate Tribology, the study of friction and interfacial
contact regimes, and the thermal properties of asperity contact and fluid conductivity. They
will understand the effects of friction on system efficiency throughout the transmission.
During the discussions regarding Tribology, and the effects of friction on system operation,
they will learn how interact with lubricant engineers to create a development plan for
creating a new feature or complete lubricant package for a specific task or function.
Completion Criteria: Attendees will be able to develop a working specification for lubricant
requirements as a function of component or sub-system within the transmission. The
attendees will;
Develop a solid practical understanding of the chemistry
Terminology requirements of modern lubricants
Applicability requirements of modern lubricants
Specification requirements of modern lubricants
Section IV: Lubrication

Learning Objective: This section compliments the preceding material on friction. Through this
section the attendee will complete their understanding of the interplay of friction materials
and the lubricants that augment their operational characteristics and functional performance.
The effect on all other systems within the transmission will be reviewed relative to the
optimization for frictional performance.
Optimize lubricant requirements as a function of frictional performance
Explain the design compromise between enhanced frictional support and degradation
of lubricity in terms of all other rotating components within the transmission system
Appreciate and explain the adverse effects of environmental factors on lubricant

performance
Discuss environmental concerns regarding the use, leakage and disposal of modern
lubricant packages
Explain the concept of additive packages;

Why they are used
Why they are separate from base stock
Environmental effects
Life and failure mechanisms
Section V: Gear Systems

Learning Objective: As part of their normal responsibilities, the attendee will be required to
interface with gear designers and analysts. This section will explain to the attendees the
methods used to specify, design, manufacture and analyze gear systems for modern vehicle
transmission systems.
Completion Criteria: Attendees will understand and be able to use the results from modern
analysis techniques to discuss;
Force analysis of gear pairs and systems as a function of driving model
Internal stress distribution models, which link to thermal models
Thermal models of gear systems
Predict failure, incipient or catastrophic, of a gear system
Section VI: Design Objectives and Considerations of Clutch Systems

Learning Objective: The intent of this section is to provide the attendee with a complete
understanding of the principle of clutch operation, design and acceptance criteria. We will
investigate all aspects of clutch design and application through classic methods and
practical examples. As a result, the attendee will understand the underlying principles of
operation and failure of clutch systems in modern transmission systems.
Thermal models of clutch packs
Force analysis of clutch operation as a function of driving model
Predict failure, incipient or catastrophic, of a clutch system
Section VII: Continuously Variable Transmission Systems

Learning Objective: This section will address technologies specific to CVT transmissions.
Specifically the attendee will explore all the associated technologies for both push / pull belt
style CVTs, as well as those of toroidal technologies.
Thermal models of CVT technology
Force analysis of CVT technology as a function of driving model


Predict failure, incipient or catastrophic, of each CVT technology
Section VIII: Bearings

Learning Objective: This section is to the study and understanding of bearings in general, and
then specific to transmissions. The attendee will work through the basic calculations that
provide a means to specify bearings, their mounting requirements, and life predictions.
They will also work through a number of practical design examples.
Design a bearing system based on transmission criteria
Predict the service life of the bearing system
Explain the root cause mechanism of an identified bearing failure
Discuss bearing performance and its affect on transmission efficiency with bearing
engineers
Section IX: Case Design

Learning Objective: The intent of this section is to expose the attendee to practical application
and operational issues regarding case design, material selection and techniques that can be
used to solve in-services issues of noise, deflection and internal component life.
Completion Criteria: The attendee will be aware of case design requirements to address;
Bearing system position and deflection criteria

Lubricant channeling and communication

Power transmission component support
Control system connectivity
Placement and structural connections to the remainder of the powertrain and chassis
Section X: Combination of Existing and New Power Distribution Technologies

Learning Objective: This section of the seminar is designed to be a discussion-based
interaction of all attendees. The intent is to bring new technologies and technical trends to a
general discussion, within confidentiality limits, to the fore. Attendees will be encouraged to
share their corporate or research directions. Recent developments within the industry will
be brought forth and discussed within the context of the previous material, its implication
and limitations. Finally, completely new technologies, power distribution techniques,
materials and layouts will be reviewed in a forum discussion style.
Completion Criteria: There will not be any definitive criteria for this section since it is to be
conducted as a forum discussion. The attendee will be exposed to new technologies and
trends, as such they will be able to both discuss state-of-the-art material, as well as
investigate information and sources.
Benefits of Attending:
By attending this seminar, you will be able to:
List the typical sensors, the sensory information they collect and describe the use of that
information as it addresses improved fuel economy and reduced combustion emissions
Describe the significance, technology, and application of:

o
o
Direct Injection (DI) of both gasoline and diesel fuels

Homogeneous Charge Compression Ignition (HCCI)
Displacement on Demand (DoD) Systems
Variable Cam Timing (VCT) and Variable Valve Timing (VVT)
o Variable Compression Ratio (VCR) engine designs
Explain the fundamental physics of the various technologies
Specify the operational parameters and inter-relationships of each of the sub-systems of

the enabling hardware
Describe the basic design synthesis and analysis techniques for each of the major
operational improvement technologies
Who Should Attend:

This is designed to be an advanced seminar; as such it is intended for anyone who is familiar
with the operational theories or functional principles of modern passenger vehicle transmission
systems. The material covered in this seminar is targeted at a number of design and
engineering disciplines
Design Engineers and Engineering Managers

Vehicle Powertrain and Driveline Designers
Component Suppliers
Powertrain and Driveline Test & Development Engineers
Design Services Managers
Anyone Involved in Product Specification, Voice of the Customer, Sales and Marketing of Any
Vehicle Type and Automotive Driveline Components
Prerequisites:
Individuals should have;
Successful Attendance of Modern Vehicle Transmission Systems: Module I

Working knowledge of transmission configurations, functions and operations
Engineering work related experience
Seminar Content
Section I: Shift Control Mechanism
Operation and Function
Implementation and Components
Valve Body
Solenoids / Mechatronics
Torque Converter Lock-up Clutch (TCC)
Clutch-to-Clutch Shifting
Electronic Controls
Advantages over mechanical and hydraulic
Disadvantage and limitations
Section II: Sensors and Instrumentation
Sensor Systems
Application strategy
Measured data
Data integration
Sensor Types
Implementation
Collection rate
Communication rate
Protocols
Section III: Friction Materials
Tribology
Interface and contact friction
Mechanism of asperity contact
Dynamic and static coefficient of friction
Lubrication
Effect of lubricant
Lubricant properties
Chemistry
Additives
Contaminants
Bulk thermal properties of lubricant
Selection of lubricant
Section IV: Gear Systems
Gear Design Techniques
Industry Best Practices
Gear Stress and Life Analysis
Gear System Specification
Requirements of Systems and Components
Section V: Clutch System Design and Integration
Thermal Development
Actuation Model
Force / Stress Analysis
Dimensional Analysis
FEA Results of Analysis
Section VI: Continuously Variable Transmission Systems
Belt, Variator, Toroidal Technology
Operational Model
Thermal Model
Actuation Model
Failure Mechanism
Section VII: Bearings
System Design
Support System Considerations
Selection and Application
Bearing types and application considerations
Application limits
Load resolution
Life prediction
Effects of lubricants & expected debris
Section VIII: Housing Design
Structural considerations
NVH considerations
Material selection considerations
Packaging and integration considerations
Section IX: Combination of Existing and New Power Distribution Technologies
Automated Manuals
Manualized Automatics
Single point of power distribution
Engine Transmission Integration
Combined Technologies
New Distribution Systems
Instructor Biography:
Dr. William Mark McVea is founder and Chief Technical Officer of KBE+, Inc. KBE+ designs and
develops complete powertrains for automotive and off-highway vehicles. It also develops and
delivers professional development seminars for the automotive industry and its supplier base.
Dr. McVea holds a B.S. in Mechanical Engineering from the Rochester Institute of Technology,
a Ph.D. in Design Engineering from Purdue University and is a licensed Professional Engineer.
He was formerly a manager of the CAE group within a tier one, powertrain supplier to world
automotive markets; a consulting engineer in vehicle dynamics, with Gear Consultants, Inc.; a
project manager of traction systems for off-highway vehicles with Clark-Hurth International;
research laboratory supervisor, developing geared traction devices with Gleason Power
Systems, Inc. He has taught and lectured at Purdue, Michigan State and Syracuse Universities.
He is published extensively on the topics of transmission systems, automated design assistant
systems, knowledge systems and knowledge based engineering in general. He also holds a
dual position as both a professor of Vehicle Dynamics in the Mechanical Engineering
department and a professor of Information Technology in the B. Thomas Golisano College of
Computing and Information Sciences at the Rochester Institute of Technology. He also teaches
at Purdue University in their Automotive Sciences department.

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Seminar Description: Advanced Transmission Systems

William Mark McVea, Ph.D., P.E.