VD - Part 05 - Power Transmission Systems

VEHICLE DESIGN
&
CAD
Işık University - AUE 421
Week #5
Atabay - Istanbul Technical University 1

Today ?
Power Transmission Systems

Alternative Propulsion Systems

Energy => Work & Function
Energy Storage Mechanical Energy

Electrical Energy + Battery
Gasoline + Tank
Diesel Fuel + Tank
Hydrogen + Tank Energy
.. Converter
..
Electric Motor
..
Int. Comb. Engine
.. Power
.. Transmission
.. Elements
Speed converter
Torque converter
Torque splitter
Differential Tires
.. On Street
..
..

Converting Power (Torque-Speed) Characteristics
INPUT ANY ELEMENT OUTPUT

nI nO
OF POWER
MI MO
TRANSMISSION
PI PO = η PI
(1−η) PI
LOSSES

Front Engine – Rear Wheel Drive
Clutch & Gearbox
Propeller shaft Axle drive

and differential
Engine
Side shafts
Rim +
Tire

Main Powertrain Schemes for Passenger Cars
Rear wheel drive

(standard drive)
Top view
Front wheel drive

Top view
Coaxial gearbox

Packaging

Arrangement of the Powertrain Elements in a Passenger Car
Front-wheel drive Standard drive
Rear-motor drive
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Powertrain Packaging for Trucks with One or More Powered Axles

Powertrain Packaging for Buses

Powertrain Packaging for all-wheel drive passenger
cars

Clutches

Dry Clutch – Schematic
Kavrama Diski Pressure
Baskı DiskiplateBaskı
Pressure
Yayı spring
Friction plate
Flywheel
Volan
Clutch Pedal
Kavrama pedalBağlantısı
connection
Engine
Motordan Gearbox
Moment Değiştiriciye
Max. Permissible pressure on friction plate passenger cars 0.2 ... 0.5 MPa,
heavy commercial vehicles 0.15 ... 0.25 MPa

Flywheel
Pressure plate
Friction plate
Release bearing
Dry Clutch

Clutch Diameter

Gearboxes

Automotive Transmission Types

Trends in the Use of Passenger Car
Transmissions in Europe

Passenger Car Transmission Designs: Market Shares and
Prediction
2000 2010
2015

5 Speed Manual Passenger Car Transmission
(VW Golf)

Two-Range, 12-Speed Gearbox

Three- Range, 18 Speed Gearbox

8-Speed Automatic Transmission - ZF
Torque
Converter Pump
Excitation
Gear Shifting Elements
Lock-Up
Clutch
Gear Lever Connection

CVT Example - Mini

Autotronic CVT (Daimler)
Mmax: 280 Nm
imax: 10,74 – 13,21
Overall transmission ratio : 6,41
m: 88 kg
Starting with : Trilok Converter
Reverse gear with : Planetary gear set
Reference: Grainer, J., Front-CVT Automatikgetriebe von Mercedes-Benz, VDI-Berichte Nr. 1827, 2014.
Multitronic CVT (Audi)
Mmax: 330 Nm (2006: 400 Nm)
n: 700...6850 1/min
imax: 12,15 – 17,1
Overall transmission ratio : 6,25
m: 87,5 kg
Start with : Wet (disk) clutch
Reverse gear with : Planetary gear
set
Chain
Reference: Schibema, P., Gesenhaus, R., Audi multitronic-leistungsfähig und sportlich, VDI-Berichte Nr. 1827, 2014.
DCT's

DCT's
Output Shaft 2 Output Shaft 3 Part 2
Input Shaft 2
Engine Torque
Input Shaft 1
Output Shaft 1 Part 1

Reference: Volkswagen AG.
Powertrain to Body – Connection Points
Reference: ATZ.
Shafts

Universal Joint
Reference: https://en.wikipedia.org/wiki/Universal_joint.
Hooke Joint – Angular Difference & Velocities
ϕ 2 = arctan ( cos ( β ) tan (ϕ1 ))
ω2 cos ( β )
=
ω 1 1− sin 2 ( β ) sin 2 (ϕ1 )
where
dϕ dϕ 2
ω1 = 1 ω2 =
dt dt
Reference: Seherr-Thoss, H. C., Schmelz, F., Aucktor, E., Universal Joints and Driveshafts, Springer, 2006.
Universal Joint Configurations
Universal Joint Configurations
Between Shaft #1 and Shaft #2 Between Shaft #2 and Shaft #3
tan (ϕ 2 ) = cos ( β1 ) tan (ϕ1 ) ( ) ( ) ( )

tan ϕ 2 = cos β 2 tan ϕ 3
cos ( β1 ) tan (ϕ1 )

Hence tan (ϕ 3 ) =
cos ( β 2 )
If β1 = β2, then tan (φ1) = tan (φ3) or tan (φ1) − tan (φ3) = 0.
This means that there will be no lag between shaft #1 and shaft #3, and φ1 = φ3.
Therefore, ω1 = ω3.

Driveshafts
Driveshafts
Driveshafts
Axle Drive

Axle Drives for Passenger Cars
• spur gear axle drive,
• bevel gear axle drive of helical bevel or hypoid design
• worm gear axle drive.

Differential
When travelling in a straight line, the differential cage 2, the axle bevel
gears 4, the axle shafts 6 which are torsionally locked to the axle bevel
gears, and the differential bevel gears 3 inside the cage rotate as a block.
There is no relative movement between the differential shaft 5 and the
differential bevel gears mounted on it. When cornering, the outer axle shaft has
to rotate faster than the inner one; axle bevel gears and differential bevel gears
move on rolling contact. This enables speed compensation between the
wheels.

Powertrain to Body – Connection Points
Reference: ATZ.
All Wheel Drive

Porsche Cayenne Powertrain Architecture

BMW X5 Powertrain Architecture
(V8 ICE + Automatic Gearbox as classical AT)
Reference: ATZ.
All Wheel Drive – Four Wheel Drive
Design Criteria and

Customer
Expectations
● Good handling and
driving safety
● Better traction on
slippery pavements
● Driving pleasure
and agility
● More mass
● More friction and
inertia
M Ön M Giriş M Arka
● More fuel
consumption
● Higher price
All Wheel Drive Systems
BE BE
BE... Brake engagement
D... Differential
D D MDC Multiple Disc Clutch,
MDC electric activated
BE BE e.g. BMW X3
BE BE
D/MDL Differential,
Multiple Disc Lock
D/MDL D
D/MDL e.g. Land Rover Discovery
BE BE
BE
D D e.g. Hyundai Tucson 4WD

MDC
BE
Reference: Auto Motor & Sport 1/2005.
BE BE BE... Brake engagement
D... Differential
D/MDL Differential,
D/MDL D Multiple Disc Lock
D/MDL
BE e.g. Porsche Cayenne

BE
BE BE
HC Haldex Clutch
D D
HC e.g. VW Golf 4Motion
BE BE
BE BE
e.g. Mercedes 4Matic

D D
D
BE BE
BE BE
BE... Brake engagement
D... Differential
D D TD Torsen Differential
TD
e.g. Audi quattro
BE BE
MDC Multiple Disc Clutch,

electric activated
D/VL D VL Visco Lock
MDC
e.g. Subaru Outback
VC Visco Clutch
D D
VC
e.g. Fiat Panda 4x4

EMC... Electro Magnetic Clutch
EMC D... Differential
D D VC Visco Clutch
VC
EMC e.g. Honda Legend

Alternative Propulsion Systems

Full Electric Vehicles – Conceptual Examples
Rear Wheel Drive Direct Drive at Wheels Direct Drive at all Wheels
+ - + -
BAT BAT G/EM G/EM
FA FA FA
INV INV + -
BAT
G/ INV
EM
D
G/EM G/EM G/EM G/EM
RA RA RA
G : Generator INV : Inverter FA : Front Axle

EM : Electric Motor BAT : Battery RA : Rear Axle
D : Differential : electric : mechanic
Reference : IfF – TU BS
Series Hybrid Structure
T
Series Hybrid
D
G INV EM iDif
ICE
BAT
FA RA
Ø Permanent E-Drive! Mechanical

Ø No conversion of ICE torque or rpm! Electrical
Chemical
Reference : IfF – TU BS.

Series Hybrid Structure
Advantages - Disadvantages
Low efficiency (too many

energy conversions)
Series Hybrid
"Big" e-machines to satisfy

performance requirements
-
-
High mass and
Series - costs
Hybrid
+
Free selection of the - Big e-machines
ICE operating point require large
packaging cavities

Parallel Hybrid – ICE&EM on the same Shaft
"Torque Adding"
T
T
Parallel Hybrid
GB D
G/EM iGB iDif.
Mechanical
ICE C0 C1 Electrical
INV Chemical
BAT
FA RA
Ø If all clutches closed and e-machine off : Conventional powertrain!!

Parallel Hybrid – ICE&EM on the same Shaft
Advantages & Disadvantages
Adaptation to existing vehicles No free selection of ICE
possible operating point
Only "1" e-machine

+
-
If battery full, ICE operating
+
Parallel Hybrid
point can not be altered.

Existing drivetrain
components are used. One Shaft -
+ Parallel
Hybrid - Packaging difficulties if ICE
High benefit/cost ratio
+ position front lateral
+ -
Packaging OK No fuel consumption or
Additional mass OK CO2 benefit at highway
driving!

Fuel Cell System on a Hydrogen Electric Vehicle
Battery
Inverter E-Motor Gearbox

Air + + -
Water
On-Board Producing
of Electric Energy Air
Valve
with the help
of a fuel cell stack
Storage
H2

Fuel Cell System on a Hydrogen Electric Vehicle
Battery
Inverter E-Motor Gearbox

Air + + -
Water
H2 Humidifier Compressor Air

Valve
FC FC FC FC FC FC FC
Storage Pump and Cooling System

H2


VD - Part 05 - Power Transmission Systems

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VD - Part 05 - Power Transmission Systems

Uploaded by

Copyright:

Available Formats

VEHICLE DESIGN

Atabay - Istanbul Technical University 1

Power Transmission Systems

Atabay - Istanbul Technical University 2

Energy Storage Mechanical Energy

Atabay - Istanbul Technical University 3

INPUT ANY ELEMENT OUTPUT

Atabay - Istanbul Technical University 4

Clutch & Gearbox

Propeller shaft Axle drive

Atabay - Istanbul Technical University 5

Rear wheel drive

Front wheel drive

Atabay - Istanbul Technical University 6

Atabay - Istanbul Technical University 7

Front-wheel drive Standard drive

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Atabay - Istanbul Technical University 12

Atabay - Istanbul Technical University 13

Atabay - Istanbul Technical University 14

Atabay - Istanbul Technical University 15

Atabay - Istanbul Technical University 16

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Atabay - Istanbul Technical University 20

Atabay - Istanbul Technical University 21

Atabay - Istanbul Technical University 22

Gear Lever Connection

Atabay - Istanbul Technical University 24

Atabay - Istanbul Technical University 27

Output Shaft 1 Part 1

Atabay - Istanbul Technical University 30

ϕ 2 = arctan ( cos ( β ) tan (ϕ1 ))

tan (ϕ 2 ) = cos ( β1 ) tan (ϕ1 ) ( ) ( ) ( )

cos ( β1 ) tan (ϕ1 )

Atabay - Istanbul Technical University 34

Atabay - Istanbul Technical University 38

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Atabay - Istanbul Technical University 42

Atabay - Istanbul Technical University 43

(V8 ICE + Automatic Gearbox as classical AT)

Design Criteria and

D D e.g. Hyundai Tucson 4WD

BE e.g. Porsche Cayenne

e.g. Mercedes 4Matic

MDC Multiple Disc Clutch,

Reference: Auto Motor & Sport 1/2005.

Reference: Auto Motor & Sport 1/2005.

Atabay - Istanbul Technical University 50

G : Generator INV : Inverter FA : Front Axle

Ø Permanent E-Drive! Mechanical

Reference : IfF – TU BS.

Low efficiency (too many

"Big" e-machines to satisfy

Reference : IfF – TU BS.

Reference : IfF – TU BS.

Only "1" e-machine

point can not be altered.