GEARBOX APPARATUS

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Contents

1. Purpose Page 3

2. Introduction Page 3

3. Technical parameters Page 8

4. Technical Introduction Page 8

5. Experiments Page 9

6. Problem thinking Page 11

7. Note attention Page 11

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1. Purpose

The car gearbox model transparently and intuitively demonstrates the basic
structure and working principle of the transmission.

Students can clearly understand the mechanical structure and function of each part
of the automobile transmission.

2. Introduction

The transmission is a three‐axis stepped gear transmission.

1. Shell part:

The shell of the five‐speed transmission is composed of four parts: a small cover, an
upper cover, a transmission fork shaft bracket, and a lower body.

2. Gear mechanism:

(1) The first shaft always meshes with the driving gear and the shaft is made into
one body.

(2) From front to back on the second shaft are constant mesh (fifth gear), fourth
gear, third gear, second gear, first gear, and reverse gear

(3) The front and rear ends of the intermediate shaft are supported on the housing
with bearings.

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3. Working principle

The figure below shows that the engine transmits power to the clutch through the
crankshaft, the clutch transmits to the gearbox, and the gearbox transmits to the
drive shaft, which is connected to the wheels to provide the power for the wheels
to rotate.

A three‐dimensional view of the inside of the real gearbox

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For ease of understanding, let's first look at the picture of a two‐speed gearbox as
follows.

The green one is called the gearbox input shaft, which is an input shaft through
which the clutch transmits power to the gearbox.

The red part is called the intermediate shaft, and they rotate together.

As long as the green shaft is rotating, the intermediate shaft will rotate together to
transmit power.

The yellow shaft connects the differential and the drive shaft to transmit power to
the tires. It should be noted that the yellow shaft and the purple sleeve are
connected by splines.

The actual picture shows the shape of the spline.

There is a hole in the middle of the purple sleeve. It has internal teeth and meshes
with the teeth of the spline on the yellow shaft. That is to say, the sleeve and the
yellow shaft always rotate together.

However, the blue gear is not connected to the yellow shaft, they are free at this
time. When you are sliding in neutral, the wheel is still rotating, and the yellow
shaft is also rotating.

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But the blue gear does not rotate at this time because there is no power
transmission. But when we pull the gear lever, the shift fork will move left and right,
If the sleeve slides to the right, it is in the first gear, and if it slides to the left, it is in
the second gear.

We can see that the gear is very large and the red gear is very small. Here is a gear
ratio. The gear ratio of the first gear is always the largest.

The advantage of this is that the engine crankshaft makes a lot of revolutions, and
the gear of the first gear only makes one revolution. The power is sufficient, but the
running is not fast.

In order to run faster, we need to make the wheels turn faster, and the engine does
not turn so fast, so we need a smaller gear ratio.

As you can see, the gear ratio of 2nd gear is just It will be smaller. In the picture,
push the gear lever, the shift fork moves to the right, the sleeve and the blue gear
mesh, the sleeve and the yellow shaft rotate together, so the power is transmitted
to the yellow shaft, and then to the transmission shaft. Tire, the car will run.

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Let's take a look at this 5MT transmission.

With the previous explanation, this picture is well understood. The gear ratio
gradually decreases from 1‐5 gears, and the 5th gear is the final ratio. This ratio is
generally 1:1, that is, the engine crankshaft makes one revolution. The 5th gear
makes one revolution, which is also the most economical gear ratio. So our car will
go to the highest gear after driving to a certain speed to get the best fuel economy.

Let's take a look at how the gear shift is implemented in combination with the
following picture. In fact, a 5MT car has three shift forks. We can't see clearly from
the picture above, so it's easy to see here.

The gear lever is connected to the three shift forks through three connecting rods,
so we know very well that you are in the first gear and the second gear, in fact, the
shift fork pushes the sleeve to the blue gear of the first or second gear. When you
move the gear lever left and right, you are actually choosing different shift forks
(different sleeves), and when moving forward and backward, you are choosing
different blue gears.

Reverse gear: Reverse gear is actually adding a small gear (idler gear) between the
red and blue gears to make the blue gear rotate in the opposite direction to achieve
reverse.

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3. Technical parameters:

 Volume: 500mm×270mm×570mm

 Net weight: 6800g

 Rotation form: manual

4. Technical Introduction:

① Parking brake

② First shaft of gear lever

③ Tooth fan

④ Rotating lever

⑤ Shift operating lever

⑥ Small cover

⑦ Upper cover

⑧ Rocker arm

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5. Experiments

1. Neutral gear experiment

Operate the shift lever so that the transmission is in the N position.

Shake the hand wheel and touch the reel on the output shaft.

You will find that no power is transmitted from the input shaft to the output shaft
when in neutral.

2. Parking experiment

Operate the shift lever so that the transmission is in the N position.

Operate the parking lever brake, and then turn the output reel, you will find that
the reel cannot be turned, indicating that the vehicle is now in the parking state.
When you release the brake, you can turn the reel.

3. Forward gear experiment

Operate the shift lever to make the transmission in the first gear position, shake the
handwheel for 5 turns, and record the number of turns of the output shaft and the
direction of rotation.

Operate the shift lever to make the transmission in the 2nd gear position, shake the
handwheel for 5 turns, and record the number of turns of the output shaft and the
direction of rotation.

Operate the shift lever to make the transmission in the 3rd gear position, shake the
handwheel for 5 turns, and record the number of turns of the output shaft and the
direction of rotation.

Operate the shift lever to make the transmission in the 4th gear position, shake the
handwheel for 5 turns, and record the number of turns of the output shaft and the
direction of rotation.

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Operate the shift lever to make the transmission in the 5th gear position, shake the
handwheel for 5 turns, and record the number of turns of the output shaft and the
direction of rotation.

Calculate the speed ratio of each gear.

4. Reverse gear experiment

Operate the shift lever to make the transmission in the R position, shake the
handwheel for 5 turns, and record the number of turns of the output shaft and the
direction of rotation.

Calculate the speed ratio of the reverse gear.

5. Torque transmission experiment (can be done if possible)

There is a threading hole on each reel. You can find two spring scales to hang on the
two reels respectively.

Make the transmission in different gears, pull the spring scale with proper force in
the tangential direction of the input reel, and pull the spring scale with proper force
in the tangential direction of the output wheel, and record the value of the
respective spring scale force when the shaft is stationary and not rotating.

Since the diameters of the two reels are equal, this force can be used to calculate
the torque ratio.

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6. Problem thinking

Think about whether the relationship between the speed ratio and the torque ratio
conforms to the following relationship.

Ni/No=To/Ti

(Ni, input speed; No, output speed; To, output torque; Ti, input torque)

7. Note attention:

(1) Acrylic teaching model, limited firmness, be cautious to operate.

(2) Handle with care, store at normal temperature, and strictly forbid direct
sunlight.

(3) In the process of practical operation, you need to be careful to move the
joystick lightly, and not to move the joystick bluntly.

(4) When shifting control, you must first return to the middle position, and make
sure that the shifting links are all in the middle position and kept in parallel, and
then turn the handle again to realize the gear shift of the gearbox. The gear
distribution of the reducer is shown in the figure below.

(5) When you open the package for the first use, please install the shaker (in a
plastic bag).

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