MME 3623

POWER TRAIN SYSTEMS

PROJECT:

GEAR BOX CALCULATOR

NAME : AHMAD NAFIS BIN MUHD RADZI (1413275)

MOHAMAD ARIF BIN MOHD ALI (1410051)

SECTION :1

SUBMISSION DATE : 14ST DECEMBER 2018

LECTURER : DR. FADLY JASHI DARSIVAN BIN RIDHUAN SIRADJ

 CHAPTER 1

INTRODUCTION

Gearbox is among the vital part of power train in an automobile. It is also called

transmission box. Gear box is the second system in transmission right after the clutch system. gears

and gear trains are used to provide speed and torque conversions which is obtained from a rotating

power source to another device. By using gear box, the speed and torque of vehicle can be

manipulated according to condition of road and driving state. Among the importance of gear box

are for setting the range of combustions of torque and rpm and to maintain the engine speed at an

efficient range.

Meanwhile, gear ratio can be defined as the speed of the output shaft rotates compared to

the input shaft. There are 3 categories of gear ratio, which are low, intermediate and high. For

going uphill and instant acceleration, lower gear ratio can provide both the torque and low power.

Meanwhile for high gear, it has high top speed but low in torque.

For this power train project, we are for this mini project, we are assigned to design a

software for calculating many features which related to gearbox. To put it in a simple manner, we

are going to design a gearbox calculator. This software will enable user to design any gearbox

according to the specifications of their vehicle. It gives the user choices to design it either rear

wheel drive or front wheel drive. In addition, it also allows the user to choose number of gears of

their vehicle, which for this project, the maximum gear is 5.

 CHAPTER 2

OBJECTIVE

 To design a software that enable user to create their own preferred gearbox based on their

specifications of vehicle.

 To produce a gearbox calculator that can:

i. Design gear ratio

ii. Design RWD

iii. Design FWD

iv. Calculate Torque

 To design a software that can generate graph of performance of the gearbox created.
 CHAPTER 3

METHODOLOGY

i. The parameters of vehicle parameters that will be fill by user are :

 Vehicle mass, W

 Tire rolling radius, , rw

 Coefficient of rolling resistance, fR

 Maximum engine torque, Te

 Road adhesion coefficient, µp

 Aerodynamic coefficient, C

 Front weight distribution b/l

 Rear weight distribution, a/l

 Centre of gravity height to wheelbase ratio, h/l

 Driveline efficiency, ηd

 Maximum engine speed, ωe

 Number of gears, n

ii. Lowest gear ratio:

𝑏 ℎ
+𝑓𝑅 .
 Value of kF is calculated using the formula, kf = 𝑙 𝑙
1+ µpℎ⁄𝑙

𝑎 ℎ
−𝑓𝑅 .
 Value of kR is calculated using the formula, kR = 𝑙 𝑙
1− µpℎ⁄𝑙

 By using the value of Kf and Kr, lowest gear ratio is determined.

rw
 Lowest gear ratio, nL (FWD) = kF µp W ηd Te
 rw
 Lowest gear ratio, nL (RWD) = kR µp W ηd Te

iii. Highest gear ratio (maximum engine speed, ωe):

 Power of the engine is calculated by using the formula:

P = Te ωe = (fR . W + C𝑉 2 𝑡𝑜𝑝)Vtop

 From the equation of Power, a cubic Vtop is generated:

(𝐶)𝑉 3 𝑡𝑜𝑝 + (0)𝑉 2 𝑡𝑜𝑝 + (fR . W)𝑉𝑡𝑜𝑝 − (𝑇𝑒 ωe ) = 0

 a=C

 b=0

 c = fR . W

 d = -Te. ωe

 In order to find the value of Vtop, additional variables are defined:

3c 𝑏2
( )–( 2 )
a 𝑎
 f= 3

2𝑏3 9𝑏𝑐 27𝑑

( 3 )−( 2 )+( )
𝑎 𝑎 𝑎
 g= 27

𝑔2 𝑓3
 h = ( 4 ) +(27)

𝑔
 R = -( 2) + √ℎ

3
 S = √𝑅
𝑔
 T = -( 2) - √ℎ

3
 U = √𝑇

 Vtop can be determined by using the formula:

𝑏
Vtop = (S + U) – (3𝑎)
iv. Intermediate gear ratio:

 Value of geometric progression constant, Cgp is calculated:

𝑛−1 nL
Cgp = √
nH

 Once the value of Cgp is calculated, intermediate gears can be determined.

ni = (ni+1)(Cgp)

 The vehicle speed for every gear at lowest speed (𝜔𝐿 ) and at highest engine speed

(𝜔𝐻 ):

𝜔𝐿 × 𝑟𝑤 × 𝜋
𝑉𝑎𝑡 𝜔𝐿 = ( ) (3600)(0.001)
𝑛𝑖 × 30

𝜔𝐻 × 𝑟𝑤 × 𝜋
𝑉𝑎𝑡 𝜔𝐻 = ( ) (3600)(0.001)
𝑛𝑖 × 30

v. Torque:

 Torque will be calculated using this formula:

Torque = slope*rad/s + constant

 CHAPTER 4

SIMULATION

i. The simulation of this Gearbox Calculator is provided in the Microsoft Excel file named

“GEARBOX_CALCULATOR.xlsx”.

ii. Click on “ENABLE EDITING” button to be able to run the simulation.

 CHAPTER 5

RESULT

Figure 1: User Defined Sheet

Figure 2: Gear Ratio Sheet

Figure 3: Gear Ratio Sheet

Figure 4: RWD Sheet

 Figure 5: RWD Sheet

Figure 6: FWD Gear Sheet

Figure 7: Torque Sheet
 CHAPTER 6

DICSUSSION

Throughout this project, 5 sheets of Microsoft Excel have been used in order to design this

Gearbox Calculator. The following sheets are User-Defined sheet, Gear Ratio Sheet, RWD sheet,

FWD sheet and Torque sheet. The step for calculating these number computations can be referred

in Chapter 3, Methodology. In addition, this software also can be used to find the lowest gear ratio,

intermediate gear ratio and highest gear (6) ratio for both Front-Wheel Drive and Rear-Wheel

Drive.

In User-Defined sheet, the users need to fill up few order to calculate the ratio of the the

users need to fill up e gear. Among the information needed are vehicle mass, tire radius, coefficient

of rolling resistance, maximum engine torque, road adhesion coefficient, aerodynamic coefficient,

weight distribution for both front and rear, center gravity height to wheelbase ratio, driveline

efficiency, maximum engine speed and number of gears. To select either Front-wheel drive or

Rear-wheel drive, user can toggle through Sheet 1 and to view the result user can browse to sheet

4 or 5 which state the “FRONT WHEEL DRIVE” and “REAR WHEEL DRIVE”.

Once the “FRONT WHEEL DRIVE” button is selected, Excel will re-direct the user via

hyperlink to FWD sheet which is the 4th sheet. Here, users will have access on the information

and numbers on the geometric progression constant, CGP, low gear ratio, high gear ratio and

intermediate gear ratio. Meanwhile for low gear ratio table, there are two information given; kF

(front low gear ratio) and nL (lowest gear ratio).

 Meanwhile, once the “REAR WHEEL DRIVE” button is selected, Excel will re-direct the

users to RWD sheet which is the third sheet provided. In this sheet, the users will be getting the

very similar information with the one in FWD sheet.

Lastly, user also can calculate the torque generated by the graft provided and also view the

differential for the power train system.

 CHAPTER 7

CONCLUSION

To conclude, the objectives of this project are effectively achieved. We are able to designed

a software that enable user to design gearbox according to the specifications of the vehicle. This

calculator is capable of calculating the lowest, intermediate and highest gear ratio for the users

based on the specification provided. This calculator can be so beneficial to the users since it can

calculate all numbers of gear ratio and vehicle speed that the users want and can be the fastest way

too because it is only a click away before getting all the information that they want for the gearbox.
 CHAPTER 8

APPENDIX

 Vehicle Powertrain Systems First Edition, Behrooz Mashadi and David Crolla

 https://www.youtube.com/watch?v=u1LF0uv7eH0