MEL 518 – Gears and Transmission Ratio

Objectives:
Trace the flow of power through an automatic transmission.
Explain how an automatic transmission shifts gears.
Compare the different types of automatic transmissions.
Analyze the transmission ratio in various gears.

Discussion:
In the previous experiment we have learned about the automatic transmission. In this experiment
we will expand about the special planetary transmission of the car's automatic transmission. The
function of this planetary transmission is to enable shifting gears and receiving various
transmission ratios including the possibility of reverse.

2.1 Transmission structure

The following transmission is a typical automatic transmission system. This transmission is
composed of two suns (big and small) and one ring for the two suns. The big sun planets drive
the shared ring. The small sun planets drive the big sun planets and they drive the ring.

W10
Input Shaft W8 W11
W9
W1 W4 W5 W7 W12 W14
W6
W2 W3 W13

Output Shaft

Figure 2-1

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The planetary transmission is composed of the following gears:

W9 - Big sun (36 teeth)

W10 - Big sun planets
W11 - Small sun planets
W12 - Small sun (30 teeth)
W13 - Planets carrier (of the big sun and the small sun)
W14 - The ring connected to the output shaft (72 teeth)

The input shaft is connected to gear W5 and it drives the transmission system using clutches C1,
C2, and C3.

When C1 is activated, it drives the big sun (W9).

When C2 is activated, it drives the planet carrier (W13).
When C3 is activated, it drives the small sun (W12).

Check this.

Brake B1 enables braking and stopping the big sun (W9).

Brake B2 enables braking and stopping the planet carrier (W13).

The system also includes one-way clutch F1, which causes the planets carrier to rotate only in
one direction.

2.2 Gears analysis

First gear:
At first gear, C3 clutch is activated and causes the small sun to move. The big sun is released.
The small sun rotates its planets and they rotate the big sun planet, and they rotate the ring.

The one-way clutch disables the planet carrier to rotate with the small sun, thus the planets
carrier is halted.

In this case, the planets are used only as movement and power transfers and the received
transmission ratio is the ratio between the number of the ring's teeth and the number of the small
sun's teeth:

 R  W14 72
GR (Gear Ratio) =   = = = 2.4
 S  W12 30

The transmission ratio is 2.4:1, which means that the output shaft performs one rotation for each
2.4 rotations of the input shaft.

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The ring rotates in the same direction as the small sun (the input shaft direction) due to the
double inversion received from two planets.

The planets carrier braking can be done in two methods – using the one-way clutch F1 or using
the brake B2.

When shifting into first gear, the braking is done by brake B2. In this case, the gear is also used
for braking, like driving downhill. The gears try to rotate faster than the engine and the
transmission causes the turbine of the torque converter to rotate faster than the accelerator
rotation, which is used (with the engine) as the wheels brake.

When shifting to a higher gear, the planets carrier braking is done by the one-way clutch. The
braking is done only when the accelerator speed is higher than the turbine speed. The engine's
rotations drop while driving downhill or when releasing the acceleration pedal, but the wheels
can rotate freely without the engine halting them.

Second gear:
Brake B1 and clutch C3 are activated in the second gear.

In this state, the small sun is activated. The big sun is locked and then the big planet rotates on
the big sun. The big sun behaves a ring for its planets and they pull the ring with them.

The small sun is the driving gear, the ring (the big sun) is occupied and the planets carrier
rotates. The transmission formula between the small sun and the planet carrier is:

1+ R
S
In our case, R is the big sun's number of teeth.

GR 1 = 1 + W9 = 1 + 36 = 2.2
W12 30
The transmission ring (which drives the output shaft) is the driven part and the planet carrier is
the part that drives the ring. As said before, the big sun is clocked.

The transmission formula between the planet carrier and the ring is:

1
 S 
1 +
 R

Which means:

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GR 2 = 1 = 1 36 = 0.67
(1 + W14 ) (1 + 72 )
W9

The overall transmission ratio equals the transmission ratios multiplication:

GR = GR 1 ⋅ GR 2 = 2.2 ⋅ 0.67 = 1.47

The transmission ratio is 1.47:1, which means that the output shaft performs one rotation for
each 1.47 rotations of the input shaft

Third gear:
Clutches C2 and C3 are activated in third gear.

In this state, the planet carrier is attached to the big sun. It turns all the planetary transmission
into one block, including the ring, which rotates in the same direction as the input shaft. The
transmission ratio is 1:1.

Fourth gear (Over Drive – OD):

This gear is called OD (Over Drive) because the transmission ratio received is smaller than 1 (the
output shaft rotates faster then the input shaft). In this state, the clutch C2 and the brake B1 are
activated.

The planet carrier is the driving part and the big sun is locked. In this case, the transmission
formula is:

1
GR =
(1 + RS )
Which means:

1
GR =
(1 + 7236 ) = 0.67
The transmission ratio is 0.67:1, which means that the output shaft performs one rotation for
each 0.67 rotations of the input shaft. The output shaft is faster 1.5 times than the input shaft.

Reverse (R) gear:

Clutch C1 and brake B2 are activated in the reverse gear.

C1 causes the big sun to rotate and the planet carrier is halted by B2.

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The big planets are used for transferring movement to the ring and also to invert its movement
direction.
The transmission ratio is the ratio between the ring
ring's number
ber of teeth and the big sun's
sun number of
teeth:

GR = − R = − W14 = − 72 = −2
S W9 36
The transmission ratio is –2:1.

Idle gears (N and P):

In these two gears all the clutches and brakes are released. The input shaft does not rotate any of
the gears and actually rotates
tates freely.

The output shaft is connected to the gears and can move freely.

In P (Parking) state, the transmission is also used as wheels break. In this state, a lever, that
enters a small handle between two teeth of the gear on the output shaft.

This gear is not aimed for driving another gear, but to be used only for braking.

Figure 2-2

2.3 Shifting gear

The automatic transmission system is controlled by a combined controller called TCU
(Transmission Control Unit) or transmission EC
ECU (Electronic Control Unit).

The TCU received the requested gear, the car car'ss speed (the output shaft rotation speed) and the
engine'ss rotations speed in RPM as input data.
The TCU transfers the car'ss speed and the engine
engine'ss rotations speed to the engine ECU
EC (if it does
not receive it directly), and also that the gear is shifted.

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 If the engine is loaded, the engine ECU transfers a signal to the TCU, to shift down the gear.

The TCU operates solenoids and electrical valves (described in experiment 3) and gradually
brings the transmission to the desired gear. The transmission has a number of transmission
modes, which determine the gears shifting method. These working methods are described in
experiment 4. In any case, shifting gears is done as follows.

In the first and reverse gear no gear shifting occurs. The transmission ratio is constant and not
dependent on the car's speed. Pressing the accelerator pedal increases the car's speed limited by
the desired and possible engine's rotation speed.

When the gear stick is at the second gear, first, the first gear is activated in the transmission.
Only when the car's speed increases, the transmission moves to second gear.

Because the transmission ratio drops, the engine's rotation speed drops a little.

A similar behavior occurs when the gear stick is at the third or OD gear. Any way, the
transmission starts with the first gear. When the car's speed increases, the TCU shifts to second
gear and then to third and to fourth (in case of OD). The transmission cannot be at a higher gear
than the gear stick is at.

The TCU acts according to the car's speed table describing the speeds for shifting gears. Each
transmission mode has a different table of speeds.
While braking or dropping speed, the TCU lowers the gears according to the table. The speed of
shifting to higher gear is not equal to the speed of shifting to lower gear.

A flywheel with teeth is mounted on the crankshaft (and rotates according to the engine's
rotations) includes teeth. Another teeth wheel is also mounted on the output shaft. Induction
sensors are installed near these wheels. The teeth movement is converted to pulses. The pulses
rate is measured by the TCU and translated to speed.

The SPEED sensors (the output shaft speed) and the RPM are marked on the trainer's panel. A
voltage as function of the speed and not the pulses appear on the banana sockets next to them in
order for us to observe the speed characteristic behavior.

The following table indicates the status of the transmission in each gear.

Input B1 B2 C1 C2 C3 F1 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 Output

Shaft Shaft
P CW - - - - - - CW - - - - - - - - B B
R CW - + + - - - CW - - CW CW CCW CCW CCW B CCW CCW
N CW - - - - - - CW - - - - - - - - - -
OD CW + - - + - - CW CW - B B CW CW CCW CW CW CW
3 CW - - - + + - CW CW CW CW CW B B CW CW CW CW
2 CW + - - - + - CW - CW B B CW CW CW CW CW CW
1 CW - - - - + + CW - CW - - CW CW CW B CW CW

The plus (+) sign indicates that the component is ON.

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CW Clockwise (the same direction of the input shaft)
CCW Counter clockwise
- Free and not rotating
B Blocked

Notice that the input shaft is part of wheel W5.

Preparation questions:
1. If the engine's rotations speed during gear shifting is 3000 RPM, mark the drive shaft speed
in RPM at each gear before shifting it in the following table.

Gear Transmission Engine RPM Drive RPM Engine RPM after

Ratio Before shifting gear (Speed) Shifting to a higher gear
1
2
3

2. If right after shifting the gear, the car's speed is still not changed, record the engine's
rotation speed after shifting the gear in the table.
Procedure:
Step 1: Connect the TPS-3579 simulator to the power supply.

Step 2: Connect the power supply to the Mains.

Step 3: Set the Auto/Manual switch (located on the bottom left of the simulator) to Manual
position.

Step 4: Set the IGNITION switch to OFF position.

Set the GEAR switch to the NORMAL position.

Step 5: Turn the ACCELERATION potentiometer (located on the bottom left of the
simulator) counter clockwise to the maximum.

Step 6: Turn ON the POWER switch.

Step 7: Make sure that the FAULT display displays the number 00. If not, use the keys
above the FAULT display to display the number 00 (no fault condition) on the
FAULT 7-SEG. display and press the ENTER key beneath this display.

Step 8: Make sure that the STATE display displays the number 00. If not, use the keys above
the STATE display to display the number 00 on the STATE 7-SEG. display and
press the ENTER key beneath this display.

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Step 9: Set the IGNITION switch to ON position.

The ignition LED should turn ON.

The P LED on the GEAR selector unit should turn ON.

Identify that.

The number 1000 should appear on the RPM display.

The RPM indicates the engine's rotations speed (at the input to the torque converter).

The motor is at normal IDLE condition.

Step 10: The simulator includes a monitor (like a car diagnostic monitor) that enables to read
the sensors' values and the engine conditions.

The LCD display shows:

The status of the acceleration pedal (in percentage).

The car's speed in Km/h (kilometers per hour).
The output shaft rotation speed is displayed as RPM OUT.
The shift gear.
The transmission ratio between the RPM OUT and the RPM IN.
The input shaft rotation speed is displayed as RPM IN (the torque converter output).
The transmission oil pressure.
STH value.
ON/OFF state of S1, S2, SL.

Let's repeat the previous experiment at STATE = 00.

Step 11: LED P should turn ON.

If not, press the pushbutton next to it.

This state is similar to the IDLE state with one difference: the output shaft is locked
with an additional mechanical brake.

All the gears should be free.

Check that all the clutches and brakes LEDs are OFF.

Step 12: Press key 1 on the gear selector.

LED 1 should turn ON.

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 The state GEAR = 1 should appear on the LCD display.

The engine's speed in RPM IN stays 1000.

The F1 and C3 LEDs should turn on indicating that the one-way clutch F1 and clutch
C3 are operated.

Check if the rotation direction and the transmission mode fit your writing in
preparation question.

Check the car's speed and the output shaft rotation speed in RPM on the display.

Calculate the transmission ratio between the output shaft and the input shaft.

Step 13: Key the number '2' on the keyboard and then '#'.

The display shows the car's speed in miles per hour.

Step 14: To return to the Km/h type '1' and then '#'.

Step 15: Press the shift gear 2 pushbutton.

LED 2 should turn ON.

The RPM speed stays 1000.

C3 and B1 should turn ON.

Observe this.

Check if the rotation direction and the transmission mode fit your writing in
preparation question.

Check the car's speed and the output shaft rotation speed in RPM on the display.

Calculate the transmission ratio between the output shaft and the input shaft.

Step 16: Press the 3 pushbutton.

LED 3 should turn ON.

The RPM speed stays 1000.

C2 and C3 should turn ON.

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 Observe this.

Check if the rotation direction and the transmission mode fit your writing in
preparation question.

Check the car's speed and the output shaft rotation speed in RPM on the display.

Calculate the transmission ratio between the output shaft and the input shaft.

Step 17: Press the OD pushbutton.

LED OD should turn ON.

The RPM speed stays 1000.

C2 and B1 should turn ON.

The LED next to W3 turns ON too, indicating that W3 was mechanically attached to W2 to
receive transmission without any sliding.

Observe this.

Check if the rotation direction and the transmission mode fit your writing in
preparation question.

Check the car's speed and the output shaft rotation speed in RPM on the display.

Calculate the transmission ratio between the output shaft and the input shaft.

Step 18: Press the N pushbutton.

LED N should turn ON.

The state of the clutches and brakes is similar to the P state.

This is an idle state without locking.

Check this.

Step 19: Press the R pushbutton.

LED R should turn ON.

The RPM speed stays 1000.

C1 and B2 should turn ON.

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 Check if the rotation direction and the transmission mode fit your writing in
preparation question.

Check the car's speed and the output shaft rotation speed in RPM on the display.

Calculate the transmission ratio between the output shaft and the input shaft.

Step 20: Normal state:

Set the number 01 on the STATE display and press ENTER.

In this state, the transmission is dynamic and shifts gears according to the gear stick
state and the car's speed.

Step 21: Press the OD key on the gear selector.

This step simulates shifting the gear stick to this location.

LED OD should turn ON.

LEDs F1 and C3 should turn ON and indicate that the one-way clutch F1 and clutch
C3 are activated.

The gear is the first gear.

Step 22: Slowly turn the ACCELERATOR potentiometer clockwise until angle of 20% (the
angle appears on the LCD) and observe the engine's RPM and the car's speed
displayed on the monitor.

The RPM speed increases with the car's speed.

At a certain car speed the transmission ECU shifts the gear to the second gear.

C3 is ON, F1 is OFF and B1 is ON.

The RPM speed drops, but the car's speed remains the same.

Observe this.

Note that the displayed transmission ratio is according to the gear.

Also observe the direction of the transmission wheel.

Step 23: At which car speed it happens?

Note:

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 If you haven't succeeded to view the whole process, repeat the process again:
press the P key on the gear selector and then press the OD key.

Step 24: Keep the acceleration pedal at the same angle.

The car keeps accelerating.

The RPM increases as the car's speed increases.

At a certain car speed, the TCU shifts the gear to the third gear.

C3 is ON, C1 is OFF and C2 is ON.

Observe this.

Note that the displayed transmission ratio is according to the gear.

Also observe the direction of the transmission wheel.

Step 25: Keep the acceleration pedal at the same angle.

The car keeps accelerating.

The RPM increases as the car's speed increases.

At a certain car speed, the ECU shifts the gear to the OD gear.

C2 is and B1 are ON.

Observe this.

Also observe the direction of the transmission wheel.

Step 26: Turn the ACCELERATION potentiometer counter clockwise all the way.

This state simulates slow brake (acceleration drop).

The car's speed drops with the automatic gear shifting.

Follow the change in gears and the clutches and brakes states.

Step 27: Press the P key on the gear selector.

Turn the ACCELERATOR potentiometer to 80% angle.

Press the OD key on the gear selector.

Observe the gears shifted at higher rate.

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Step 28: Turn the ACCELERATION potentiometer counter clockwise all the way.

Follow the change in gears and the clutches and brakes states.

Step 29: Press the P key on the gear selector.

Step 30: Turn the ACCELERATION potentiometer clockwise to 20%.

Step 31: Press the third gear on the gear selector and observe the system's reaction.

Step 32: Turn the ACCELERATION potentiometer counter clockwise for braking and
observe the system's reaction.

Step 33: Press the P key on the gear selector.

Step 34: Turn the ACCELERATION potentiometer clockwise to 20%.

Step 35: Press the second gear on the gear selector and observe the system's reaction.
Step 36: Turn the ACCELERATION potentiometer counter clockwise for braking and
observe the system's reaction.

Step 37: Press the P key on the gear selector.

Step 38: Turn the ACCELERATION potentiometer clockwise to 20%.

Step 39: Press the first gear on the gear selector and observe the system's reaction.

Step 40: Turn the ACCELERATION potentiometer counter clockwise for braking and
observe the system's reaction.

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