MODULE - II

TRANSMISSION SYSTEMS
INTRODUCTION TO TRANSMISSION SYSTEM

Transmission System / Powertrain

Fig. Power transmission from engine to road wheels

REQUIREMENTS OF A TRANSMISSION SYSTEM

 Connection / disconnection of engine with road wheels

 Torque Multiplication

 Power transmission in reverse direction

 Power transmission at varied angles and varied lengths.

 Power diversion at right angles.

 Permanent speed reduction

 Provision to turn the driving wheels at different speeds when required.

 Bear the effect of torque reaction, driving thrust and braking effort effectively.
MAIN UNITS OF A TRANSMISSION SYSTEM
 Clutch

 Gear Box

 Transfer Case

 Propeller Shaft with Universal Joints and Slip Joint

 Final Drive

 Differential

 Torque Tube
Mapping of
 Road Wheel
requirements with units
TYPES OF TRANSMISSION SYSTEMS

Transmission Systems

Manual Semi automatic Automatic

Constant Sliding Synchro

mesh mesh mesh

Hydramatic

Fluid Torque
coupling converter
TRANSMISSION CATEGORIES

Transmission

Mechanical Hydraulic Electrical &

Electromagnetic
 Hydrostatic

 Hydrodynamic

Typical Applications
 Mechanical transmission
 Mechanical + Hydraulic transmission
 Hydraulic transmission
 Electrical transmission
CLUTCH

 What is Clutch ?

 Location

 Clutch position – Engaged / Disengaged

 The clutch is disengaged when

i) Starting the engine

ii) Shifting the gears
iii) Stopping the vehicle
iv) Idling the engine
REQUIREMENTS OF AN AUTOMOTIVE CLUTCH
o Max. torque transmission

o Gradual engagement

o Ease of operation

o Dynamically balanced

o Better heat dissipation

o Vibration-damping

o Smaller in size

o Adequate clutch free pedal play

o Longer life of clutch components

TYPE OF CLUTCHES
Clutches
Types of clutches
Positive engaged
clutchPositive engaged Gradually engaged
Dog clutchclutches clutches
Gradually engaged
clutch Dog clutch
Friction
clutch Friction clutch Fluid coupling

Semi centrifugal Centrifugal

Cone clutch Disc clutch
clutch clutch

Single plate Multiplate

clutch clutch
PRINCIPLE OF FRICTION CLUTCHES
MATERIALS FOR FRICTION LINING
Requirements
1. Should have high and uniform coefficient of friction (µ)

2. Should not be affected by moisture and oil

3. Ability to withstand high temperature caused due to slippage Importance

4. Should have high thermal conductivity

5. Should have high resistance to wear and scoring

Materials
 Asbestos – ruled out

 Compound Organic Resin with Copper Wires (µ = 0.35)

 Ceramic (µ = 0.25)

 Fiberglass

 Kevlar

 Metallic friction linings

SINGLE PLATE CLUTCH

Fig. Exploded view of coil spring clutch

OPERATION OF SINGLE PLATE CLUTCH

→ Normal – engaged condition

→ Clutch disc

→ Clutch shaft

→ Clutch disengagement

→ Constructional & Working details

SINGLE PLATE CLUTCH – CONTD..
Advantages

1. It is better for heavy-duty uses because more coil springs can be installed to make
the clutch to be applied with more force.

2. Putting a weight at the end of the release lever results in centrifugal force applying
the clutch more tightly at higher speeds.

Disadvantages

1. More pedal pressure is required from the driver to disengage it.

2. It does not apply the clutch as heavily as the disc wears.

3. Coil spring clutch covers must be precisely balanced after assembly.

DIAPHRAGM SPRING CLUTCH

Fig. Working of diaphragm spring clutch

DIAPHRAGM SPRING CLUTCH – CONTD..

Fig. Exploded view of diaphragm spring clutch

CHARACTERISTIC OF DIAPHRAGM SPRING
ADVANTAGES OF DIAPHRAGM SPRING CLUTCHES

o It is more compact than other designs.

o It is easier to balance rotationally and is less subjected to unwanted effects due to

centrifugal force at high rotational speeds.

o It gives uniformly distributed pressure on pressure plate.

o No needs release levers.

o Minimum effort is sufficient to disengage the clutch.

o It provides minimum number of moving components and hence

minimum internal friction is experienced.

o This is very commonly used in cars, light lorries and mini trucks but
is not much used in heavy vehicles.
TORQUE TRANSMITTED BY A SINGLE PLATE
CLUTCH
Torque transmitted T = n * F * R
F – frictional force = µ * P
µ – coefficient of friction

P – Axial load

n – number of effective surfaces Limitations for clutch

torque capacity
R – effective mean radius of frictional surface

Torque transmitted by the clutch depends upon

Coefficient of friction

Diameter of the driven plate

Thrust force applied over the pressure plate

WET VS. DRY CLUTCHES
A wet clutch is immersed in a cooling lubricating fluid which also keeps the surfaces
clean and gives smoother performance and longer life. Wet clutches, however, tend
to lose some energy to the liquid. Since the surfaces of a wet clutch can be slippery
(as with a motorcycle clutch bathed in engine oil), stacking multiple clutch discs can
compensate for the lower coefficient of friction and so eliminate slippage under
power when fully engaged.

Generally the two wheeler clutches are wet clutches and that relied entirely on
viscous effects, rather than on friction.

A dry clutch, as the name implies, is not bathed in fluid and should be literally dry.
MULTIPLATE CLUTCH

Fig. Multiplate clutch

MULTIPLATE CLUTCH – CONTD..
HYDRAULIC CLUTCHES

Fig. Fluid coupling

 FLUID COUPLING – CONTD..

Fig. Fluid coupling

 FLUID COUPLING – CONTD..

Fig. Operation of fluid coupling

Fig. Working of fluid coupling

Fig. Essential parts of a fluid coupling
 FLUID COUPLING – CONTD..
Advantages
o Power transmission is free from vibration and shocks
o Power transmission is smooth even in extreme condition
o Motor or engine starts unloaded
o Overload protection
o Fluid coupling can be used in both vertical and horizontal application

Disadvantages
o There is always slip.
o Fluid coupling can not develop torque when both driving and driven shafts
are rotating in same angular velocity
o Under stalling condition, the coupling dissipates energy as heat which may
lead to damage.
 FLUID COUPLING – CONTD..

Fig. Characteristics of fluid coupling