Title Page

Copyright Page

Contents

Series Preface

Preface

Chapter 1 Automotive Engine Matching

1.1 Introduction

1.2 Output Characteristics of Internal Combustion Engines

1.2.1 Engine Output Power and Torque

1.2.2 Engine Fuel Map

1.2.3 Engine Emission Map

1.3 Road Load, Driving Force, and Acceleration

1.3.1 Axle Loads

1.3.2 Road Loads

1.3.3 Powertrain Kinematics and Traction

1.3.4 Driving Condition Diagram

1.3.5 Ideal Transmission

1.3.6 Power–Speed Chart

1.4 Selection of Gear Ratios

1.4.1 Highest Gear Ratio

1.4.2 First Gear Ratio

1.4.3 Intermediate Gear Ratios

1.4.4 Finalization of Gear Ratios

References

Problem

Chapter 2 Manual Transmissions

2.1 Introduction

2.2 Powertrain Layout and Manual Transmission Structure

2.3 Power Flows and Gear Ratios

2.4 Manual Transmission Clutches

2.4.1 Clutch Structure

2.4.2 Clutch Torque Capacity

2.4.3 Clutch Design

2.5 Synchronizer and Synchronization

2.5.1 Shift without Synchronizer

2.5.2 Shift with Synchronizer

2.6 Dynamic Modeling of Synchronization Process

2.6.1 Equivalent Mass Moment of Inertia

2.6.2 Equation of Motion during Synchronization

2.6.3 Condition for Synchronization

2.7 Shifting Mechanisms

References

Problems

Chapter 3 Transmission Gear Design

3.1 Introduction

3.2 Gear Design Fundamentals

3.2.1 Conjugate Motion and Definitions

3.2.2 Property of Involute Curves

3.2.3 Involute Curves as Gear Tooth Profiles

3.2.4 Characteristics of Involute Gearing

3.3 Design of Tooth Element Proportions of Standard Gears

3.3.1 Gear Dimensional and Geometrical Parameters

3.3.2 Standardization of Tooth Dimensions

3.3.3 Tooth Dimensions of Standard Gears

3.3.4 Contact Ratio

3.3.5 Tooth Thickness and Space along the Tooth Height

3.4 Design of Non-Standard Gears

3.4.1 Standard and Non-Standard Cutter Settings

3.4.2 Avoidance of Tooth Undercutting and Minimum Number of Teeth

3.4.3 Systems of Non-standard Gears

3.4.5 Design of General Non-Standard Gear System

3.5 Involute Helical Gears

3.5.1 Characteristics of Involute Helical Gearing

3.5.2 Design Parameters on the Normal and Transverse Sections

3.5.3 Tooth Dimensions of Standard Involute Helical Gears

3.5.4 Minimum Number of Teeth for Involute Helical Gears

3.5.5 Contact Ratio of Involute Helical Gears

3.5.6 Design of Non-standard Involute Helical Gears

3.6 Gear Tooth Strength and Pitting Resistance

3.6.1 Determination of Gear Forces

3.6.2 AGMA Standard on Bending Strength and Pitting Resistance

3.6.3 Pitting Resistance

3.6.4 Bending Strength

3.7 Design of Automotive Transmission Gears

3.8 Planetary Gear Trains

3.8.1 Simple Planetary Gear Train

3.8.2 Dual-Planet Planetary Gear Train

3.8.3 Ravigneaux Planetary Gear Train

References

Problems

Chapter 4 Torque Converters

4.1 Introduction

4.2 Torque Converter Structure and Functions

4.2.1 Torque Multiplication and Fluid Coupling

4.2.2 Torque Converter Locking up

4.3 ATF Circulation and Torque Formulation

4.3.1 Terminologies and Definitions

4.3.2 Velocity Diagrams

4.3.3 Angular Momentum of ATF Flow and Torque Formulation

4.4 Torque Capacity and Input–Output Characteristics

4.4.1 Torque Converter Capacity Factor

4.4.2 Input–Output Characteristics

4.4.3 Joint Operation of Torque Converter and Engine

4.4.4 Joint Operation of Torque Converter and Vehicle Powertrain

References

Problem

Chapter 5 Automatic Transmissions

5.1 Introduction

5.2 Structure of Automatic Transmissions

5.3 Ratio Analysis and Synthesis

5.3.1 Ford FWD Six-Speed AT

5.3.2 Ford six-speed RWD Ravigneaux AT

5.3.3 ZF RWD Eight-Speed AT

5.4 Transmission Dynamics

5.4.1 Ford FWD Six-Speed AT

5.4.2 Ford RWD Six-Speed AT

5.4.3 ZF RWD Eight-Speed AT

5.5 Qualitative Analysis on Transmission Shifting Dynamics

5.6 General Vehicle Powertrain Dynamics

5.6.1 General State Variable Equation in Matrix Form

5.6.2 Specific State Variable Equation

5.6.3 Solution of State Variables by Variable Substitution

5.6.4 Vehicle System Integration

5.7 Simulation of Vehicle Powertrain Dynamics

References

Problems

Chapter 6 Automatic Transmissions

6.1 Introduction

6.2 Components and Hydraulic Circuits for Transmission Control

6.3 System Circuit Configurations for Transmission Control

6.3.1 System Hydraulic Circuitry for the Previous Generation of ATs

6.3.2 System Hydraulic Circuitry for ATs with Independent Clutch Pressure Control

6.3.3 System Hydraulic Circuitry for ATs with Direct Clutch Pressure Control

6.4 Transmission Control Strategy

6.4.1 Transmission shift schedule

6.4.2 Torque Converter Lock Control

6.4.3 Lock-Release Schedule

6.4.4 Lock-Release Operation

6.4.5 Engine Torque Control During Shifts

6.4.6 Shift Process Control

6.4.7 Initial Clutch Pressure Profiles

6.4.8 Initial Piston Stroke Attributes

6.4.9 Feedback Shift Control

6.4.10 Torque Based Shift Control

6.4.11 System Diagnosis and Failure Mode Management

6.5 Calibration of Transmission Control System

6.5.1 Component Level Calibration

6.5.2 System Level Calibration

References

Problem

Chapter 7 Continuously Variable Transmissions

7.1 Introduction

7.2 CVT Layouts and Key Components

7.2.1 Belt Structure

7.2.2 Input and Output Pulleys

7.2.3 Basic Ratio Equation

7.3 Force Analysis for Belt CVT

7.3.1 Forces Acting on a Metal Block

7.3.2 Forces Acting on Pulley Sheaves

7.3.3 Block Compression and Ring Tension

7.3.4 Torque Transmitting Mechanism

7.3.5 Forces Acting on the Whole Belt

7.3.6 Relation between Thrusts on Input and Output Pulleys

7.3.7 Ratio Changing Mechanism

7.4 CVT Control System Design and Operation Control

7.4.1 VBS Based Control System

7.4.2 Servo Mechanism Control System

7.4.3 Comparison of the Two Control System Designs

7.5 CVT Control Strategy and Calibration

7.5.1 Line Pressure Control

7.5.2 Continuous Ratio Control Strategy

7.5.3 Stepped Ratio Control Strategy

7.5.4 CVT Control Calibration

References

Problems

Chapter 8 Dual Clutch Transmissions

8.1 Introduction

8.2 DCT Layouts and Key Components

8.2.1 Dry Dual Clutch Transmissions

8.2.2 Wet Dual Clutch Transmissions

8.3 Modeling of DCT Vehicle Dynamics

8.3.1 Equations of Motion during Launch and Shifts

8.4 DCT Clutch Control

8.5 Clutch Torque Formulation

8.5.1 Correlation on Clutch Torque and Control Variable

8.5.2 Case Study on Clutch Torque and Control Variable Correlation

8.5.3 Algorithm for Clutch Torque Calculation under Real Time Conditions

8.5.4 Case Study for the Clutch Torque Algorithm

References

Problems

Chapter 9 Electric Powertrains

9.1 Basics of Electric Vehicles

9.2 Current Status and Trends for EVs

9.3 Output Characteristic of Electric Machines

9.4 DC Machines

9.4.1 Principle of DC Machines

9.4.2 Excitation Types of DC Machines

9.4.3 Speed Control of DC Machines

9.5 Induction Machines

9.5.1 Principle of Induction Motors

9.5.2 Equivalent Circuit of Induction Motors

9.5.3 Speed Control of Induction Machine

9.5.4 Variable Frequency, Variable Voltage Control of Induction Motors

9.5.5 Efficiency and Losses of Induction Machine

9.5.6 Field-Oriented Control of Induction Machine

9.6 Permanent Magnet Motor Drives

9.6.1 Basic Configuration of PM Motors

9.6.2 Basic Principle and Operation of PM Motors

9.7 Switched Reluctance Motors

9.8 EV Transmissions

9.8.1 Single-Speed EV Transmission

9.8.2 Multiple Ratio EV Transmissions

9.9 Conclusions

Bibliography

Chapter 10 Hybrid Powertrains

10.1 Series HEVs

10.2 Parallel HEVs

10.3 Series–Parallel HEVs

10.4 Complex HEVs

10.4.1 GM Two-Mode Hybrid Transmission

10.4.2 Dual Clutch Hybrid Transmissions

10.4.3 Hybrid Transmission Proposed by Zhang, et al.

10.4.4 Renault IVT Hybrid Transmission

10.4.5 Timken Two-Mode Hybrid Transmission

10.4.6 Tsai’s Hybrid Transmission

10.4.7 Hybrid Transmission with Both Speed and Torque Coupling Mechanism

10.4.8 Toyota Highlander and Lexus Hybrid, e-Four Wheel Drive

10.4.9 CAMRY Hybrid

10.4.10 Chevy Volt Powertrain

10.5 Non-Ideal Gears in the Planetary System

10.6 Dynamics of Planetary Gear Based Transmissions

10.7 Conclusions

References

Index

EULA