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RESEARCH PAPERS

Power Loss Predictions in Geared Transmissions Using Thermal Networks-Applications to a Six-Speed Manual Gearbox

[+] Author and Article Information
C. Changenet

Mechanical Engineering Department, ECAM Lyon, France

X. Oviedo-Marlot

PSA Peugeot Citroën, La Garenne-Colombes, France

P. Velex

LaMCoS, UMR CNRS 5514, INSA de Lyon, Francephillippe.velex@insa-lyon.fr

J. Mech. Des 128(3), 618-625 (Aug 18, 2005) (8 pages) doi:10.1115/1.2181601 History: Received December 23, 2004; Revised August 18, 2005

Abstract

A model is presented which makes it possible to predict power losses in a six-speed manual gearbox. The following sources of dissipation, i.e., power inputs in the model, are considered: (i) tooth friction; (ii) rolling element bearings; (iii) oil shearing in the synchronizers and at the shaft-free pinion interfaces; and (iv) oil churning. Based upon the first principle of Thermodynamics for transient conditions, the entire gearbox is divided into lumped elements with a uniform temperature connected by thermal resistances which account for conduction, convection, and radiation. The numerical predictions compare favorably with the efficiency measurements from the actual gearbox at different speeds and torques. The results also reveal that, at lower temperatures (about $40°C$), power loss estimations cannot be disassociated from the accurate prediction of temperature distributions.

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Figures

Figure 1

Kinematic model of the ML6C gearbox

Figure 2

Oil churning test rig

Figure 3

ML6C Test rig

Figure 4

ML6C drag torque versus engaged gear

Figure 5

Efficiency at 3000rpm and 80°C versus engaged gear

Figure 6

Efficiency at 5000rpm and 40°C versus engaged gear

Figure 7

Thermal network of ML6C gearbox when the sixth gear is engaged

Figure 8

Efficiency at 5000rpm and 40°C versus engaged gear—combined temperature/efficiency calculations

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