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

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.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Kinematic model of the ML6C gearbox

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Figure 2

Oil churning test rig

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Figure 4

ML6C drag torque versus engaged gear

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Figure 5

Efficiency at 3000rpm and 80°C versus engaged gear

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Figure 6

Efficiency at 5000rpm and 40°C versus engaged gear

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Figure 7

Thermal network of ML6C gearbox when the sixth gear is engaged

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Figure 8

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



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