Hello everyone! Recently, we have analyzed a lot of materials that related to the transmission - this is and. What is a gearbox in relation to a car - this is the topic I would like to discuss on the pages of my blog!
If one of the readers remembers, then we touched on, also taking part in working with. Unlike it, the gearbox does not redistribute this moment, but is designed to lower or increase it. Each drive axle has its own gearbox - that's why they are called front and rear.
This device is made of steel alloys, which are highly durable and can guarantee long-term operation in adverse conditions.
The rear gearbox provides for a drive gear connected to the cardan shaft and a driven gear. For each gearbox, one of the main parameters is the gear ratio. At the same time, in passenger cars it is traditionally lower than in commercial vehicles. In order to understand the essence of the gear ratio, it is enough to imagine the number of teeth on the driven and driving gears. The number itself means how many times the slave can turn in 1 revolution of the master.
The work of the main couple - what affects
This is where the concept of the “main pair” of the gearbox comes from. The larger its gear ratio, the faster the engine will be able to gain its maximum speed. This also affects the driving dynamics. Reducing this number leads to a deterioration in dynamics, but it can improve fuel efficiency, since the engine speed at the same speed will be lower. Please note: to change the number of the reducer, you need to keep in mind the following:
- characteristics of the power unit;
- and disks, etc.
Some owners of used cars, both domestic and foreign, change gearboxes for analogues with a different gear ratio. These experiments do not always lead to an improvement in overclocking qualities. The pursuit of the best acceleration dynamics when starting from a standstill threatens to lead to excessive fuel consumption and accelerated wear of transmission parts. Read the forums and reviews of experts before deciding to take such a radical step.
Maintenance and malfunctions
However, gearbox parts and lubrication remain one of the most vulnerable spots and sources of breakdowns. Prolonged lack of sufficient oil leads to overload of the unit. How to determine the breakdown yourself without calling the master from the service station? Pay attention to the new hum that has appeared, extraneous sounds and vibration. There may be a leak of the working fluid due to leaky seals. Buying and replacing a gearbox is not a cheap pleasure, so I recommend listening to such sounds.
The moment of service is one of the most important to extend the performance of this transmission unit. The working fluid needs to be changed every 100 thousand kilometers traveled. Oil seals should also be changed in a timely manner - all this will reduce the cost of potential repairs. 
Let's say goodbye, dear readers! If you have new questions regarding the operation and problems of the transmission, write these wishes. I will try to include them to the maximum on the pages of my blog. Thanks for staying in touch and bye!
Many motorists know that there is a gearbox in the design of the transmission of their car. But few are aware of what kind of mechanism it is, how it works, what functions it performs depending on its location, what malfunctions are characteristic of it and how to fix them. Today we will talk about all the features of an automobile gearbox.
Purpose and device of the gearbox
This car transmission unit got its name from the English verb to reduce (reduce). The purpose of the gearbox is to take over the torque from the crankshaft of the engines and, having reduced it, transfer it further to the transmission units (the center differential, which distributes the torque to the drive wheels in a certain proportion). Depending on where it is installed, a front and rear axle gearbox is distinguished. In front-wheel drive vehicles, a front axle gearbox is used, which is integrated into the gearbox, and in rear-wheel drive vehicles, this unit is installed on the rear axle. In all-wheel drive vehicles, two gearboxes are used - the front one is located in the gearbox, and the rear one is on the axle, both gearboxes are connected to each other using a cardan shaft.
The gear mechanism looks like this:
- Housing with seals (glands) and fasteners. Made of high-strength steel or light alloys, it provides protection of the main gear and the cross-axle differential from external influences. Fasteners serve to tie the gearbox housing to the bases, and oil seals prevent leakage of transmission fluid, which lubricates the gears of the gearbox and differential.
- Main gear. a) drive gear. Designed to receive torque from the secondary shaft of the gearbox and then transfer it to the driven gear. b) driven gear. It receives torque from the drive gear and transmits it further to the cross-axle differential mechanism. The driven gear is larger than the drive gear and has more teeth - this is done in order to reduce the high torque coming from the drive gear.
- Interwheel. a) housing with seals. Protects differential gears from damage. b) satellite gears. Usually there are three of them, two are parallel to each other, and one is perpendicular, it is connected to the main gear driven gear. The function of satellites is the transmission of torque from the driven gear to the gears of the axle shafts. c) gears of the axle shafts of the wheels. They receive a reduced torque from the satellites and transfer it to the shafts of the wheel axle shafts. d) bearings. Installed between the gears of the axle shafts and the drive shaft. Provide rotation of shafts of semiaxes of wheels.
If the main gear is responsible for obtaining torque, reducing or increasing it, then the cross-axle differential, in addition to distributing the gear received from the gear between the wheels, regulates the speed of rotation of the wheels when the car turns. When the car turns, the outer wheel gets more torque and the inner wheel gets less. Without a differential, such an operation would not be possible.
Depending on how the teeth of the driving and driven gears are connected, four types of gears are distinguished:
- Bevel, consists of two bevel gears located at an angle of 90 degrees. It is used on cars with rear and all-wheel drive.
- Cylindrical, consists of two cylindrical gears coupled in parallel. This type of final drive is used on front wheel drive vehicles.
- Hypoid, is a gear located at an angle of 45 degrees with respect to each other. It is used on cars with rear and all-wheel drive.
- Worm, is a perpendicularly coupled screw (worm) and a worm driven gear. It is used in the steering mechanism, it is not used in the transmission of cars.
The main characteristic of the gearbox is the gear ratio, which reflects the ratio of the angular velocity of the drive shaft to the angular velocity of the driven shaft. Reducers with a high gear ratio are installed on the transmission of vehicles with a large curb weight. Such machines move at low speed, but have a greater carrying capacity. Reducers with a low gear ratio are installed on the transmission of machines with a small curb weight, which ensures their high speed. The gear ratio of the gearbox is determined by the number of engagements of the drive gear with the driven gear. For example, if the gear ratio is 5.1, then in one revolution of the drive gear, the driven gear will engage with it and leave it 5 whole and 1 tenth times.
What is the difference between a gearbox and a differential
This question is often asked by novice motorists. The gearbox, as we said above, is a node that increases or decreases the torque coming to it from the engine crankshaft. And the differential is a unit that divides the torque coming from the gearbox between the axles (interaxle differential) or semi-axes (interaxle differential) in a certain proportion, and is also responsible for supplying more or less torque to the outer wheel when turning the car.
Damage and repair of the gearbox
Most often in automotive gearboxes, gears, oil seals and bearings fail. The reason is the wear of these parts due to operation with increased loads, prolonged oil starvation due to lack. These breakdowns are diagnosed by the presence of a hum or clicks at the junctions of gears and bearings. Oil seal wear can be determined by drops of transmission fluid that seeps through the cracks that have appeared in the seals. It is recommended that at each maintenance check the operation of these elements of the gearbox and, if necessary, replace worn parts with new ones.
Less common is the breakdown of the body of the automobile gearbox itself or the breakage of the fasteners with which it is attached to the base. This breakdown can occur when the car hits an obstacle. Dust and dirt can get into the gap formed during a breakdown, which will affect the condition of the transmission fluid. That, in turn, will not be able to perform its functions, which will lead to overheating of the gears, breakage or wear of their teeth. Damage to the gearbox housing is also fraught with the appearance of a loud hum, which is produced by working elements, which will affect the acoustic comfort when driving. You can diagnose a malfunction of the gearbox housing by the appearance of traces of gear oil under it. In this case, you can weld the gearbox housing or replace it with a new one.
In any case, in order to prevent the gearbox from failing, you need to monitor the level of the transmission fluid filled into it, change it every 100 thousand kilometers or when the oil seals are forced to be replaced. It is also recommended to periodically diagnose the operation of the transmission and, if there are the slightest signs of damage to the gearbox elements, to carry out their replacement and maintenance in a timely manner.
To understand what a single-stage gearbox is, you must first determine what the device is in the classic version. A gearbox is a mechanism consisting of clutch gears that transmit the working movement to each other. Due to their simplicity, high efficiency and low cost, gearboxes are widely used in mechanical engineering to create a variety of interconnected mechanisms.
The gearbox housing contains worm or gear drives that are welded or otherwise immobilized on shafts or axles. The first ones are pressed into the bearings, which are located in the holes specially made for them in the housing. Such a transmission can be mounted directly on the unit that produces mechanical movement, but installed in a separate housing (reducer) has several advantages. In particular, these are:
- guarantee of high precision assembly of the mechanism;
- increased efficiency;
- better lubrication of gear parts;
- reduced wear;
- an increased level of protection against the ingress of harmful saws and dirt.
What is the gearbox made of?
It consists of a steel welded or cast iron body. It houses shafts, axles, gears, worm gears, bearings and other elements. Some gearboxes contain special devices that provide lubrication of the gearbox elements. For example, it can be equipped with an oil pump or a device that provides cooling for this unit (a coolant coil is often mounted in a worm gear).
Gearboxes are different. At the same time, they differ not only in types, but also in individual characteristics, therefore, gearboxes are designed for certain equipment or a unit, depending on the need, gear ratio and torque that must be transmitted to the receiving device.
Main types of gearboxes
They share:
- By type of transfer connection to:
- jagged;
- combined.
- Depending on the shape of the gears on;
- conical and others.
- According to the location of the shafts in space on:
- vertical;
- horizontal.
- Depending on the features of the kinematic system that underlies a particular mechanism, on:
- deployed;
- with double stage, etc.
- By the number of steps on:
- single-stage;
- two-stage.
Single stage spur gearboxes
This type of gearbox differs from others in the position of the shafts in the housing and the number of steps. Single-stage spur gearboxes can be vertical and horizontal. The gears of these devices can have oblique and straight, as well as chevron teeth. Enclosures are made from welded steel or cast iron. Shafts are often mounted in plain or rolling bearings. The former are often installed in heavy gearboxes.
The composition and layout possibilities of a single-stage gearbox are limited. The main feature that distinguishes them from each other is the arrangement of shafts and axes in space. At the same time, the gear ratio of these units ranges from 1.6 to 6.3. The angle of inclination of gears made using a helical gear is in the range from 8 to 200 degrees.
The maximum gear ratio that the unit is capable of providing is 12.5, but at the same time, gearboxes with a maximum gear ratio are rarely used. Often, those that have a gear ratio not exceeding the number 6 are used.
Which position of the gearbox to choose - vertical or horizontal? It all depends on the need for the convenience of the overall layout of this transmission device. In particular, it matters how the unit that produces the mechanical movement, its working shaft, etc. is located.
To create such a device, you first need to make its circuit. We propose to study one of the options for a single-stage gearbox with a horizontal axis.
The principle of operation of a single-stage gearbox
It is simple enough to understand. In such a mechanism, through a smaller sprocket located on one shaft, a rotational movement is transmitted through the teeth to a larger sprocket mounted on another shaft. The effect of reducing the number of revolutions per minute is achieved due to the difference in the diameter of the sprockets. The length of the circle that the first one outlines in the process of movement is significantly less than the one that the second one outlines, so the large asterisk rotates more slowly.
In this case, reverse action devices are created that do not reduce the number of revolutions per unit of time, but rather increase.
This type of gearbox is the simplest. It differs from others in that the transmission of motion is carried out through one link, and not through several, while the incoming and outgoing rotations have opposite directions.
Torque transmission can also be carried out using a worm gear, but the diameter of the “worm” affects the gear ratio.
Where and for what are single-stage horizontal gearboxes used?
They find their uses:
- where a constant or variable load is needed, reversible and one direction;
- to ensure permanent work or with short breaks;
- to ensure the rotation of the shafts in different directions.
They cannot be used or it is dangerous to use if the shaft speed exceeds 1800 revolutions per minute, as well as when the dust content of the air is above 10 mg per cubic meter. meter and atmosphere of the first and second types in accordance with GOST 15150-69.
Design process of single stage spur gearboxes
Before proceeding with the manufacture of this device, a design calculation is made:
- selection of materials;
- selection of the maximum allowable rolling stress;
- calculation of the net useful torsion of the shaft.
As part of the work, the preliminary layout of the gearbox is being prepared.
The calculation of the dimensions of the shafts of this device is carried out in 2 stages:
- approximate calculation of the number of revolutions of pure torsion;
- accurate calculation of strength indicators of bending and torsion stress.
For the production of such units, it is recommended to use heat-treated alloy steel. The calculation of shafts in the preparation of the project is carried out depending on the torsion stress, stress concentration, its cycles. If it is planned to install high-speed shafts, then smaller values are taken into account for the calculation, and large ones are taken into account for quiet running.
At the final design stage, an assembly drawing of this device is created. It includes all previously developed drawings of each of the elements of the gearbox separately. In this case, a drawing of an already finished device is created, in longitudinal and transverse sections.
To achieve balance and coaxiality of the arrangement of various elements of this device, kinematic schemes of single-stage gearboxes are being developed. They are images in different sections of the body and parts that make up the gearbox, reflect their relative position, proportions, mating points, etc.
The layout of a single-stage gearbox may be different. It may have additional elements that significantly improve its performance. For example, an oil pump that provides forced lubrication in places where liquid does not enter when the sprocket flywheel rotates or in a worm-type gearbox.
The rear axle gearbox includes several components, the main ones being the differential and final drive. The main gear is the mechanism by which the gear ratio of the vehicle's transmission is increased. So what is a gearbox, when it was created, what kind of malfunctions can befall it, and much more, we will tell in this article.
The history of the gearbox
The process of the industrial revolution was marked by the transition of wooden parts to metal ones. Wind and water-powered propellers already created such forces that it was difficult for wooden parts to withstand. The main factor of the industrial revolution was the creation of more advanced mechanisms, the search for new energy resources.
The advent of the steam engine required very large capacities. Consequently, there was a need to design metal gearboxes. By the middle of the nineteenth century, hand looms had already begun to recede far into the background and be replaced by mechanical ones with three times the productivity. Energy began to become cheaper, which led to an increase in the speed of machine tools and strengthened their economic advantage. The steam engine was powerful enough to run several textile looms.
The machines were placed around the steam engine to increase efficiency. The steam engine unleashed the hands of manufacturing possibilities, which made it possible to build enterprises both near the water and in those places where there were coal, transport, labor and markets. Modern times have selected optimal gear designs. Those that gave the highest economic effect gained great popularity.
The middle of the 19th century was marked by the appearance of the first serial gearboxes. Well, the appearance of internal combustion engines and an electric drive a few years later marked the creation of gearboxes with specified parameters. Gear mechanisms transmitted rotational movements from high-speed engines and converted their parameters. Even the first models of electric motors and internal combustion were endowed with too much speed and torque, which, a priori, was not suitable for use in industry. Today, of course, it is difficult to find any vehicle or technological equipment that is devoid of a gear mechanism. Gearboxes are used in almost all vehicles and technological equipment. As you already understood, gears have gone through many years of development.
The design and principle of operation of the gearbox
Despite the fact that many models of rear-wheel drive vehicles, as part of the rear axle design, have reducer, it looks quite identical, with the rare exception of some samples. Here we immediately recall the definition of a gearbox, which says that this is a device that changes the speed of rotation at the moment of transfer of force between forces between devices. As a result of a change in the speed of rotation, a change in its magnitude and direction is quite likely. It is according to this principle that the operation of the gearbox used in the design of the rear axle of almost every vehicle is implemented.
The transmission from the drive shaft to the driven shafts, which are located at right angles to it, uses gears, which are gear wheels. Due to the location of the shafts at different angles, the teeth of the gears are made in a specific shape - these gears are called bevel gears. Bevel gears are used, in an understandable way, for rotation, but it is the design of this type of gears that minimizes the noise emitted during their operation, and this is very important if you are moving in a compact passenger car, for example.
In order for the gearbox to really lower the rotation speed, the drive wheel must be several times smaller than the driven ones. If the design is aligned correctly, then with the full rotation of the drive shaft around its axis, the driven shaft will not complete a complete revolution. Thus, there is a reduction in the speed of rotation, that is, its decrease. In some types of vehicles, a significant reduction in shaft speed is often required, for example, on SUVs, which overcome various kinds of mud obstacles slowly enough not to sit down on their belly or get stuck.
Gearbox types
As you already understood, a gearbox is a mechanism that allows you to reduce the speed while increasing torque at the same time. This is a special unit that consists of one or more meshed gears installed in the housing. It is adapted to change the speed of rotation of the shafts both downward and upward. Today, gearboxes are widely used not only in the automotive industry, but also in the construction industry, for lifting loads, manufacturing, coal mining and oil industries.
Reducers are divided into various types. They are usually classified according to several criteria. The most important of these is the type of transmission used. And according to this principle, they are divided into several types: conical, planetary, cylindrical, worm, spiroid, wave and combined.
Helical gearboxes, often in hoisting mechanisms and other areas with frequently repeated short-term loading. They are very durable and their efficiency is quite high.
Bevel gearboxes are more complex in their design than cylindrical ones. The ratio of performance and compactness they stand out very favorably against the background of other types. Bevel gearboxes are widely used in cranes of various designs.
Worm gearboxes are adapted to transmit rotation between shafts that cross at right angles, by means of a worm and a worm wheel, which is associated with it. A worm is a kind of screw with a trapezoidal thread and close to it. A worm wheel is also called a gear wheel. Its teeth are curved. Worm-type gearboxes are widely applicable in machine tools, trolleybuses and hoists. The main advantage of such gearboxes is noiselessness and smooth operation. The big disadvantage is the increased heat generation, which leads to low efficiency and accelerated wear.
Planetary gears compared to others, they perfectly withstand loads, while having a low specific capacity of materials. They are very reliable and at the same time have a compact size. They can also be transformed by manufacturers depending on the type of transmission used. Wave reducers were previously used only in rocket science and the defense industry. Wave reducers are very reliable and have a large overload capacity, and they also have a long operating time, they are very compact, smooth and silent in their operation.
Spiroid gearboxes- These are budget units for the implementation of a drive of low power for relatively little money. Combined gearboxes, based on their name, use gears of different types in one housing. For example, worm-bevel and bevel-helical gearboxes. When choosing one or another type of gearboxes, you must be based on the load data - force, mass, moment of inertia, operating time and the number of inclusions in a given time.
Reducer malfunctions
Most often, gearbox breakdowns, as an integral element of an automobile transmission, are often associated with the complete exhaustion of the resource of parts that require subsequent replacement. The main reasons contributing to subsequent malfunctions of the rear axle gearbox are:
- worn shank seals;
Worn shank and differential bearings;
Failed elements of the differential;
Worn or broken main pair parts.
It is simply impossible not to notice the signs of a broken rear axle gearbox. This is an oil leak from the gearbox itself, and a characteristic howling sound that comes from this assembly during movement. All this immediately gives the cause of the breakdown. And if the leakage of transmission oil is easy enough to eliminate by installing a new shank oil seal, then the noise that a broken transmission makes is not so easy to remove.
First of all, you should check whether the noise disappears when the car is coasting. If it disappears, then the cause of the noise, of course, is in the main pair of the gearbox. If the noise and rumble have not disappeared anywhere, then most likely the reason for this is broken shank or differential bearings. Why is it so easy to diagnose such serious malfunctions? We answer. While the car is coasting, the elements of the main pair do not come into contact with force, therefore they are not able in any way to influence the appearance of a strange noise in the car.
Note that often the main pair is subject to increased wear due to low oil levels. When gear parts are not sufficiently lubricated, this naturally exposes them to very high frictional and thermal overloads. And the oil level, in turn, drops sharply due to faults in the stuffing box, which becomes unusable when the shank nut is not tightened well. The next reason leading to the replacement of the rear axle gearbox is the increased load on the transmission, which occurs when the machine is used for a long time with a strong overload. Also, do not rule out a defect in parts from the conveyor that are installed on the rear gearbox, the cost of which is prohibitively high.
How is the rear axle gear set up?
The device of the rear axle gearbox of the car should be considered together with other elements that are functionally related to it. This:
- main gear (GP);
Cross-axle differential.
Power from the internal combustion engine, more precisely from the gearbox through the drive gear is supplied to the driven gear. These two gears are called the final drive. GP changes the magnitude and direction of torque transfer. The driven gear is interconnected with the axle shafts, which transfer power from the engine to the wheels. The cross-axle differential distributes it between different semi-axes, allowing them to rotate at different speeds at the moment of changing the direction of movement. This principle of constructing a mechanism is implemented on most rear-wheel drive vehicles. This device is very reliable and works perfectly even in the most difficult road conditions.
Rear axle gear adjustment
It is necessary to adjust the rear axle only in those cases when it really began to bother you with a strange hum, which is already audible at speeds from 30 km / h. The main reason for the characteristic noise in the rear axle gearbox is the constant exposure of the car to large overloads or too frequent driving with a trailer or simple mechanical damage. Therefore, do not delay with a visual diagnosis of the mechanism.
Oil seals and flanges, bearings, satellites (star-shaped element in the differential) and their axles - all this will need to be removed and inspected, and in case of wear, immediately replaced. How all these parts should look in normal working condition, you will learn from the manual for your vehicle. Replacing a gearbox in a domestic car will not be expensive. And if you have a foreign car, then it is better to study all the price lists and make inquiries in auto parts stores.
Now that all the parts are in good order (this was revealed during visual diagnostics), the gearbox can be assembled. The first step is the drive gear, then the shim, flange and spacer with bearings. Next, tighten the nut with the necessary force. To do this, we take a special key with a built-in dynamometer; in the absence of one, you will have to constantly use the measuring lever. Each millimeter of lever travel will need to be accompanied by a pressure measurement with a steelyard. And this is very troublesome and long, and requires a certain accuracy and caution. The nut must be tightened by 1 Newton, during which time the flange must not move. It must be secured with a special wrench with spacers that exactly fit the grooves of the flange in size. Then we mount the driven gear in its place in the differential housing and tighten the bolts.
Now we proceed to the direct adjustment of the backlash. After installing all the parts in their place, tighten all the nuts to a minimum and turn the driven gear. Next, we check it for the presence of a small backlash, shaking the gear from side to side. Remember, there should be a backlash, but not significant! This, one might say, is a spare place for heating the gearbox. So that nothing bursts when moving.
At the final stage, we check the distance between the bolts holding the nuts that we recently tightened. The nuts must be tightened to the same distance, for this you should use a caliper. After that, we check the gear again for backlash. It's important that it stays that way. Everything, the gearbox adjustment is over.
Mechanical gearbox
Downshift Chassis
Reducer (mechanical)- a mechanism that transmits and converts torque, with one or more mechanical gears. The main characteristics of the gearbox are efficiency, gear ratio, transmitted power, maximum angular shaft speeds, number of driving and driven shafts, type and number of gears and steps.
Usually, a gearbox is a device that converts a high angular speed of rotation of the input shaft into a lower one on the output shaft, while increasing the torque. A gearbox that converts a low angular velocity into a higher one is usually called a multiplier.
A gearbox with a step change in angular speed is called a gearbox, with a stepless one - a variator.
Gearbox types
First of all, gearboxes are classified according to the types of mechanical transmissions.
Also, gearboxes can be classified by type of housing, by cooling method, by types of bearings used, by rotation speeds, gear ratio; transmitted, converted, distributed power.
Gear housings
In mass production, standardized cast gear housings are widely used. Most often in heavy industry and mechanical engineering, bodies made of cast iron are used, less often from cast steels. When it is required to lighten the design as much as possible, light-alloy housings are used. On the gearbox housing, most often there are attachment points - paws and / or ears, for which the gearboxes are moved and / or attached to the base. Seals are placed at the output of the shafts to prevent oil leakage. The gearbox housings often have structural elements that prevent the increase in pressure inside the gearbox resulting from the heating of the gearbox during its operation.
In single-piece production, welded housings are widely used, which make it possible to obtain individual design solutions.
gear ratio
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