Hello! Recently, we have analyzed a lot of materials that related to the transmission - this and. What is a gearbox in relation to a car - I would like to discuss this topic on the pages of my blog!
If one of the readers remembers, then we touched on who is also taking part in the work with. In contrast, the gearbox does not redistribute this moment, but is intended to decrease 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 a drive gear connected to the propeller shaft and a driven gear. One of the main parameters of each gearbox is the gear ratio. At the same time, in passenger cars it is traditionally lower than in commercial transport. In order to understand the essence of the gear ratio, it is enough to imagine the number of teeth in the driven and driving gears. The number itself means how many times the slave can turn in 1 revolution of the leader.
The work of the main couple - what affects
This is where the concept of "main pair" of a gearbox comes from. The larger its gear ratio, the faster the engine will be able to pick up its maximum speed. The dynamics in the driving process also depends on this. A decrease in this number leads to a deterioration in dynamics, but it can increase fuel efficiency, since the engine speed at the same speed will be lower. Please note: in order to change the gearbox number, 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 assembly, change gearboxes for analogues with a different gear ratio. These experiments do not always lead to an improvement in overclocking qualities. The pursuit of better acceleration dynamics when starting from a standstill dynamics threatens to lead to excessive fuel consumption and accelerated wear of transmission parts. Read forums and expert reviews before deciding on such a radical step.
Service and faults
However, gearbox parts and lubrication remain one of the most vulnerable points and sources of damage. Prolonged absence of a sufficient amount of oil leads to overloading of the unit. How to determine the breakdown yourself without calling a master from a service station? Pay attention to new hum, extraneous sounds and vibration. Leakage of working fluid may be observed due to leaky oil seals. Buying and replacing a gearbox is not a cheap pleasure, so I recommend listening to such sounds.
The maintenance point is one of the most important to prolong the performance of this transmission unit. The working fluid must be changed every 100 thousand kilometers traveled. It is worth changing the oil seals 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 work and problems of the transmission, write these wishes. I will try to take them into account to the maximum on the pages of my blog. Thanks for staying in touch and bye!
Many motorists know that their car's transmission has a gearbox. But few are aware of what kind of mechanism it is, how it works, what functions it performs depending on the location, what malfunctions are characteristic of it and how to fix them. Today we will tell you about all the features of an automotive gearbox.
Purpose and design 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 on the torque from the crankshaft of the engines and, having reduced it, transfer it further to the transmission units (center differential, which distributes the moment to the drive wheels in a certain proportion). Depending on where it is installed, a distinction is made between a front and rear axle gearbox. Front-wheel drive vehicles use a front axle reducer that is integrated into the gearbox, while rear-wheel drive vehicles use this unit on the rear axle. In all-wheel drive vehicles, two gearboxes are used - the front gearbox is located in the gearbox, and the rear gearbox is located on the axle, both gearboxes are interconnected using a cardan shaft.
The gear mechanism looks like this:
- Body with seals (oil seals) and fasteners. Made of high-strength steel or light alloys, it protects the final drive and cross-axle differential from external influences. Fasteners are used to tie the gear housing to the bases, and the oil seals prevent the leakage of transmission fluid, which lubricates the gears of the gear and differential.
- Main gear. a) the drive gear. Designed to receive torque from the secondary shaft of the gearbox and then transfer it to the driven gear. b) a driven gear. It receives torque from the pinion gear and transfers it further to the cross-axle differential mechanism. The driven gear is larger than the drive gear and has more teeth to reduce the high torque from the drive gear.
- Crosswheel. a) body with oil 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 connects to the driven gear of the main drive. The function of the satellites is the transfer of torque from the driven gear to the gears of the axle shafts. c) gears of half-axles of wheels. The reduced torque is received from the satellites and transmitted to the wheel axle shafts. d) bearings. Installed between the axle gears and the drive shaft. They provide rotation of the axle shafts of the wheels.
If the main gear is responsible for obtaining torque, decreasing or increasing it, then the interwheel differential, in addition to distributing it from the gear transmission between the wheels, regulates the speed of rotation of the wheels when the car turns. When the car turns, the outer wheel receives more torque and the inner wheel less. Without the differential, such an operation would not have been possible.
Depending on how the teeth of the drive and driven gears are connected, there are four types of gear drives:
- Bevel, consists of two bevel gears located at an angle of 90 degrees. It is used on vehicles with rear and four-wheel drive.
- Cylindrical, consists of two parallel helical gears. This type of final drive is used on front wheel drive vehicles.
- Hypoid, consists of gears located at an angle of 45 degrees in relation to each other. It is used on vehicles with rear and four-wheel drive.
- Worm gear, is a perpendicularly interconnected 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 speed of the drive shaft to the angular speed of the driven shaft. High-ratio gearboxes are used in transmissions of vehicles with high curb weight. Such machines move at low speed, but have a higher carrying capacity. Reducers with a low gear ratio are installed on the transmission of cars with a low curb weight, which ensures their high travel speed. The gear ratio of the gearbox is determined by the number of engagement of the driving gear with the driven gear. For example, if the gear ratio is 5.1, then in one revolution of the driving gear, the driven gear will mesh with it and will 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 unit that increases or decreases the torque coming to it from the engine crankshaft. A differential is a unit that divides the torque coming from the gearbox between the axles (center differential) or semi-axles (center differential) in a certain proportion, and is also responsible for supplying more or less torque to the outer wheel when the car is turning.
Gearbox breakdown and repair
Gears, oil seals and bearings fail most often in automotive gearboxes. 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 hum or clicks at the joints of gears and bearings. The wear of the oil seals can be determined by the drops of transmission fluid, which seeps through the cracks in the seals. It is recommended to check the operation of these gearbox elements at every service and, if necessary, replace worn parts with new ones.
Less often, the body of the automobile gearbox itself breaks down or the fasteners break, with the help of which it is attached to the base. This breakdown can occur when the car hits an obstacle. Dust and dirt can enter 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 fraught with the appearance of a loud hum, which is produced by operating elements, which will affect the acoustic comfort while driving. You can diagnose a malfunction of the gearbox housing by the appearance of traces of transmission 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 failure of the gearbox, you need to monitor the level of transmission fluid poured into it, change it every 100 thousand kilometers or when the oil seals are forced to replace. It is also recommended to periodically diagnose the operation of the transmission and, if the slightest signs of a breakdown of the gearbox elements appear, promptly replace and repair them.
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 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, which are welded or otherwise immobilized on shafts or axles. The former are pressed into the bearings, which are located in holes specially made for them in the housing. Such a transmission can be mounted directly on a unit that produces mechanical movement, but installed in a separate housing (gearbox) has a number of advantages. In particular, these are:
- guarantee of high precision assembly of the mechanism;
- increased efficiency;
- better lubrication of gearbox parts;
- reduced wear;
- increased level of protection against the ingress of harmful saws and dirt.
What does the gearbox consist of?
It includes 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 (the coolant coil is often mounted in a worm gear).
Reducers are different. At the same time, they differ not only in types, but also in individual characteristics, therefore, gearboxes are designed for a specific equipment or unit, depending on the need, the gear ratio and torque force that must be transmitted to the receiving device.
The main types of gearboxes
They share:
- By the type of transfer connection for:
- toothed;
- 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, which underlies a particular mechanism for:
- deployed;
- with a double stage, etc.
- By the number of steps for:
- one-stage;
- two-stage.
Single stage helical gearboxes
This type of gearbox differs from others in the position of the shafts in the housing and the number of stages. Single-stage helical gearboxes can be vertical or horizontal. The gears of these devices can have oblique and straight, as well as chevron teeth. Housings are made of steel by welded method or cast iron by casting. 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 location of the shafts and axes in space. Moreover, 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 can provide is 12.5, but gearboxes with the maximum gear ratio are rarely used. Often, those are used that have a gear ratio not exceeding the number 6.
Which gearbox arrangement to choose - vertical or horizontal? It all depends on the need for the convenience of the overall layout of this transfer device. In particular, it matters how the unit that produces mechanical movement is located, its working shaft, etc.
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 horizontal axes.
The principle of operation of a single-stage gearbox
It's simple enough to understand. In such a mechanism, through a smaller sprocket located on one shaft to a larger size mounted on the other shaft, rotational motion is transmitted through the teeth. 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 outlines in the process of movement is significantly less than that of the second, so the large sprocket rotates more slowly.
In this case, reverse action devices are created, which do not reduce the number of revolutions per unit of time, but, on the contrary, increase it.
This type of reducer is the simplest. It differs from others in that the transmission of motion is made through one link, and not through several, while the incoming and outgoing rotations have opposite directions.
The transmission of torque can also be carried out using a worm gear, but the gear ratio is affected by the diameter of the "worm".
Where and why are single-stage horizontal gearboxes used?
They find their use:
- where constant or variable load is required, reversible and in one direction;
- to ensure continuous work or with short breaks;
- to ensure 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 air is dusty above 10 mg per cubic meter. meter and atmosphere of the first and second types in accordance with GOST 15150-69.
Design process for single stage helical gearboxes
Before proceeding with the manufacture of this device, a design calculation is made:
- selection of materials;
- selection of the maximum allowable rolling stress;
- calculating net useful shaft torsion.
As part of the work, a 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:
- an approximate calculation of the number of revolutions of pure torsion;
- accurate calculation of strength indicators of bending and torsion stresses.
It is recommended to use heat-treated alloy steel for the production of such units. Calculation of shafts when drawing up a project is carried out depending on the torsional stress, stress concentration, its cycles. If it is planned to install high-speed shafts, then for the calculation lower values \u200b\u200bare taken into account, quiet ones - large ones.
At the final design stage, an assembly drawing of this device is created. It includes all previously developed drawings of each of the gearbox elements separately. This creates a drawing of an already finished device, in longitudinal and cross sections.
To achieve balance and alignment of the arrangement of various elements of this device, kinematic diagrams of single-stage gearboxes are being developed. They represent images in different sections of the body and the parts that make up the gearbox, reflect their relative position, proportions, mating points, etc.
The layout of a single-stage gearbox can vary. It may have additional elements that significantly improve its work. For example, an oil pump that provides forced lubrication in places where liquid does not enter when the flywheel of the sprocket rotates or in a worm-type gearbox.
The rear axle reducer includes several units, the main ones being the differential and the main gear. The main gear is the mechanism by which the gear ratio of the vehicle's transmission is increased. So what is a reducer, when it was created, what malfunctions can befall it, and much more we will tell in this article.
Gearbox history
The process of the industrial revolution was marked by the transition from wood to metal. Wind and water-powered propellers have already created such forces that wooden parts were difficult to withstand. The main factor of the industrial revolution was the creation of more perfect 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-held looms had already begun to recede into the background and replaced by mechanical ones with three times higher productivity. Energy became cheaper, which led to faster machine tools and increased their economic advantage. The steam engine was powerful enough to run several textile machines.
The machines were placed around a steam engine to improve efficiency. The steam engine freed the hands of production opportunities, which made it possible to build factories both near water and in places where there was coal, transport, workers and markets. Modern times have selected the best gear designs. The most popular were those that produced the highest economic effect.
The middle of the 19th century was marked by the appearance of the first serial gearboxes. Well, the appearance a few years later of internal combustion engines and an electric drive, marked the creation of gearboxes with specified parameters. Gear mechanisms transmitted rotational motions from high-speed motors and transformed their parameters. Even the earliest examples of electric motors and internal combustion were endowed with too high 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 lacks a gear mechanism. Gearboxes are used in almost all vehicles and technological equipment. As you can imagine, gear drives have gone through many years of development.
Gearbox design and operation
Despite the fact that many models of rear-wheel drive vehicles in the structure of the rear axle have reducer, it looks quite identical, with the rare exception of some samples.Here we are immediately reminded of the definition of a gearbox, which says that it 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, it is quite possible that its magnitude and direction change. It is according to this principle that the gearbox used in the construction of the rear axle of almost every vehicle is realized.
The transmission from the drive shaft to the driven shafts, which are located at right angles to it, uses gears, which are cogwheels. Due to the arrangement 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 gear wheels of this type that minimizes the noise generated during their operation, and this is very important if you move in a compact car, for example.
In order for the gearbox to really reduce the rotation speed, the drive wheel must be several times smaller than the driven ones. If the design is verified correctly, then with full rotation of the drive shaft around its axis, the driven shaft will not complete a full revolution. Thus, the rotation speed is reduced, that is, its decrease. Some types of cars often require a significant reduction in shaft rotation speed, for example, on SUVs, which overcome all kinds of mud obstacles slowly enough so as not to belly or get stuck.
Gearbox types
As you already understood, the gearbox is a mechanism that allows you to reduce the speed, while at the same time increasing the torque. This is a special unit that consists of one or more meshed gears installed in a housing. It is adapted to change the speed of rotation of the shafts, both to decrease and increase. Today, gearboxes are widely used not only in the automotive industry, but also in the construction industry, for lifting goods, processing, coal mining and oil industries.
Gearboxes are classified into a wide variety of types. They are usually classified according to several criteria. The most important of these is the type of gear used. And according to this principle, they are divided into several types: conical, planetary, cylindrical, worm, spiroid, wave and combined.
Spur gearboxesoften in hoisting machines and other areas with frequent short-term loads. They are very durable and have a high efficiency.
Bevel gearboxes are more complex in design than spur gearboxes. Their ratio of performance and compactness is very advantageous compared to other types. Bevel gearboxes are widely used in lifting cranes of various designs.
Worm gearboxes are adapted to transfer rotation between shafts crossing at right angles, by means of a worm and a worm wheel, which is associated with it. The worm is a kind of screw with a trapezoidal thread and close to that. The worm wheel is also called a gear wheel. Its teeth are arched. Worm-type gearboxes are widely used in metal-cutting machines, trolleybuses and lifts. 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 gearboxesin comparison with others, they perfectly withstand loads, while having a low specific capacity of materials. They are very reliable and compact in size. They can also be transformed by manufacturers depending on the type of transmission used. Wave reducers were previously used only in rocketry and the defense industry. Wave reducers are very reliable and have a large overload capacity, as well as they have a long operating mode, they are very compact, smooth and quiet in their work.
Spiroid Reducers- these are budget units for the implementation of a low-power drive for relatively little money. Combined gearboxes, as their name suggests, use transmissions of different types in one housing. For example, worm-bevel and bevel-helical gearboxes. Choosing one or another type of gearboxes, you should be based on the load data - force, mass, moment of inertia, operating time and number of starts for a given time.
Gearbox malfunctions
Most often, the breakdown of a gearbox, as a component of an automobile transmission, is often associated with the full depletion of the resource of parts that require subsequent replacement. The main reasons contributing to subsequent failures of the rear axle gearbox are:
- worn shank oil seals;
Worn shank and differential bearings;
Failed differential elements;
Worn or broken parts of the main pair.
Signs of a broken rear axle gearbox are simply impossible to miss. This is the leakage of oil from the gearbox itself, and the characteristic howling sound that comes from this unit when driving. All this immediately gives out the cause of the breakdown. And if the leakage of transmission oil is easy enough to eliminate by installing a new oil seal of the shank, then the noise that a broken transmission emits is not so easy to remove.
First of all, you should check if the noise disappears when the machine is coasting. If it disappears, then the cause of the noise is naturally in the main pair of the gearbox. If the noise and hum have not disappeared anywhere, then most likely the reason lies in the broken bearings of the shank or differential. Why is it so easy to diagnose such serious malfunctions? We answer. When 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 strange noise in the car.
Note that the main steam is often subject to increased wear due to the low oil level. When gearbox 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 malfunctions in the oil seal, which becomes unsuitable for operation with a poorly tightened tail nut. The next reason leading to the replacement of the rear axle gearbox is the increased transmission load, which occurs during prolonged use of the machine with a strong overload. Also, do not exclude a defect in parts from the conveyor that are installed on the rear gearbox, the cost of which is prohibitively high.
How does the rear axle gearbox work?
The device of the gearbox of the rear axle of the car should be considered together with other elements that are functionally related to it. It:
- main transfer (GP);
Cross-axle differential.
Power from the internal combustion engine, more precisely from the gearbox through the drive gear, goes to the driven gear. These two gears are called the final drive. GP changes the magnitude and direction of torque transmission. The driven gear is interconnected with the axle shafts, which transmit power from the engine to the wheels. An interwheel differential distributes it between different axle shafts, allowing them to rotate at different speeds when the direction of travel changes. This principle of building the mechanism is implemented on most rear-wheel drive vehicles. This device is very reliable and works great even in the most difficult road conditions.
Rear axle reducer 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 heard at speeds of 30 km / h. The main reason for the appearance of characteristic noise in the rear axle gearbox is the constant exposure of the car to high overloads or too frequent driving with a trailer or simple mechanical damage. Therefore, do not hesitate 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 changed. How all these parts should look in normal working order, you will learn from the manual for your vehicle. Replacing the gearbox in a domestic car will not be expensive. And if you have a foreign car, then it is better to study all price lists and make inquiries in auto parts stores.
Now that all the parts are in good order (this was revealed during visual diagnostics), you can assemble the gearbox. The first step is the drive gear, then the adjusting washer, flange and spacer sleeve with bearings. Next, tighten the nut with the required effort. To do this, we take a special key with a built-in dynamometer; in the absence of such, you will have to constantly use the measuring lever. Every millimeter of lever travel will need to be accompanied by a pressure measurement with a steelyard. And this is very troublesome and time-consuming, and requires a certain degree of precision and care. The nut should be tightened 1 Newton, during which time the flange should not move. It must be secured with a special wrench with spacers that fit exactly the flange grooves. 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 a slight backlash by swinging the gear from side to side. Remember, there should be some backlash, but not significant! This is, one might say, a spare place for heating the gearbox. So that nothing bursts when moving.
In the final step, we check the distance between the bolts holding the nuts that we recently tightened. The nuts must be tightened the same distance using a vernier caliper. Then we again check the gear for backlash. It is important that he stay that way. That's it, the gearbox adjustment is over.
Mechanical reducer
Low gear Chassis
Reducer (mechanical) - a mechanism that transmits and converts torque, with one or more mechanical transmissions. The main characteristics of the gearbox are efficiency, gear ratio, transmitted power, maximum angular speeds of shafts, number of driving and driven shafts, type and number of gears and stages.
Usually, a gearbox is a device that converts a high angular speed of rotation of the input shaft to a lower one on the output shaft, while increasing the torque. A gearbox that converts a low angular velocity to a higher one is usually called a multiplier.
A gearbox with a stepped change in angular speed is called a gearbox, with a continuously variable - a variator.
Gearbox types
First of all, gearboxes are classified according to the types of mechanical transmissions.
Also, gearboxes can be classified by the type of housing, by the cooling method, by the type of bearings used, by rotation speed, gear ratio; transmitted, converted, distributed power.
Gearbox housings
In series production, standardized cast gearbox housings are widely used. Most often, in heavy industry and mechanical engineering, casings are used from cast iron, less often from cast steels. When it is required to lighten the structure as much as possible, light-alloy bodies are used. The gearbox housing most often has attachment points - paws and / or ears, for which the gearboxes are moved and / or fastened to the base. Seals are placed at the shaft outlet to prevent oil leakage. Structural elements are often placed on the gearbox housings to prevent an increase in pressure inside the gearbox arising from the heating of the gearbox during its operation.
In piece production, welded housings are widely used, allowing to obtain individual design solutions.
Gear ratio
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