Car Gearbox And How It Works

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What Is Gear?
Gears are one of the most used mechanical components and are widely used in mechanical transmissions. From small gears for clocks to large gears for ship turbines, it can reliably transmit power.

The Function of the Gear

By selecting a combination of different numbers of teeth, an arbitrary and correct speed ratio can be obtained. Using the increase or decrease of the number of gear combinations, the position of the mutual relationship between the rotary axes can be freely changed. It can be used for transmission between various axes such as parallel axes, intersecting axes, and staggered axes.

What Is a Car Gearbox?

A gearbox, also known as a transmission, is a mechanical component that helps to transfer power from the engine to the wheels by using different gear ratios. It is usually located between the engine and the wheels and consists of several gears, shafts, and bearings. The gearbox is connected to the engine's crankshaft through a clutch, which allows the motor and gearbox to be temporarily disengaged when changing gears. Its primary role is to churn out the right amount of power and torque for the wheels at different speeds to achieve optimal performance and mileage.

Parts Of A Car Gearbox

Here are the primary parts of a gearbox:

1: Clutch shaft: It is also known as the drive shaft, which uses the force from the engine and sends the power to other parts. A clutch attaches the drive shaft to the engine and other components. When you engage the clutch, the drive shaft starts to rotate.

2. Counter shaft: It is the second most prominent gearbox part and includes various gears in different sizes that can produce enough torque to propel the vehicle.

3. Main shaft: It is also referred to as an output shaft. It offers mandatory torque to the vehicle. It has ridges and teeth, so the gears can move smoothly.

4. Bearings: They support the rotating shafts and minimize friction.

5. Gears: These transfer power from one shaft to another. The torque transferred through the gears depends on the number of ridges and teeth and the gear size.

How Does A Car Gearbox Work?

The gearbox in a car works by transferring power from the engine to drive the wheels by employing a set of gears that can be shifted to change the speed and torque. The gears are arranged in different patterns to offer different speeds while maintaining the engine performance. A car gearbox is controlled by a lever or an electronic selector inside the vehicle, and the driver physically selects the desired gear. In a manual transmission-equipped car, the driver must shift the gears physically by moving the lever or the selector. In contrast, in an automatic transmission-equipped vehicle, the gearbox employs electronic sensors to change gears based on the car's speed and load.

Types Of Car Gearboxes

The primary types of car gearboxes are manual and automatic. The automatic gearbox is further classified into Torque Converter, CVT (Continuously Variable Transmission), Automatic Manual Transmission (AMT), and DCT (Dual Clutch Transmission). Here's an overview of car transmissions:

1. Manual gearbox: A manual gearbox allows the driver to get complete control and choose the gears manually, operating both the gearstick and the clutch. Manual transmissions are affordable and easier to maintain compared to automatic transmissions. The manual version is a predominant gearbox option in Indian cars due to its low cost and maintenance.

2. Automatic gearbox: An automatic gearbox is a type of gearbox that automatically shifts gears and doesn't require manual intervention. It uses electronic sensors to monitor the vehicle's speed and shift gears with the help of an Electronic Control Unit (ECU). Automatic gearboxes are more convenient and easier to use than manual transmissions, but they are more complex and expensive to maintain and repair. Here is an overview of different types of automatic gearboxes in cars.

Automated Manual Transmission (AMT): An AMT gearbox is a type of gearbox that automates the manual gearbox by employing a hydraulic to actuate the clutch pedal. It removes the manual effort of using the clutch (physically) and gears since the AMT gearbox uses electronic sensors to perform the task. The AMT gearbox in cars has revolutionized the car market in India, offering the option of affordable automatic cars. Its biggest highlight is the lower cost factor since it has fewer components compared to pure automatic gearboxes, thereby reducing the overall cost of the vehicle.

Torque Converter Gearbox: The Torque Converter Gearbox is an automatic gearbox that utilizes fluid coupling to transfer power from the engine to the transmission. This gearbox doesn't require a clutch pedal to shift gears, like other automatic transmissions. The torque converter is one of the traditional gearboxes that has witnessed a decline in its popularity in recent times due to its low fuel efficiency and high maintenance cost.

Continuously Variable Transmission (CVT): A CVT gearbox is a type of automatic transmission that works via a pulley system. It uses several intricate parts to shift between a range of preset gears. The CVT system includes cones at each pulley linked through a belt and moves to increase or decrease the chain belt diameter to change gear ratios. The CVT is reliable and offers higher fuel efficiency. It is common in Japanese cars such as the Hondas, Nissans, and Toyotas.

Dual Clutch Transmission (DCT) The DCT employs two clutches to shift gears, offering optimum performance. It uses two separate clutches for odd and even gear sets, reducing gear shift lag. This allows for quicker and smoother gear shifts compared to traditional gearboxes. While one of the clutches is engaged, offering the required power, the other pre-selects the next gear, allowing for faster transitions. DCTs are popular among high-performance and sports cars. However, it is fast becoming one of the most preferred in the mass-market car segment. Brands such as Volkswagen, Skoda, Audi, and more are offering DCT in their Indian car portfolios.

Functions of A Car Gearbox

Here are some of the functions of the car gearbox:.
Change gear ratio: The gearbox changes gear ratio to match driving conditions. It allows the driver to manually change the gear ratio as per the speed and road conditions.

Transfer power to the wheels: The gearbox transfers the required amount of power from the engine to the wheels at different speeds. This allows for optimising fuel efficiency and performance.

Control the speed: It controls the car's speed by allowing the driver to slow down or speed up the car by selecting the appropriate gear.
Offers torque: It multiplies the engine's torque output to offer more power to the wheels, enabling the vehicle to drive through steep inclines.

Lubrication Method of Gearbox:

Commonly used gearbox lubrication methods include gear oil lubrication, semi-fluid grease lubrication, and solid lubricant lubrication. For better sealing, high speed, large load, and good sealing performance, gear oil can be used for lubrication. For those with poor sealing performance and low speed, semi-fluid grease can be used for lubrication.

The lubrication system of the gearbox is of great significance to the normal operation of the gearbox. Large-scale wind power gearboxes must be equipped with a reliable forced lubrication system to lubricate the gear meshing area and bearings. Insufficient lubrication accounts for more than half of the reasons for gearbox failure. Lubricant temperature is related to component fatigue and the life of the entire system. - Generally speaking, the maximum oil temperature of the gearbox should not exceed 80℃ during normal operation, and the temperature difference between different bearings should not exceed 15℃. When the oil temperature is higher than 65℃, the cooling system starts to work. When the oil temperature is lower than 10℃, the lubricating oil should be heated to the predetermined temperature before starting.

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