Ain Shams University

October 21,2023

Lab 2

Introduction to Autotronics
Submitted by
• Abdelrahman Mohamed Hagag 20P7509
20P7509
Contents
INTRODUCTION............................................................................................................................. 3
TRANSMISSION ............................................................................................................................. 3
How A Transmission Works ................................................................................................ 4
Car Transmission Importance ............................................................................................ 5
SLIDING MESH ............................................................................................................................... 6
CONSTANT MESH.......................................................................................................................... 7
Synchronizer Hub .................................................................................................................... 9
Shift Sleeve .................................................................................................................................. 9
Synchronizer Cone................................................................................................................ 10
Baulk Ring ................................................................................................................................ 11
Ring Spring .............................................................................................................................. 11
Strut ............................................................................................................................................ 12
DIFFERENTIAL OPERATION AND COMPONENTS ....................................................... 13
Components of a Differential ...................................................................................... 13
AUTOMATED MANUAL ............................................................................................................ 14

Figures
FIGURE 1 - REAR WHEEL DRIVE TRANSMISSION..........................................................................................................................3
FIGURE 2 - CLUTCH VS TORQUE CONVERTER ............................................................................................................................4
FIGURE 3 - HILL CLIMBING ...................................................................................................................................................5
FIGURE 4 - SLIDING MESH ....................................................................................................................................................6
FIGURE 5 - CONSTANT MESH .................................................................................................................................................8
FIGURE 6 - CONSTANT MESH COMPONENTS ..............................................................................................................................8
FIGURE 7 - SYNCHRONIZER HUB .............................................................................................................................................9
FIGURE 8 - SHIFT SLEEVE ....................................................................................................................................................10
FIGURE 9 - SYNCHRONIZER CONE .........................................................................................................................................10
FIGURE 10 - BAULK RING ....................................................................................................................................................11
FIGURE 11 - RING SET ........................................................................................................................................................12
FIGURE 12 - DIFFERENTIAL..................................................................................................................................................14
FIGURE 13 - AUTOMATED MANUAL TRANSMISSION DIAGRAM....................................................................................................16

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INTRODUCTION

In the world of cars, making sure power goes smoothly from the engine
to the wheels is really important. This lab report is all about how different types
of transmissions work, like Sliding Mesh and Constant Mesh (Synchromesh).
We'll also check out what makes differentials tick, and look at how Automated
Manual Transmissions (AMTs) operate. By understanding these things, we'll get
a better grasp of how cars work and what makes them drive well.

TRANSMISSION

A transmission in a car is a mechanical component responsible for

controlling the power generated by the engine and transferring it to the
vehicle's wheels. It plays a vital role in regulating the speed and direction of the
wheels, allowing the car to move forward or backward at different speeds.

Figure 1 - rear wheel drive transmission

How A Transmission Works

When the engine generates power, it produces a rotating motion. This

power is initially transferred to the transmission through the engine's output
shaft. Then, the transmission contains a set of gears, start rotating in pairs.
These gears can be shifted to create different gear ratios. Lower gears provide
more power but lower speed, while higher gears offer more speed but less
power.
In manual transmissions, a clutch is used to engage or disengage the
engine from the transmission, allowing you to shift gears. In automatic
transmissions, a torque converter serves a similar purpose but operates
automatically. The driver or the transmission system (in automatics) selects the
appropriate gear. When you shift gears, the transmission changes the gear ratio
to adjust the power output to the wheels.

Figure 2 - Clutch vs Torque Converter

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Car Transmission Importance

A car's transmission system serves various essential purposes, ensuring

an efficient and enjoyable driving experience. It optimizes engine performance,
allowing the engine to work effectively for acceleration, hill-climbing, or
highway cruising.
Moreover, it contributes to a smoother ride and better fuel efficiency. With
different gears to choose from, the driver can easily speed up or slow down,
preventing the engine from working too hard or not hard enough in different
driving situations. This, in turn, results in a more comfortable drive and reduced
fuel consumption.
Furthermore, transmissions provide control and adaptability. They let you
move the car forward or backward and adjust the power output as needed,
which is crucial for safe driving in various traffic and road conditions.

Figure 3 - Hill Climbing

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SLIDING MESH

A sliding mesh transmission is a type of manual transmission used in

some older vehicles. It operates on a simple principle: gears on the input and
output shafts have to physically mesh or slide into place to engage, allowing
power to transfer from the engine to the wheels.
In a sliding mesh transmission, changing gears involves sliding one gear on the
output shaft while another gear on the input shaft remains stationary. This
process can be a bit rough and noisy, as the gears need to match their speeds
perfectly to engage smoothly.
Sliding mesh transmissions are less common in modern vehicles due to their
limited ability to provide smooth gear changes. They have been largely replaced
by more user-friendly transmissions like constant mesh (synchromesh) and
automatic transmissions, which offer smoother gear shifting and better overall
driving experiences.

Figure 4 - Sliding mesh

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CONSTANT MESH

A constant mesh transmission, commonly known as a synchromesh

transmission, is a type of manual gearbox found in many modern vehicles. It is
designed to simplify gear shifting and enhance the driving experience through
a set of sophisticated components.
At the core of this transmission type are the gears, each with a specific number
of teeth. These gears are always in mesh with each other, allowing for a seamless
transition between them. However, what sets the synchromesh transmission
apart are its synchronizers. These small yet crucial components include a
synchronizer hub, shift sleeve, synchronizer cone, baulk ring (synchronizer
blocker ring), ring spring, and strut.
When you want to change gears, these synchronizers come into action. The
synchronizer hub connects to the gear, and the shift sleeve moves to engage or
disengage the gear. The synchronizer cone plays a key role in matching the
speeds of the input and output shafts, ensuring a smooth and trouble-free gear
shift. The baulk ring aids in preventing gear grinding and facilitates smooth gear
engagement. Meanwhile, the ring spring and strut provide resistance and help
keep the gear in place once it's engaged.
The advantages of a synchromesh transmission are numerous. It enables
smooth gear shifting, eliminating the need for double-clutching and making
gear changes a breeze. This not only enhances the overall driving experience
but also prolongs the transmission's lifespan by minimizing wear and tear on
the gears. As a driver-friendly transmission, it is suitable for individuals with
varying levels of experience, from novices to seasoned drivers. Furthermore, its
efficiency in adapting gear ratios to driving conditions results in improved fuel
efficiency and overall vehicle performance.
In summary, constant mesh, or synchromesh, transmissions are known for their
smooth gear changes and their ability to enhance the driving experience. This
transmission type has become the standard in modern vehicles, characterized
by its user-friendly nature and durability, which contribute to an improved
driving experience.

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 Figure 5 - constant mesh

Figure 6 - constant mesh components

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Synchronizer Hub

The synchronizer hub is a critical component in a constant mesh

transmission. It is responsible for connecting the selected gear to the input
shaft. When a driver shifts gears, the synchronizer hub plays a vital role in
initiating this change. By engaging or disengaging with the gear, it facilitates a
smooth transition, ensuring that the gear meshes properly with the rotating
input shaft. This seamless operation of the synchronizer hub is what enables
drivers to shift gears without encountering grinding , ultimately enhancing the
overall driving experience.

Figure 7 - Synchronizer hub

Shift Sleeve

The shift sleeve is a fundamental part of a constant mesh transmission

system. It functions as the bridge between the synchronizer hub and the chosen
gear. When the driver wants to shift gears, the shift sleeve is responsible for
sliding into position, connecting the synchronizer hub to the gear. This action
determines which gear is engaged. Essentially, the shift sleeve's role is to
facilitate the smooth and precise transition between gears, allowing drivers to
change speeds without encountering the harshness or grinding often
associated with older transmission designs.

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 Figure 8 - shift sleeve

Synchronizer Cone

The synchronizer cone, a key element in a constant mesh transmission, is

instrumental in achieving smooth gear shifts. Its primary function is to
synchronize the speeds of the rotating gears and the input shaft. When a gear
change is initiated, the synchronizer cone applies pressure to the selected gear,
helping it match its rotational speed with the input shaft. This synchronization
is essential in preventing any grinding during gear engagement, resulting in a
seamless and comfortable transition between gears, ultimately improving the
overall driving experience.

Figure 9 - synchronizer cone

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Baulk Ring

The baulk ring, also known as the synchronizer blocker ring, is a critical
component within a constant mesh transmission. Its primary purpose is to
prevent gear grinding and ensure smooth gear engagement. When a driver
shifts gears, the baulk ring exerts a slight resistance, making it more challenging
for the gear to engage if the speeds are not properly synchronized. This
resistance helps avoid harsh and damaging gear shifts. Essentially, the baulk
ring acts as a protective barrier, enhancing the overall driving experience by
facilitating seamless gear changes and prolonging the life of the transmission.

Figure 10 - baulk ring

Ring Spring

The ring spring, or synchromesh spring, is a vital component in a constant

mesh transmission. Its main job is to keep the selected gear firmly in place once
engaged. This prevents the gear from accidentally shifting during driving,
ensuring a smooth and dependable driving experience. In essence, the ring
spring's role is crucial in maintaining gear stability, enhancing the overall
performance of the transmission system, and preventing potential gear-related
issues on the road.

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 Figure 11 - ring set

Strut

The strut in a transmission system is a crucial element that supports and

aligns the gear shafts. It helps maintain the proper spacing between the gears,
preventing them from grinding against each other and ensuring smooth and
reliable gear engagement. The strut's role is fundamental in keeping the gears
in their designated positions, contributing to a trouble-free driving experience
and the overall durability of the transmission system.

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DIFFERENTIAL OPERATION AND
COMPONENTS

The differential is a vital component in a vehicle's drivetrain, especially in

rear-wheel-drive and all-wheel-drive setups. Its primary function is to enable
the wheels on the same axle to rotate at different speeds when the vehicle is
turning, thus allowing for smooth and safe cornering.

Components of a Differential

1. Ring Gear: The ring gear is mounted to the differential case and is
turned by the driveshaft.
2. Pinion Gear: The pinion gear is connected to the driveshaft and is
responsible for driving the ring gear.
3. Differential Case: The differential case holds the ring and pinion gears,
allowing them to rotate.
4. Spider Gears: Spider gears are located inside the differential case and
permit the wheels to rotate at different speeds when turning. They are
crucial for smooth cornering.
5. Side Gears: These are attached to the axles and mesh with the spider
gears, transferring power to the wheels.
6. Bearings and Seals: These components provide support and prevent
lubricants from leaking out.

In operation, when a vehicle turns, the outside wheel must travel a greater
distance than the inside wheel. The differential allows for this variation in
wheel speed. When driving straight, the spider gears inside the differential case
rotate at the same speed, allowing both wheels to receive equal power. However,
when turning, the spider gears enable the outside wheel to rotate faster than
the inside wheel, ensuring stable and controlled maneuverability. The

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differential is essential for a smooth and safe driving experience, preventing
wheel skidding and enhancing traction when navigating curves or corners.

Figure 12 - differential

AUTOMATED MANUAL

An Automated Manual Transmission (AMT), sometimes known as an

Automated Gearbox or Robotized Manual Transmission, is a type of
transmission system that combines the features of both manual and automatic
transmissions. It is designed to provide the convenience of automatic shifting
while retaining some elements of manual control.

Operation:

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 AMTs utilize a manual gearbox but are equipped with an automated
shifting mechanism. Instead of a traditional manual clutch pedal, AMTs use an
electro-hydraulic or electro-pneumatic system to engage and disengage the
clutch. The shifting of gears is controlled electronically, either by the driver
through paddle shifters or automatically by the vehicle's computer.

Advantages:

• Ease of Use: AMTs are easier to operate than traditional manual

transmissions since there's no need to manually operate the clutch and
shift gears.
• Fuel Efficiency: AMTs can be more fuel-efficient than traditional
automatic transmissions since they often allow the engine to operate in
an optimal range.
• Cost-Efficiency: AMTs are usually more cost-effective than conventional
automatic transmissions, making them a popular choice for budget-
conscious consumers.
• Manual Mode: Many AMTs offer a manual mode, allowing drivers to take
control and shift gears manually when desired, providing a more
engaging driving experience.

Disadvantages:

• Shift Lag: Some AMTs may exhibit a slight delay in gear shifts compared
to traditional automatics.
• Smoothness: The shifting process in AMTs may not be as smooth as
traditional automatic transmissions, which can lead to a different
driving feel.
• Learning Curve: While easier than manual transmissions, AMTs still
have a learning curve for drivers accustomed to traditional automatics.

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 AMTs are commonly found in a variety of vehicles, offering a compromise
between the convenience of automatic transmissions and the fuel efficiency of
manual transmissions, making them a popular choice in many parts of the
world.

Figure 13 - Automated manual transmission diagram

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