 What is Gear Box....?

Gear Box
The gear box is necessary in the transmission system to
maintain engine speed (or torque) at the most economical value
under all conditions of vehicle movement.
An ideal gear box would provide an infinite range of gear
ratios, so that the engine speed should be kept at or near that the
maximum power is developed whatever the speed of the
vehicle.
  Types of Gear Box:
Sliding Mesh Type Gear Box
Constant Mesh Type Gear Box
Synchro Mesh Type Gear Box
Planetary Mesh Tpe Gear Box
1. Sliding Mesh Type Gear Box:
  Construction of Sliding Mesh Gear box:
• The clutch shaft is connected to the engine output and rotates
when the engine rotates. A gear is mounted on the clutch shaft
which is connected with a gear of lay shaft.
• The lay shaft has several gears, one of which is connected to
gear of clutch shaft and others gears connect with different gear
of main shaft to obtain different gear ratio. Also, one gear in lay
shaft is reverse gear and has and idler gear which is placed
between the lay shaft gear and main shaft gear when operated.
• The main shaft has several gears and these gears can slide over
the main shaft to mesh with different gears of main shaft.
  Working of Sliding Mesh Gearbox:
•At first, the clutch shaft is driven by engine. It carries the engine output
and rotates in the same direction as that of engine. The gear connected to
the clutch shaft also rotates.
•As gear of clutch shaft rotates, the lay shaft gear which is connected to
the clutch shaft gear also rotates but in opposite direction.
•So the lay shaft rotates due to rotation of lay shaft gear that is rigidly
fixed in the lay shaft. Due to rotation of lay shaft other gears of lay shaft
also rotates as all the gears in lay shaft are rigidly fixed including the
reverse gear.
•The gears of main shaft are internally splined and the main shaft is also
splined, so the gears of main shaft can slide over it. The gear of main
shaft are shifted and meshed with different gears of lay shaft to obtain
different gear ratios required to face different road problems.
  Advantages of Sliding Mesh Gear Box:
• 1 Since only one gear is in mess in sliding mesh gearbox so less
fluctuating loads on shafts causing less vibration and noise
unlike the contant mesh gearbox in which all gears are in
constant mesh.
• 2. Its efficiency is more than constant gearbox as only one gear
is in mess unlike the contant mesh gearbox in which all gears
are in constant mesh.
• 3. Its manufacturing is easy as compared to constant mesh
gearbox.
• 4. Its mechanism is simple.
  Disadvantages of Sliding Mesh Gearbox:
• 1 Only spur gears can be used as gears are not in constant mesh
like constant mesh gearbox in which helical or herringbone gears
can be used.
• 2 More effort is required to engage the gear as the gear has to be
slided in sliding mesh gearbox unlike constant mesh gearbox
where only dog clutch has to be slided for enagement of different
gears.
• 3 Less life of gear as more wear and tear of gear is caused in
sliding mesh gearbox due to friction.
• 4 It takes more time nad money to replace the gears if the gearbox
fails but in constant mesh gearbox only dog clutches are to be
replaced at failure which takes less time and money.
2. Constant Mesh Gearbox:
  Construction of Constant Mesh Gearbox:

• The output of the engine is carried by clutch shaft. The gear in clutch
shaft is in constant mesh with the gear of lay shaft.
• There are 5 gears in lay shaft, one of which is connected to gear of
clutch shaft and the other 4 are connected with gears of main shaft.
• All four gears are of different sizes to obtain different gear ratios.
• An idler gear is present between the gear of lay shaft and gear of main
shaft to form reverse gear.
  Working of Constant Mesh Gearbox:
• When the dog clutch is engaged with different gears of main shaft
different gear ratios are obtained as gears of main shaft are always
paired with gears of counter shaft to form different gear ratios.
• If the dog clutch is not in contact with any gear of main shaft the gears
of main shaft rotates freely and does not rotates the main shaft as they
are connected with main shaft using bearings.
• The main shaft rotates only when one of the dog clutch is engaged with
any of the gear of the main shaft.
• Reverse gear is obtained in this gearbox using the same technique that
was in sliding gearbox i.e using the idle gear between main shaft gear
and counter shaft gear.
  Advantages of Constant Mesh Gearbox:
• 1.Contsant Mesh Gearbox are quiter because helical or herringbone
gears can be used in this gearbox instead of spur gears.
• 2.Since the gears are engaged by dog clutches, if any damage occurs
while engaging the gears, the dog unit members get damaged and not
the gear wheels.
  Disadvantages of Constant Mesh gearbox:
• In this type of gear, shifting is not as quickly as possible.
• Defects occur in this type of gears is more.
3.Synchro Mesh Gearbox:
 Construction or Parts of Synchromesh Gearbox:
• The components involved in the synchromesh gearbox are parts
such as clutch shaft, layshaft, main shaft, needle bearing,
synchronizer, helical gears, spur gears, idler gear, shift fork, and
shift rod.
  Working of Synchromesh Gearbox:
• The gears on the clutch shaft, layshaft, and main shaft rotate
along as long the clutch shaft rotates due to the power provided
when the engine.
• When the driver needs to engage the first gear, the clutch is
disengaged which brings the rotating parts to a complete stop.
  Advantages of SynchroMesh Gearbox:
• De-clutching is not required as in case of the constant mesh
gearbox.
• Helical gears present make lesser noise compared to other gears
due to teeths cut at a certain angle.
• Synchronizer device present avails quiet transition of gears in
synchromesh gearbox.
• There is no loss of torque during the transmission due to the
synchronizers.
• As a result, it can provide more power transmission
• Vibration of the gearbox is less.
• The clattering and grinding problem of constant mesh gearbox
can be overcome using synchromesh gearbox.
  Disadvantages of Synchromesh
Gearbox:
• The synchromesh gearbox is costly due to the manufacturing cost of the
fine and small parts present in the system.
• It is a more complex and bulky system, as a result servicing becomes
difficult.
• Greater amount of space is required.
• Improper engagement of gears can lead to damage.
• Higher loads can cause the teeth coming in contact to break, hence it
cannot handle too high loads.
• Some cars use a synchronizer system only on the higher gears and use
constant mesh gears on lower and reverse gear. This is done to decrease
the manufacturing cost.
4.Planetary Mesh Tpe Gear Box:
 Planetary Mesh Tpe Gear Box:
  Construction of planetary Gearbox:
• planetary gear set is made up of three types of gears: a sun gear,
planet gears, and a ring gear.
• The sun gear is located at the center (yellow) and transmits
torque to the planet gears (blue) which are typically mounted on
a moveable carrier (green)
  Working of planetary Gearbox
• Planetary Gearboxes are a type of gearbox where the input and
output both have the same centre of rotation.
• This means that the centre of the input gear revolves around the
centre of the output gear and the input and output shafts are
aligned.
  Advantages of Planetary Gearbox
• Coaxial arrangement of input shaft and output shaft
• Load distribution to several planetary gears
• High efficiency due to low rolling power
• Almost unlimited transmission ratio options due to
combination of several planet stages
• Suitable as planetary switching gear due to fixing this or that
part of the gearbox
• Possibility of use as overriding gearbox
• Favorable volume output
• Suitability for a wide range of applications
  Disadvantages of Planetary Gearbox
• Complex construction
• Higher power dissipation than with spur gears
• Complex bearings