Evaluate two sets of 5 speed manual transmission gear ratio

Reference no: EM132321055

Theory of Machines and Mechanisms Assignment

You are a staff engineer in an automotive company and leading Engine & Transmission Development team. The company has embarked a new project which is to develop a new compact and small sedan with 5 speed manual transmission and 1200 cc 4 cylinder spark ignition engine. The target markets for this new vehicle model are for fresh graduates and young executives.
The management has requested you and your team to complete two tasks:

Task 1

To evaluate two sets of 5 speed manual transmission gear ratio from different suppliers and recommend your selection.

Task 2

To solve for maximum secondary unbalanced force inside the 1200 cc 4 cylinder spark ignition engine and its relation with engine speed and connecting rod length to crank radius ratio.

Task 1 Description

There are two suppliers which offer their five (5) speed manual transmission which have different set of gear ratios. Your team has conducted performance simulation on these two transmissions and the results are shown in graphs below.

1107_Figure 1.jpg

Figure 1: Supplier A transmission performance

1753_Figure 1.2.jpg

Figure 1.2: Supplier B transmission performance

Graphs parameters:

• x-axis: vehicle speed in km/h (vehicle top speed is at 190 km/h)

• y-axis: Running Resistance (N), Traction Force (N), engine speed (rpm)

• Black solid line represents total resistance forces on vehicle due to aerodynamic (drag), inertia, rolling and gradient (slope of road).

o For example, solid black line 5% indicates total resistance forces in Newton (N) on vehicle according to vehicle speed at 5% gradient (% gradient is a unit to measure road slope)

• Coloured solid line represents engine speed (rpm) vs. vehicle speed (km/h) for each gear ratio.

• Coloured dotted line represents the traction force in Newton (N) for each gear ratio according to vehicle speed.

• In general, the coloured dotted lines must be above the black solid lines so that the vehicle can climb the slope. However, the gap cannot be too far or else the transmission is over-designed and consume more fuel. (Hint: You just need to select a transmission for a small sedan, not for a 4 wheeled vehicle!)

Table 1.1 shows other details for your consideration.

Table 1.1: Other details

	Supplier A transmission	Supplier B transmission
Part price	RM3, 000	RM5, 500
Warranty	60, 000 km or 5 years	30, 000 km or 3 years
Transmission oil service	60, 000 km and 120, 000 km
Transmission oil price	RM48/liter	RM30/liter
Testing cost	RM500, 000
Emission requirement	Meet EU3	Meet EU5

Task 1 Deliverables

Write a technical report of 500 - 1000 words on your evaluation of transmission of Supplier A and B to convince your management on your recommended transmission.

Your report must be used font type Arial, size 12, double spacing.

Task 2 Description

The 1200 cc 4 cylinder spark ignition engine has two outer cranks set at 120° to each other, and their reciprocating masses are each 400 kg. The distance between the planes of rotation of adjacent cranks are 450 mm, 750 mm and 600 mm. The crank radius is 300 mm. The engine is to be in complete primary balance. ( F_{S (max)} = mω² (r/n))

1733_Figure 2.1.jpg

Figure 2.1: Positions of planes

Task 2 Deliverables

a. Construct following vector polygons using SolidWork to solve for the reciprocating mass and the relative angular position for each of the inner cranks. Then measure the secondary unbalanced force.

• Data tabulation in a table

• Primary crank positions

• Primary couple polygon

• Primary force polygon

• Secondary crank positions

• Secondary force polygon

b. Produce a graph using Excel/Matlab to illustrate the relationship between maximum secondary unbalanced forces vs. engine speed. Range of engine speed from 0 to 1000 rpm. The ratio of connecting rod length to crank radius, n is 4. Analyse the graph.

c. Produce a graph using Excel/Matlab to illustrate the relationship between maximum secondary unbalanced forces vs. connecting rod length to crank radius ratio, n. The ratio range, n is 1 to 10. The engine speed is constant at 300 rpm. Analyse the graph.

d. Conclude your findings.

Reference no: EM132321055

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