List of content

Task NO.1 page NO.

1.Describe the function and the name of each component for the couplings

shown in figure 1 and 2…………………………..………………………………………2/3

2. Describe the method of operation of each type and compare them in terms of torque and
speed ratios…………………………………….…………………………………………. 4

3. Explain the function of lockup clutch and in which coupling is used? Also, Explain its
operating principle……………………….……………………………………………….. 5/6

4. Discuss the different problems caused by torque converter……………………….. …. 7

5. You have checked the coupling in the service center store and find that there is no coupling
with same dimensions. Evaluate the effect of changing the torque converter with another one
with different diameter (smaller or larger) on vehicle performance………………………. 8

Task No.02

1.Write two different types of compound planetary gear sets used in automatic transmission?
Illustrate the construction of each type. Also, explain the difference between them…….. 8/9

2. For a simple planetary gear sets shown above, calculate the reduction ratios for the first,
reverse gears and direct drive. Also, state the condition of each gear for actuating the first and
reverse gear ……………………………………………………………………………….10/11
3. Present as a team (maximum 5 students) a presentation showing the procedures for
disassembling the automatic transmission out from the vehicle and disassemble

of the gear sets………………………………………………………………………………. 11

4. If you found that the planet and sun gears are damaged and need replacement. You checked
the store, and the only available sun is smaller than the original by 20%. Discuss the effect of
changing the planetary gear on vehicle performance………………………………………… 12

5. References ………………………………..……………………………………………….. 12

1
 Task NO.1

1. Describe the function and the name of each component for the couplings shown in
figure 1 and 2.

Figure.1 Figure.2
(Fluid coupling ) (Torque converter)
 Fluid coupling function : A fluid coupling or hydraulic coupling is a device which is
employed for transmission of power from one shaft to another through a liquid medium. The
magnitude of input and output torques are equal. And smooth out the power pulses produced by
the engine and reduce the rotational vibration
 Main component

1. Impeller or pump : Connected to the engine, it spins and generates fluid movement within the
converter. It is also known as pump because it acts as a centrifugal pump.

2. Turbine : Connected to the transmission input shaft, it receives fluid from the impeller and
transfers torque to the transmission

3. Housing : It is also known as the shell. It has oil-tight seal around the drive shaft. It also protects
the impeller and turbine from outside damage

Figure.3

2
  torque converter function :

1. increases the torque of the vehicle reducing its speed

2. It provides a continuous variation of ratio from low to high.

3. its ability to multiply torque five times the torque available at the driving shaft with an efficiency of
about 90%

4. smooth out the power pulses produced by the engine and reduce the rotational vibration

 Main component

1. Transmission fluid : provide fluid coupling / it fills the converter, transferring power and
facilitating smooth operation.

2. impeller pump : Connected to the engine, it spins and generates fluid movement within the
converter.

3. stator (one way) : It redirects the fluid with the direction of the pump and provide to multiply
torque when there is a substantial difference between input and output rotational speed

4. turbine :Connected to the transmission input shaft, it receives fluid from the impeller and transfers
torque to the transmission

5. lock up clutch in modern car : Engages at higher speeds to mechanically lock the impeller and
turbine for more efficient power transfer

Figure.4

3
2. Describe the method of operation of each type and compare them in terms of torque
and speed ratios.

 Fluid coupling Operation

1. As the prime mover moves, it rotates the impeller of the coupling. The impeller acts as a centrifugal
pump and throws the fluid outward and directs it towards the turbine blade.

2. As the high moving fluid strikes the turbine blades, it also starts rotating, after striking on the blades,
the direction of the fluid is changed and it is directed towards the impeller again. The blades of the
turbine are designed in such a way that it can easily change the direction of the fluid. It is the changing
of direction of the fluid that makes the turbine to rotate.

3. As the impeller speed increases, the speed of the turbine also increases. After some time the speed of
both the impeller and the turbine becomes equal. In this way, power is transmitted from one shaft to
another by the use of fluid coupling.In same way torque converter works but the difference is that it has
stator placed in between impeller and turbine for torque multiplication

 Torque converter Operation :

The liquid flowing from the pump impeller to turbine runner exerts a torque on the stationary guide
vanes which changes the directions of liquied,thereby making possible the transformation of torque and
speed.Thus by suitably designing the stationary guide vanes the torque transmitted to the driving unit
can be either increase or decrease. its ability to multiply torque five times the torque available at the
driving shaft with an efficiency of about 90%

In terms of Fluid coupling torque converter

Torque -torque is approximately equal to -As the speed ratio approaches 90%, torque
input torque 1:1 when the turbine multiplication becomes minimal and a torque converter
speed is about 90 per cent of the functions like a fluid coupling.
pump speed. -The torque convertor increases the torque in a ratio of
about 2:1 / 2.5:1 to 3:1.
- As the speed increases, the torque multiplication
decreases, eventually approaching a 1:1 ratio.

Figure.5
speed -Input speed (engine) = Output -Depending on the load and throttle input. Example:
ratios speed (transmission) speed ratio Input speed (engine) bigger than Output speed
close to 1:1 (transmission) at low output speeds
-Stall Speed:the speed ratio is essentially 0:1.As the load
on the torque converter decreases, the speed ratio
gradually increases
4
3. Explain the function of lockup clutch and in which coupling is used? Also, Explain its
operating principle.

 function of lockup clutch

1. Elimination of Slippage : where allows for a direct transfer of power without energy losses
associated with fluid coupling.When the lockup clutch is engaged, it mechanically connects the torque
converter's impeller (driven by the engine) and turbine (connected to the transmission).
2. improve efficiency : by eliminating the energy losses that occur during fluid coupling. By creating a
direct mechanical connection, the lockup clutch reduces power loss, heat generation, and fuel
consumption during higher-speed where achieves a 1:1 speed ratio between the engine and the
transmission output shaft
3.improve fuel economy approximately 4% to 5% during freeway cruising
4. improved acceleration, smoother shifts, and better overall vehicle performance

 used in : Torque converter

Figure.6

 lockup clutch Operation :

1. Engagement :
The engagement of the lockup clutch is controlled by the vehicle's electronic control unit (ECU) it
sends a signal to the lockup solenoid, which controls the flow of transmission fluid to the lockup
clutch. and directs transmission fluid to the lockup clutch, creating hydraulic pressure that applies the
clutch plates together then lockup clutch plates engage,. As a result, the lock-up clutch and converter
case rotate together.This creates a direct mechanical link,bypassing the fluid coupling and allowing for
a solid power transfer.

5
2. Disengagement:
The ECU constantly monitors the driving conditions, and when it determines that lockup clutch
disengagement is necessary, it sends a signal to the lockup solenoid to release the hydraulic
pressure.the flow of transmission fluid to the lockup clutch is stopped, and the hydraulic pressure is
released ,the lockup clutch plates disengage, separating the impeller and the turbine. This restores the
fluid coupling action of the torque converter, allowing for slippage and torque multiplication during
low-speed or transitional driving conditions.

Figure.7

6
4. Discuss the different problems caused by torque converter

problems Symptoms causes

Slippage : refers to the condition  reduced power transfer  worn friction
where the torque converter does  decreased efficiency materials of lock up
not achieve a solid mechanical  increased heat generation clutch
connection between the impeller  poor acceleration  damaged clutch
and the turbine.  higher fuel consumption plates
 noises comes from the  insufficient hydraulic
transmission pressure
Overheating : It may result in  If your car transmission  torque converter is
reduced torque converter keeps overheating, you may failing
efficiency, increased transmission also notice your transmission  prolonged slippage
fluid temperatures, and potential starts to go into fail and stay  wear of internal
damage to seals and clutch in one gear and not shift at all components due to
materials  The end result is the torque nsufficient cooling,
converter isn't able to transfer or fluid
that power completely and contamination
efficiently from the engine to
the transmission
Fluid Contamination : torque  decreased efficiency  worn seals
converter relies on transmission  noises comes from the  deteriorated
fluid to operate correctly. If the transmission transmission fluid
fluid becomes contaminated,  increased heat generation  external factors like
anything that uses and relies on  wear and damage to the water intrusion
the fluid can be damaged internal components  metal particles
Corroded
Torque Seal Damage : the  Fluid leaks  External factors such
torque converter needs to transfer  noises comes from the impact road hazards
the power from the engine to the transmission  Fluid contamination
transmission by fluid. This will  increased heat generation  Excessive Heat
cause damage to both the  wear and damage to the  Improper Installation
transmission and the converter internal components

7
5. You have checked the coupling in the service center store and find that there is no
coupling with same dimensions. Evaluate the effect of changing the torque converter with
another one with different diameter (smaller or larger) on vehicle performance.
- The outside diameter of a torque converter and the angle of its stator blades determine the stall speed
of the converter. When both a small and large diameter converter share the same stator blade angle and
turn at the same speed, the smaller converter creates less centrifugal force to move the fluid inside.

Effect on Larger Diameter Torque Converter Smaller Diameter Torque Converter

vehicle -reduce stall speed, multiplies torque at -increase stall speed, multiplies torque at
performance lower engine speeds, higher engine speeds,
-power transfer from the engine to the -the engine will need to rev higher before
transmission will occur at lower engine power is transmitted, resulting in a higher
RPMs thus improved launch performance stall speed. thus lead to improved launch
and greater fuel economy and lowest performance and quicker acceleration
possible exhaust emissions leading to better fuel economy
Task No.02

1. Write two different types of compound planetary gear sets used in automatic
transmission? Illustrate the construction of each type. Also, explain the difference between
them.
1. Simpson Gear Construction :
- Consist of (one sun gear, two sets of planet gears, an two outer ring gear, and a two carrier assembly)
- The carrier assembly holds two sets of planet gears: one set meshes with the sun gear, while the other
set meshes with the outer ring gear.

Figure.8

8
2. Ravigneaux Gear Construction :
- Consist of (two sun gears : one small and one large, two sets of planet gears three long pinions and
three short pinions,common planetary carrier,A single ring gear surrounds the complete assembly)
- The small sun gear is meshed with the short planetary pinion gears. These short pinions act as idler
gears to drive the long planetary pinion gears. The long planetary pinion gears mesh with the large sun
gear and the ring gear.

Figure.9

In terms of difference between them

Sun Gears The Ravigneaux gear set has two sun gears (one small and one large)
Simpson gear set has one sun gear
Plant Gears The Ravigneaux gear set has (two sets of planet gears three long pinions
and three short pinions)
two sets of planet gears (front / rear)
Configuration In the Ravigneaux gear set, one set of planet gears meshes with the outer
ring gear, while the other set meshes with the sun gears
In the Simpson gear set, one set of planet gears meshes with the sun gear,
while the other set meshes with the outer ring gear.
Advantages The Ravigneaux is very compact. It can carry large amounts of torque
because of the great amount of tooth contact.
Output Shaft In the Ravigneaux gear set, the output shaft is connected to one of the sun
Connection gears
In the Simpson gear set, the output shaft is connected to the carrier
assembly
Complexity the Simpson gear is more complex
the Ravigneaux gear is more compact

9
2. For a simple planetary gear sets shown above, calculate the reduction ratios for the
first, reverse gears and direct drive. Also, state the condition of each gear for actuating the
first and reverse gear.

1. First gear :
Ring : held ( = 0)
Sun gear : input
Carrier : output
=2
=2 +2 =4
+ =( + )
=0
=( + )

= = = =3

2. reverse gears :
Ring : output
Sun gear : input
Carrier : held ( = 0)
+ =( + )

= = = =
10
 3. direct drive :

Sun gear: input

Carrier & Ring : held ( = )=0

3. Present as a team (maximum 5 students) a presentation showing the procedures for

disassembling the automatic transmission out from the vehicle and disassemble of the gear
sets.

IN WORKSHOP

11
4. If you found that the planet and sun gears are damaged and need replacement. You
checked the store, and the only available sun is smaller than the original by 20%. Discuss
the effect of changing the planetary gear on vehicle performance.

1.With a smaller sun gear, the gear ratio would be altered, potentially affecting the overall
performance characteristics of the transmission

2. Changing the size of the sun gear may affect the gear shift points, which may cause the
transmission to change gears too early or too late, thus affecting acceleration.and Double
torque is less

3. With a smaller sun gear, the engine may operate at different RPM ranges, potentially
impacting fuel consumption

 References
1. file:///E:/new%20cairo%20technology/%D8%AA%D8%A7%D9%84%D8%AA%
D9%87%20%D8%AC%D8%A7%D9%85%D8%B9%D9%87/%D8%A7%D9%8
4%D8%AA%D8%B1%D9%85%20%D8%A7%D9%84%D8%AA%D8%A7%D9
%86%D9%8A/automatic%20transmission/auto%202.pdf
2. Automatic-Transmission-gear ratio system.pdf

12