SAE AE-29-2012 Design Practices Passenger Car Automatic Transmissions (Fourth Edition To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、AE-29 Design Practices Passenger Car Automatic T ransmissions Design Practices Passenger Car Automatic T ransmissions Design Practices Passenger Car Automatic T ransmissions Fourth Edition Fourth Edition Fourth Edition Since the mid Twentieth Century, automatic transmissions have benefited drivers b

2、y automatically changing gear ratios, freeing the driver from having to shift gears manually. The automatic trans- missions primary job is to allow the engine to operate in its speed range while providing a wide range of output (vehicle) speeds automatically. The transmission uses gears to make more

3、 effective use of the engines torque and to keep the engine operating at an appropriate speed. For nearly half a century, Design Practices: Passenger Car Automatic Transmissions has been the “go-to” handbook of design consider- ations for automatic transmission industry engineers of all levels of ex

4、perience. This latest 4th edition represents a major overhaul from the prior edition and is arguably the most significant update in its long history. In summary, this team has put together the most definitive handbook for automatic transmission design practices available today. Virtually all existin

5、g chapters have been updated and improved with the latest state-of-the-art information and many have been significantly expanded with more detail and design consideration updates; most notably for torque converters and start devices, gears/splines/chains, bearings, wet friction, one-way clutch, pump

6、s, seals and gaskets, and controls. In fact, all new chapters have been added, including state-of-the-art information on: lubrication; trans- mission fluids; filtration, and contamination control. Finally, details about the latest transmission technologiesincluding dual clutch and continuously varia

7、ble transmissionshave been added. This edition is made possible in part through sponsorship by The Lubrizol Corporation. About the authors This complete overhaul was an exhaustive effort by many of the industrys most knowledgeable experts, developed over a signifi- cant period of time. This required

8、 major commitment from both individual chapter authors and also the members of SAEs Auto- matic Transmission phone 877-606-7323 (U.S. and Canada only) or 724-776-4970 (outside U.S. and Canada); fax 724-776-0790; email CustomerServicesae.org; website http:/books.sae.org AE-29_Ch00_FM.indd 2 4/10/12 1

9、2:00:13 PMDesign Practices: Passenger Car Automatic Transmissions fourth edition AE-29 Prepared under the auspices of SAE Transmission/Axle/Driveline Forum Committee First edition published 1962 Second edition published 1973 Revised second edition published 1988 Third edition published 1994 Fourth e

10、dition published 2012 Warrendale, Pennsylvania USA Sponsored by AE-29_Ch00_FM.indd 3 4/10/12 12:00:14 PM Copyright 2012 SAE International. eISBN: 978-0-7680-7531-1400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-49

11、70 (outside USA) Fax: 724-776-0790 This edition is made possible in part by sponsorship of The Lubrizol Corporation. Copyright 2012 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any

12、means without the prior written permission of SAE. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; email: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765. ISBN 978-0-7680-1125-8 SAE Order Number AE-29 DOI 10.4271/AE-29 L

13、ibrary of Congress Cataloging-in-Publication Data Design practicespassenger car automatic transmissions. 4th ed. p. cm. “SAE Order Number AE-29. ” “Prepared under the auspices of SAE Transmission/Axle/Driveline Forum Committee. ” Includes bibliographical references. ISBN 978-0-7680-1125-8 1. Automob

14、ilesTransmission devices, AutomaticDesign and construction. I. SAE Transmission/Axle/Driveline Forum Committee. II. Title: Passenger car automatic transmissions. TL263.D47 2012 629.2 446dc23 2011044834 Information contained in this work has been obtained by SAE International from sources believed to

15、 be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is pu

16、blished with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. To purchase bulk quantities, pl

17、ease contact: SAE Customer Service Email: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-0790 Visit the SAE International Bookstore at http:/books.sae.org AE-29_Ch00_FM.indd 4 4/10/12 12:00:14 PMv Contents Foreword xi Preface to the Fourth

18、Edition xvChapter 1 Transmission Cases and Parking Mechanisms 1-1 1.1 Transmission Cases 1-1 C. E. Shellman with updates by Ernest DeVincent 1.2 Parking Mechanisms 1-10 A. GuptaChapter 2 Torque Converters and Start Devices 2-1 2.1 Fluid Couplings 2-1 J. W . Qualman and E. L. Egbert 2.2 Multiturbine

19、Torque Converters 2-17 F. H. Walker 2.3 Application of Hydrodynamic Drive Units to Passenger 2-31 Car Automatic Transmissions E. W . Upton 2.4 Design of Single-Stage, Three-Element Torque Converter 2-49 V . J. Jandasek 2.5 Technology Needs for the Automotive Torque Converter Part 1; Internal Flow, B

20、lade Design, and Performance 2-70 Robert R. By and John E. Mahoney with updates by Thomas G. Brand 2.6 An Experimental Analysis of Fluid Flow in a Torque Converter 2-85 Akio Numazawa, Fumihiro Ushijima, Kagenori Fukumura, and Tomo-o-Ishihara 2.7 A Loss Analysis Design Approach to Improving Torque Co

21、nverter Performance 2-93 Masaaki Kubo and Eiji Ejiri 2.8 The Chrysler Torque Converter Lock-Up Clutch 2-103 A. P . Bloomquist and S. A. Mikel with updates by Thomas G. Brand 2.9 Control Technology of Minimal Slip-Type Torque Converter Clutch 2-117 Takeo Hiramatsu, Takao Akagi, and Haruaki Yoneda AE-

22、29_Ch00_FM.indd 5 4/13/12 11:02:26 AMContents vi 2.10 Dynamic Behavior of a Torque Converter with Centrifugal Bypass Clutch 2-125 M. C. Tsangarides and W . E. ToblerChapter 3 Gears, Splines, and Chains 3-1 3.1 Design of Planetary Gear Trains 3-2 O. K. Kelley, with updates by E. L. Jones and M. T. Be

23、rhan 3.2 Transmission Gear Design for Strength and Surface Durability 3-8 E. L. Jones, with updates by E. L. Jones, M. T. Berhan, H. Dourra, and M. B. Leising 3.3 Manufacturing Considerations Affecting Transmission Gear Design 3-17 A. Hardy, with updates by R. J. Garrett 3.4 Gear Design for Noise Re

24、duction 3-25 W . D. Route, with updates by E. L. Jones, D. K. Ducklow, and M. T. Berhan 3.5 The Lever Analogy 3-40 H. L. Benford and M. B. Leising, with updates by M. B. Leising, H. Dourra, and M. T. Berhan 3.6 Design Practice for Automotive Driveline Splines and Serrations 3-50 W . B. McCardell, J.

25、 Mahoney, and D. Cameron, with updates by D. Cameron, E. L. Jones, and C. E. Dieterle 3.7 The Effective Fit Concept of Involute Splines and Inspection 3-68 L. DeVos, with updates by C. E. Dieterle and M. T. Berhan 3.8 Chain Drives in the Vehicle Powertrain 3-75 R. H. Mead, T. O. Morrow, and R. G. Yo

26、ung, Jr., with updates by M. Giovannini, R. G. Young, Jr., and M. T. Berhan 3.9 The Gemini Phased Chain System: A New Tool in Automotive Power Transmission 3-86 P . Mott and B. MartinChapter 4 Transmission Shaft Fatigue Design 4-1 Jeffrey K. Baran and Keith D. VanMaanen 4.1 Abstract 4-1 4.2 Introduc

27、tion 4-1 4.3 Nomenclature 4-2 4.4 Stress Calculation 4-2 4.5 Mass Relationship 4-3 4.6 Stress Concentration 4-3 4.7 Fatigue Properties (S-N Curve) 4-4 4.8 S-N Modifying Factors 4-5 AE-29_Ch00_FM.indd 6 4/10/12 12:00:14 PMContents vii 4.9 Loading Conditions 4-8 4.10 Combined Loading 4-8 4.11 Summary

28、4-11 4.12 References 4-11 4.13 Bibliography 4-11 4.14 Appendix AStress Concentration Factors 4-12 4.15 Appendix BExample Problems 4-18Chapter 5 Bearings 5-1 5.1 Design of Sleeve Bearings and Plain Thrust Washers 5-1 L. J. Pesek and W . E. Smith 5.2 Improving the Performance of Sleeve Bushings and Th

29、rust Washers 5-20 Brad L. Blaine and Christopher D. Wiegandt 5.3 The Use of Polymeric Thrust Elements in Powertrain Applications 5-26 R. G. Van Ryper 5.4 Rolling Element Bearings in Light Vehicle Automatic Transmissions 5-30 J. R. Hull, with updates by M. D. Myers 5.5 Design and Selection Factors fo

30、r Automatic Transaxle Tapered Roller Bearings 5-66 B. Martin and H. E. HillChapter 6 Friction Clutches 6-1 Robert C. Lam, Donn K. Fairbank, Keith Martin, Anthony J. Grzesiak, and Ted D. Snyder 6.1 Evolution of High-Energy Wet Friction Materials 6-2 6.2 Multi-Plate Friction Clutch 6-8 6.3 Bands 6-30

31、6.4 References 6-44Chapter 7 One-Way Clutches 7-1 Updated by John M. Kremer 7.1 Roller One-Way Clutches 7-2 7.2 Sprag One-Way Clutches 7-29 7.3 Pawl One-Way Clutches 7-49 AE-29_Ch00_FM.indd 7 4/10/12 12:00:14 PMContents viiiChapter 8 Automatic Transmission Controls 8-1 8.1 Introduction 8-2 Maurie Le

32、ising 8.2 Basic Shift ProcessesThe “How of Shifting” 8-2 M. Leising, Hussein Dourra, and Gang Chen 8.3 Shift Torque Analysis and the Continuously Variable Transmission 8-21 John E. Mahoney, Joel M. Maguire, and Shushan Bai 8.4 Shift Scheduling 8-26 Gang Chen and M. Leising 8.5 Transmission Control a

33、nd Types of Controls 8-40 Ronald Cowan, Charles Marshall, and M. Leising 8.6 Transmission Operational Features 8-44 Ronald Cowan, Charles Marshall, and M. Leising 8.7 Automatically Shifted Manual Transmissions 8-47 M. Leising, G. Chen, and H. Dourra 8.8 Control Components 8-65 John Titlow and Joseph

34、 Gierut 8.9 Development Technology 8-112 Hussein Dourra and Ronald CowanChapter 9 Automatic Transmission Pump Design 9-1 T. Roeber, M. Goulet, P . Dion, and Glenn B. Mann 9.1 Introduction 9-2 9.2 Types of Pumps 9-2 9.3 Types of Pumping Systems 9-2 9.4 Pump Design Guidelines 9-2 9.5 Survey of Transmi

35、ssion Pumps Currently in Use 9-11 9.6 What is Coming? 9-12 9.7 References 9-12Chapter 10 Seals and Gaskets 10-1 10.1 An Overview of Automatic Transmission Gaskets 10-2 Andrew F. Joseph, Jeff Nelson, and Lane Noble 10.2 An Overview of Transmission Radial Shaft Seals 10-13 Susan M. Bothe and Jeff Diet

36、erle AE-29_Ch00_FM.indd 8 4/10/12 12:00:14 PMContents ixChapter 11 Transmission Temperature Control and Lubrication 11-1 11.1 Introduction 11-1 Maurie Leising and Charles Redinger 11.2 Transmission Cooling Systems: Oil-to-Water Type 11-2 E. F. Farrell and T. M. Wang 11.3 Transmission Cooling Systems

37、: Air Cooling 11-10 M. G. Gabriel 11.4 Temperature Effects on Transmission Operation 11-20 T. J. Griffen 11.5 Temperature Control and Fuel Consumption 11-27 M. Leising and C. Redinger 11.6 Design and Validation of Automatic Transmission Lubrication Circuits 11-30 James T. GoodenChapter 12 ATF and Dr

38、iveline Fluids 12-1 Craig Tipton, Tze-Chi Jao, and Timothy Newcomb 12.1 Introduction 12-2 12.2 History of ATF Development 12-3 12.3 Key Physical Properties 12-5 12.4 Basestocks and Their Impact on Performance 12-8 12.5 Chemical Composition 12-10 12.6 Driveline Fluid Specifications 12-12 12.7 Evaluat

39、ing the Condition of Used Driveline Oils 12-18 12.8 Future Directions 12-23 12.9 Acknowledgments 12-23 12.10 Glossary of Terms 12-23 12.11 Key References 12-25Chapter 13 Metal Belt Drive Continuously Variable Ratio (CVT) Automatic Transmissions 13-1 Bruce Anderson 13.1 Introduction 13-1 13.2 Definit

40、ions 13-1 13.3 Application Considerations 13-2 13.4 Belt Design 13-5 AE-29_Ch00_FM.indd 9 4/10/12 12:00:14 PMContents x 13.5 Sheave Design 13-9 13.6 Variator System Considerations 13-11 13.7 Controls Design 13-18 13.8 Fluid 13-20 13.9 References 13-22 13.10 Applicable Publications 13-25 13.11 Append

41、ix ACVT Cross Sections 13-26 13.12 Appendix BTransmission Oil Tests 13-27Chapter 14 Automatic Transmission and Transaxle Filter Design 14-1 Larry Larkin, Andy Boast, Ibrahim Khalil, and Dan Haggard 14.1 Introduction 14-2 14.2 History 14-2 14.3 Transmission Filter Functions and Requirements 14-2 14.4 Filter Construction 14-5 14.5 Other Design Features That Can Be Built into the Transmission Sump Filter 14-10 14.6 Pressure-Side Filters 14-11 14.7 Transmission Sump Filter Testing 14-13 14.8 References 14-17 Index I-1 AE-29_Ch00_FM.indd 10 4/10/12 12:00:14 PM