COMPARISON MANUAL AND CVT TRANSMISSION FOR A CAR UNDER 1 LITER ENGINE MOHAMMAD AZLAN BIN ABDUL AZIZ Report submitted in partial fulfilment of the requirements for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG DECEMBER 2010
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COMPARISON MANUAL AND CVT TRANSMISSION FOR A CAR UNDER 1
LITER ENGINE
MOHAMMAD AZLAN BIN ABDUL AZIZ
Report submitted in partial fulfilment of the requirements
for the award of the degree of
Bachelor of Mechanical Engineering with Automotive Engineering.
Faculty of Mechanical Engineering
UNIVERSITI MALAYSIA PAHANG
DECEMBER 2010
UNIVERSITI MALAYSIA PAHANG
FACULTY OF MECHANICAL ENGINEERING
I certify that the project entitled “Comparison Manual and CVT Transmission for a Car
Under 1 Liter Engine “is written by Mohammad Azlan bin Abdul Aziz. I have examined the
final copy of this project and in my opinion; it is fully adequate in terms of scope and quality
for the award of the degree of Bachelor of Engineering. I herewith recommend that it be
accepted in partial fulfilment of the requirements for the degree of Bachelor of Mechanical
Engineering with Automotive Engineering.
Tuan Haji Amirruddin Bin Abdul Kadir
Examiner Signature
ii
SUPERVISOR’S DECLARATION
I hereby declare that I have checked this project and in my opinion, this project is
adequate in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering with Automotive Engineering.
Signature ---------------------------------
Name of Supervisor: DR SUGENG ARIYONO
Position: LECTURER OF MECHANICAL ENGINEERING
Date: 6 DECEMBER 2010
iii
STUDENT’S DECLARATION
I hereby declare that the work in this project is my own except for quotations and
summaries which have been duly acknowledged. The project has not been accepted for
any degree and is not concurrently submitted for award of other degree.
Signature ..................................
Name: MOHAMMAD AZLAN BIN ABDUL AZIZ
ID Number: MH07067
Date: 6 DECEMBER 2010
v
ACKNOWLEDGEMENTS
I am greatly grateful to ALLAH SWT on His blessing for making this project
successful.
I am grateful and would like to express my sincere gratitude to my supervisor Dr
Sugeng Ariyono for his brilliant ideas, invaluable guidance, continuous encouragement
and constant support in making this research possible. He has always impressed me with
his outstanding professional conduct, his strong conviction for science, and his belief
that a Degree program is only a start of a life-long learning experience. I appreciate his
consistent support from the first day I applied to graduate program to these concluding
moments. I also sincerely thanks for the time spent proofreading and correcting my
many mistakes.
My sincere thanks go to all my mates and members of the staff of the
Mechanical Engineering Department, UMP, who helped me in many ways and made
my stay at UMP pleasant and unforgettable. Many special thanks go to instructor
engineer and assistance instructor for their excellent co-operation, inspirations and
supports during this study.
I acknowledge my sincere indebtedness and gratitude to my parents for their
love, dream and sacrifice throughout my life. I cannot find the appropriate words that
could properly describe my appreciation for their devotion, support and faith in my
ability to attain my goals. Special thanks should be given to my committee members. I
would like to acknowledge their comments and suggestions, which was crucial for the
successful completion of this study.
vi
ABSTRACT
This thesis presented about comparison manual and CVT transmission. This thesis deals
with analysis on performance of transmission for a car under 1 liter engine. The
objective of this thesis is to compare the performance of transmission between manual
transmission and CVT transmission. Besides that, the purpose of this thesis is to analyze
the performance of the Manual Transmission and the CVT Transmission for a car under
1 liter engine. This thesis also purposes to study the suitability using CVT for a car
under 1 liter engine. Manual transmission and CVT transmission have their own
advantages and one of that is better in their performance. In performance, there are
many category that compared consist of power available, tractive force, fuel
consumption and many more. The data used for the analysis is obtained through
calculation using specification data that has got from brochure which is downloaded
from Toyota’s official web because this model only market at Europe. This model
fulfilled this project because it had two types of transmission which is CVT
transmission and Manual Transmission. The post-processing method was performed
using manual calculation with certain engineering formula and graph is plotted by using
assistance software such as Microsoft Excel. The post-processing method to analyze the
performance of transmission was performed using the SAE definition. From the results,
it is observed that the performance of CVT is better than manual transmission. It is also
observed that Manual Transmission is better than CVT in term of fuel consumption for
a car under 1 liter engine. Besides that, CVT are suitable to use for a car under 1 liter
engine because it gives more power and ride comfort ability. Future work, this
comparison between manual transmission and CVT must do in experimental or
simulation since CVT technology just begun to blossom to Malaysia. There are many
factors that required to do research by experimental especially in transmission’s
performance and driveability.
vii
ABSTRAK
Tesis ini membentangkan perbandingan tentang penghantaran manual dan penghantaran
CVT. Tesis ini berkaitan dengan analisis terhadap prestasi penghantaran untuk kereta
berenjin di bawah 1 liter. Tujuan dari tesis ini adalah untuk membandingkan prestasi
penghantaran antara transmisi manual dan transmisi CVT. Selain itu, tujuan dari tesis
ini adalah untuk menganalisis prestasi penghantan Manual dan penghantaran CVT
untuk kereta berenjin di bawah 1 liter. Tesis ini juga bertujuan untuk mempelajari
kesesuaian menggunakan CVT untuk kereta berenjin di bawah 1 liter. Penghantaran
manual dan penghantaran CVT memiliki kelebihan mereka sendiri dan salah satu yang
lebih baik dalam prestasi mereka. Dalam prestasi, ada banyak kategori yang
dibandingkan terdiri daripada kuasa, gaya traksi, penggunaan bahan bakar dan banyak
lagi. Data yang digunakan untuk analisis diperolehi melalui perhitungan dengan
menggunakan data spesifikasi yang telah didapati dari brosur yang dimuat turun dari
Laman web rasmi Toyota kerana model in hanya berada di pasaran Eropah. Model ini
memenuhi projek ini kerana mempunyai dua jenis penghantaran iaitu CVT
penghantaran dan Transmisi Manual. Kaedah pemprosesan dilakukan menggunakan
perhitungan manual dengan rumus tertentu dan graf diplot dengan menggunakan
software bantuan seperti Microsoft Excel. Kaedah yang digunakan untuk menganalisis
prestasi penghantaran dilakukan dengan menggunakan definisi SAE. Dari hasil,
diperhatikan bahawa prestasi CVT lebih baik daripada penghantaran manual. Hal ini
juga didapati bahawa Transmisi Manual lebih baik dari CVT dalam hal penggunaan
bahan bakar untuk kereta berenjin di bawah 1 liter. Selain itu, CVT sesuai digunakan
untuk kereta berenjin di bawah 1 liter kerana memberikan kekuatan lebih dan
keselesaan semasa pemanduan. Pada masa datang, perbandingan antara penghantaran
manual dan CVT harus dilakukan dalam eksperimen atau simulasi kerana teknologi
CVT baru sahaja mula berkembang di Malaysia. Ada banyak faktor yang diperlukan
untuk dilakukan kajian secara eksperimen terutama dalam prestasi penghantaran dan
kebolehan pemanduan.
viii
TABLE OF CONTENTS
Page
SUPERVISOR’S DECLARATION ii
STUDENT’S DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENT v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF SYMBOLS xiv
LIST OF ABBREVIATIONS xv
CHAPTER 1 INTRODUCTION OF THE PROJECT 1
1.1 Introduction.
1.2 Problem Statement.
1.3 Objectives.
1.4 Project Scopes
1.5 Methodology and Flow Chart
1.6 Structure of Thesis
1
2
2
3
3
5
CHAPTER 2 LITERATURE REVIEW 6
2.1 History and Development of Drivetrain.
2.2 Continuously Variable Transmission.
2.2.1 Introduction of CVT
2.2.2 CVT’s Basic Principle.
2.2.3 Types of CVT.
2.2.4 Epycyclic Gear Train Construction and Description
2.2.4 Advantages and Disadvantages of the CVT
6
8
8
9
10
14
15
2.3 Manual Transmission
2.2.1 Introduction of Manual Transmission
2.2.2 Manual Transmission’s Basic Principle.
17
17
19
ix
2.2.3 Advantages and Disadvantages of Manual Transmission
2.4 General of Toyota iQ
2.5 Summary
22
24
25
CHAPTER 3 VEHICLE DYNAMICS PERFORMANCE 26
3.1 Introduction
3.2 Vehicle Resistance and Road Disturbances
3.2.1 Aerodynamics Resistance.
3.2.2 Rolling Resistance.
3.2.3 Gravitional Resistance.
3.2.4 Acceleration Resistance
3.3 Performance of Transmission.
3.3.1 TractiveEffort-Speed
3.3.2 Power Available
3.3.3 Engine-Vehicle Speed
3.3.4 Fuel consumption
3.4 Parameter of Toyota iQ 1.0 Liter
3.5 Summary
26
27
28
29
29
30
30
30
32
34
35
35
36
CHAPTER 4 RESULT AND DISCUSSION. 37
4.1 Introduction
4.2 Performance of Power-Torque Engine Toyota 1.0 Liter
4.3 Example of Calculation
4.3.1 Power Available
4.3.2 Tractive Effort
4.3.3 Road Wheel Speed
4.4 Vehicle Performances Graph and Bar Chart
4.4.1 Power Available
4.4.2 Tractive Effort
4.4.3 Road Wheel Speed
4.4.4 Fuel Consumption
4.4.5 Carbon Dioxide Emission
4.4.6 Peak up of vehicle
4.5 Discussion
37
38
39
39
41
41
42
42
43
45
46
47
48
49
4.5.1 Comparison in Maintenance and Price
4.5.2 Compatibility of CVT for A Car under 1 Liter Engine
49
51
4.6 Summary 52
x
CHAPTER 5 CONCLUSION AND RECOMMENDATION 53
5.1 Conclusion
5.2 Recommendation
53
54
REFERENCES 55
APPENDICES 58
A1 Gantt Chart for FYP 1 58
A2 Gantt Chart for FYP 2 59
B1
B2
Technical Data For Toyota iQ 1.0 Liter (CVT)
Technical Data For Toyota iQ 1.0 Liter (Manual
Transmission)
60
61
C Table of Power and Torque engine’s performance 62
D1 Table of Tractive Effort versus Vehicle Speed
(ManualTransmission)
63
D2 Table of Tractive Effort versus Vehicle Speed (CVT) 64
E1 Table of Power Available for Manual Transmission 64
E2 Table of Power Available for CVT 66
F1 Table of Road Wheel Speed for Manual Transmission 67
F2 Table of Road Wheel Speed for CVT 68
G Table of Fuel Consumption 69
Table of CO2 emission 69
Table of Peak Up of Vehicle 69
xi
LIST OF TABLES
Table No. Title Page
3.1 The parameters of Toyota iQ 1.0 liter Specification 35
6.1 Technical Data for Toyota iQ 1.0 Liter (CVT) 60
6.2 Technical Data for Toyota iQ 1.0 Liter (Manual Transmission) 61
6.3 Table of Power and Torque engine’s performance 62
6.4 Table of Tractive Effort versus Vehicle Speed for Manual
Transmission
63
6.5 Table of Tractive Effort versus Vehicle Speed for CVT 64
6.6 Table of Power Available for Manual Transmission 65
6.7 Table of Power Available for CVT 66
6.8 Table of Road Wheel Speed for Manual Transmission 67
6.9 Table of Road Wheel Speed for CVT 68
6.10 Table of Fuel Consumption 69
6.11 Table of CO2 emission 69
6.12 Table of Peak up of Vehicle 69
xii
LIST OF FIGURES
Figure No. Title Page
1.1 Flow Chart of Project 4
2.1 CVT Transmission 9
2.2 CVT’s basic principle 10
2.2 Variable- Diameter Pulley CVT 11
2.3 Torodial CVT 11
2.4 Ratcheting CVT 12
2.5 Hydrostatic Transmission 13
2.6 Manual Transmission. 17
2.7 Manual Transmission Operation 19
2.8 Toyota iQ 1.0 liter. 24
3.1 Force acting on a vehicle 28
3.2 Tractive effort speed characteristic for CVT 30
3.3 Tractive effort speed characteristic for manual transmission 31
3.4 Graph engine power-road speed 33
3.5 Graph engine power-road speed CVT 33
3.6 Engine speed-vehicle speed curve for manual transmission 34
4.1 Graph Performance Engine for Toyota iQ 1000 cc 38
4.2 (a) Graph of Power versus Vehicle Speed for Manual Transmission. 42
4.2 (b) Graph of Power versus Vehicle Speed for CVT. 42
4.3(a) Graph of Tractive Effort versus Vehicle Speed for Manual
Transmission
43
4.3(b) Graph of Tractive Effort versus Vehicle Speed for CVT 44
xiii
4.4(a) Graph of Engine Speed versus Vehicle Speed for Manual
Transmission
45
4.4(b) Graph of Engine speed versus Vehicle speed for CVT 45
4.5 Bar chart of Fuel consumption of Manual transmission and CVT 46
4.6 Bar chart of CO2 of Manual transmission and CVT 47
4.7 Bar chart of Peak Up of Manual transmission and CVT 48
6.1 Gantt Chart FYP 1 58
6.2 Gantt Chart FYP 2 59
xiv
LIST OF SYMBOLS
A Cross-section area
Cd Aerodynamic drag coefficient
g Gravitational force
G Overall drive ratio
Gfd Final gear ratio
m Mass of vehicle
eN Engine speed
P Power available
reqP Power required
Ra Aerodynamic drag resistance
Rr Rolling resistance
Rg Gravitational resistance
Ri Acceleration resistance
r The radius of the tyre
Te Engine Torque
wT External torque
TFw Tractive effort
v vehicle speed
v Acceleration in the direction of motion of the vehicle
Air density
Road slope
Efficiency
xv
LIST OF ABBREVIATIONS
CVT Continuously Variable Transmission
FYP Final Year Project
IC Internal combustion
RPM Revolution per Minute
RWS Road wheel speed
SAE Society of Automotive Engineers
VDP Variable-Diameter Pulley
CHAPTER 1
INTRODUCTION OF THE PROJECT
1.1 INTRODUCTION
Transmission is one of part that is important after engine part. It can assume as the
heart of the drivetrain. It is because gasoline engines develop their torque over a very
narrow speed range, several gears are needed to reach useful road speeds. A manual
transmission is a type of transmission uses a driver operated clutch, typical operated by
a pedal or lever, for regulating torque transfer from internal combustion and gear shift,
either operated by hand. The CVT is a transmission which can change steplessly
through an infinite number of effective gear ratios between maximum and minimum
values.
There has been a clear trend in the automotive industry in recent years toward
increased ride comfort and fuel efficiency. As power transmission unit, transmission
plays an important role in vehicle performance and fuel economy (Lechner, 1999).
Manual transmission have an overall efficiency of 96.2 percents, this is the highest
efficiency value for any type of transmission. Current production automatics have been
improved to provide an efficiency of not more than 86.3 percents and CVT’s have an
overall efficiency of 84.6 percents. However, the major advantage of CVT is that it
allows the engine to operate in the most fuel-efficient manner (Klunger, 1999).
In order to seek the best performances, a research will be carried out to the car
under 1 liter engine. Toyota iQ 1000cc is selected in this study because only this model
which have manual and continuously variable transmission for a car under 1 liter
engine. A calculation was required to estimate which one have better performance