Energy efficiency and reliability of automotive automatic transmission systems

For those who buy a car, reliability and fuel efficiency are two important considerations after price. There is no doubt that the most terrible thing for new car owners is that the car is turned off on the way. In addition, car owners also expect the car to be as durable as possible. At the same time, as global fuel prices continue to rise, so that car owners pay more attention to fuel efficiency, and hope to minimize carbon dioxide emissions.

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The powertrain of a car includes an internal combustion engine, a multi-gear ratio transmission, and wheels. Engine torque and speed are converted in the transmission due to the traction power required by the vehicle. In addition, the car's transmission can also control the direction of rotation of the wheel.

Transmissions are generally divided into manual and automatic transmission. Automatic shifting automatically controls the selection of the friction unit, gear ratio and shifting.

Automatic shifting uses hydraulic oil for lubrication and freezing. Hydraulic oil is a very special liquid that can operate in any harsh environment. The main functions of Automatic Transmission Fluid (ATF) are:

* Transfer power from the engine torque converter to the power transmission;

* absorbs the heat generated by the torque converter and transfers it to the freezer at the front end of the car;

* As a clutch friction refrigerant, it absorbs and dissipates the heat generated by the clutch or belt engagement;

* Transfers liquid pressure through a complex hydraulic control system that uses valves, servos, pumps, clutch master cylinders, hydraulic lines and piping to control;

* As a lubricant and refrigerant for planetary gears, bearings, servos, clutches and bushings.

Cold start

The viscosity of automatic transmission fluids at operating temperatures (approximately 90 ° C / 195 ° F) is generally very low. However, if the oil temperature is too low (for example, below 0 ° C / 30 ° F), the viscosity will increase greatly, resulting in a very high drag torque. As a result, the gears are difficult to engage because the synchronous devices therein generally cannot cope with such high torque forces. If the gear cannot be engaged or shifted, the car will not start. For this reason, the “Cold Start” program is activated in response to oil temperature to ensure that at least one gear can be successfully engaged.

Warm car process

When the car starts to drive, the hydraulic oil temperature will only rise slowly, unless it requires significant acceleration or dragging of heavy objects (such as trailers), which means that the drag torque will also rise slowly. If the car is in a high-torque environment for a long time, the synchronous device will be overloaded and damaged.

Adding some losses to the gearbox, shifting the shift point to a higher speed valve and improving the quality of the gearbox lubricants all accelerate the warm-up process. As a result, the engine, gearbox and catalyst can reach the optimum operating temperature faster. The faster the transmission reaches the optimum operating temperature, the faster the gear shifting procedure for fuel consumption can be started.

The shifting components of the gears are controlled via hydraulic or electronically actuated valves. The starting of these shifting units is significantly affected by temperature because the viscosity of the automatic transmission oil rises significantly with temperature. Temperature can affect the extent and time characteristics of the applied pressure. Once the automatic transmission oil gets hot, the magnitude of the temperature change will increase, so when setting the standard shifting oil pressure, the problem of oil temperature must be considered.

Running at high temperatures

There is no doubt that automatic transmission fluids are susceptible to temperature, but they react much more to high temperatures than to low temperatures. The process of automatic shifting produces a lot of friction, and these frictions generate a lot of heat. The liquid is constantly agitated in the torque converter and pumped through the metering orifice and hydraulic circuit. Whenever a shift is shifted, the clutch assembly produces heat that is beyond the tank oil. The greater the load on the transmission, the greater the heat generated and the tank oil becomes hotter.

Typical conventional transmission oil temperatures allow for temperatures of up to 80 to 100 ° C or 175 to 212 ° F, while special gearbox oil temperatures can be as high as 110 to 130 ° C or 230 to 265 ° F. However, today's advanced cars have gearbox oil temperatures of up to 120 to 150 ° C or 250 to 300 ° F, while for heavy-duty trucks such as 18-wheel freight trains, even in hot weather, the oil temperature is even It can be as high as 160 to 170 ° C or 320 to 340 ° F. Such high oil temperatures can cause damage to the tank oil and shifting components.

Transmission oil working life

In high temperature environments, the operating life of transmission oils is reduced. Once the temperature exceeds the normal operating level (above 90 ° C / 195 ° F), the oxidation rate of the lubricant will increase, resulting in a shortened effective life. Based on the 娒 specification, when the temperature exceeds the normal operating temperature of 12 ° C / 20 ° F, the expected working life of the tank oil will be halved.

Wear of the working surface

In addition to the above effects, high temperatures can also pose a threat to the working surface of the active components of the transmission. The reason is that when the temperature is getting higher and higher, the heat that is taken away from the friction zone is less, so the chance of the gear being stuck is greatly increased. When the temperature rises above 175 ° C / 350 ° F, the hardness of the steel will decrease. If we consider that the temperature of the gear and clutch working surfaces is usually higher than the oil temperature, we can expect the hardness of the gear to decrease with the oil temperature, even if the oil temperature is lower than 175 ° C / 350 ° F.

Rubber seals and circulation pipes

Rubber seals and refrigerant flow lines are extremely sensitive to high oil temperatures. When a rubber seal encounters a high temperature, it hardens and becomes weak, resulting in a significant reduction in its working life and reliability. When the car cannot be fitted with a metal refrigerant pipe, a refrigerant flow pipe made of PA12 plastic (amide 12 or nylon 12) is used, which connects the torque converter output port to the refrigerant. At high temperatures (above 175 ° C / 350 ° F), the plastic freezing pipe may buck, causing the tank oil to flow upward and disable the refrigerant.

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