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IRJET- Design and Analysis of Hydraulic Continuously Variable Transmission
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UNIT-III FMM. DIMENSIONAL ANALYSIS
UNIT-III FMM. DIMENSIONAL ANALYSIS
Roadmap to Membership of RICS - Pathways and Routes
Roadmap to Membership of RICS - Pathways and Routes
IRJET- Design and Analysis of Hydraulic Continuously Variable Transmission
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4516 DESIGN AND ANALYSIS OF HYDRAULIC CONTINUOUSLY VARIABLE TRANSMISSION Prof. R.K. Kawade1, Nikhil Patil2, Soham Mulik3, Sarvesh Patil4, Sagar Patil5 1Associate Professor, Dr. D. Y. Patil Institute of Technology, Pune, India. 2Student & Nigdi, pune 3Student & Pimpri, pune 4Student & Sangvi, pune 5Student & Akurdi, pune ----------------------------------------------------------------***--------------------------------------------------------------- Abstract - New regulations enacted by Indian Government for emission and fuel economy has encouraged the development of Continuously variable transmissionasa key technology for improving fuel efficiency with infinite gear ratio within specified range to attain optimum performance.CTV provides better gas mileage and acceleration, as it runs at the most efficient number revolutions per minute for given vehicle speed. As a continuously variable transmission development continues, the cost will reduce and performance will increase which will make the application of CVT technology more desirable. This project deals with the design of a ContinuouslyVariable Transmission with hydraulic means of actuation. The complete design and analysis of mechanical and hydraulic system is carried out using standard design procedures and software. Key Words: CVT, GearRatio, Vehicletransmission,hydraulic system 1. INTRODUCTION The Continuously Variable Transmission (CVT) permits engines to work potentiallybyfreelymovingthroughinfinite number of gear ratios to maximize performance and fuel economy. Solid gears are a thing of the past. The CVT uses the readings through multiple sensors to keep engine rotating at a constant RPM with two variable pulleys and a steel belt[2]. CVT is a compact system and as will be described, it doesnot require the use of bulky gear sets or as many components as in the conventional transmission. A CVT system consists of two conical pulleys and a belt. As the sheaves of each pulley move closer or farther away from one another, their conical shape causes the belt to rise and fall b/w the sheaves of each pulley.[5] Depending upon the state of the belt, the active gear ratio is changed. Instead of switching between bulky fixed gears which only supply a limited number of gear ratios, the CVT pulleys create a continuous exchange of gear ratios by constantly altering the state of the belt b/w the pulleys[3]. Few mechanisms that allow the control of the pulley diameter include engine speed, flyweights, 3 springs and a torque ramp. When all of these mechanisms work simultaneously, they act to increase vehicle speed smoothly while maintaining engine speed at a particular value. This feature of engine speed maintenance is possible due to the continuity of gear ratios. Fig.1 Continuously Variable Transmission (CVT)[1] 2. METHODOLOGY The project work starts with definition of problem. This is to be followed by exhaustive literature review. The various concepts of automobile transmission should be studied. This includes manual and automatic transmission. Further, the study of CVT should be prioritized. This includes the types of CVTs, its working principles and various concepts related to design and analysis of CVT. The vehicle required for CVT design is to be selected. The various engineparametersofthe vehicle need to be selected and studied for further application in the design[4]. The design and selection of mechanical components like pulley, belt, etc. is to be carried out. 3D CAD model of the components and system should be created. The finiteelement analysis of variouscomponentsis to be carried out to ensure the safety against failure and optimization. The 2D drawings of components need to be prepared. Finally, the scaled prototype needs to be made using 3D printing for demonstration of design and
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4517 development. The methodology is outlined with the help of flow chart. Fig. 2: Project Methodology 3. ANALYTICAL DESIGN Design of CVT:- Design procedure is divided into following steps:- 1. Vehicle engine parameters. 2. Vehicle transmission specification. 3. CVT ratio selection. 4. Pulley design. 5. Belt selection. 1. Vehicle engine parameters:- Maruti Suzuki swift is selected. Table1: Vehicle Engine Specifications 2. Vehicle transmission specification: Table 2: Vehicle Transmission Specifications 3. CVT ratio selection: For maintaining the same output performance at the wheels, the 1st and 5th gear ratio of the manual version mentioned above are taken as CVT ratio limits. Therefore the CVT speed reduction varies from low gear ratio – 3.545 to high gear ratio- 0.757. This performance is obtained by changing the contact diameter of belt on driving and driven pulleys. 4. Pulley design: From the aboveCVTratiocalculationandconstantbeltlength of 925mm.The dimension ofdriving pulley and drivenpulley is calculated. As the groove angle of the belt is 20 degree, groove angle for driving pulley is taken as 12 degree and for driven pulley is taken as 10 degree to have a firm grip of the pulley on the belt. The minimum andmaximumpitchcircleof the pulley is mentioned below: Driving pulley Driven pulley Max. PCD D1=142.1 mm D2=222.7 mm Min. PCD d1=60 mm d2=100 mm Centre distance between pulley, C = 225 mm Belt length, L = 925 mm Groove angle, α = 20 degree 5. Belt selection:- Variable speed steel belt is the special type of belt for CVT to withstand high tension. Specification of the belt is obtained from the catalogue of BOSCH CVT Pushbelt. PART NUMBER: 901086 DESCRIPTION: 30/12/-/930.0/Hitachi ELEMENT WIDTH: 30 NUMBER OF RINGS: 12 BELT LENGTH: 930 mm RING MATERIAL: Hitachi
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4518 Table 3: Belt Specification 4. ACTUATING FORCES ON PULLEYS The actuating forces on driving and driven pulleys are calculated below: 4.1 CALCULATION OF FORCES ON DRIVING PULLEY Driving Pulley Driven Pulley Max PCD Di = 142.1 mm Do = 222.7 mm Min PCD di = 60 mm do = 100 mm 1. Design torque on driving pulley ( Tmaxi): Tmaxi = 138 N-m 2. Belt tensions on driving pulley( F1i and F2i): Tmaxi = (F1i-F2i)×Rmaxi 138 = (F1i-F2i)× (F1i-F2i) = 1942.29 N Di = maximum pitch circle diameter of driving pulley =142.1 mm do = minimum pitch circle diameter of driven pulley = 100mm C = Centre distance between two pulleys = 225mm αi = sin-1( ) = 0.0936 radians Θi = ᴨ-2(0.0936) Θi = 2.954 radians radians F1i = 9.8 F2i (F1i-F2i)=1942.29 N F1i = 2163.004 N 3. Total tension on driving pulley (FTi): FTi =2383.71 N 4. Normal reaction between belt and driving pulley (FNi): FNi = 9209.94 N 5. Frictional force between belt and driving pulley (Ffi): Ffi =1841.98 N 6. Component of normal reaction in axial direction on driving pulley ( Fa1i): Fa1i=8896.12 N 7. Component of frictional force in axial direction on driving pulley ( Fa2i): Fa2i = 476.74 N 8. Frictional force between shaft and driving pulley (Fa3i): Fa3i = μ FTi =0.3×2383.71 = 715.113 N 9. Total axial force on driving pulley(Fai): Fai= Fa1i+Fa2i+Fa3i Fai = 8896.12+476.74+715.113 Fai =10087.97 N …………………………. (14) 4.2 CALCULATION OF FORCES ON DRIVEN PULLEY 1. Design torque on driven pulley ( Tmaxo): Tmaxo = 5122 N-m 2. Belt tensions on driven pulley ( F1o and F2o): F1o = 5453.3 N F2o= 853.4 N 3. Total tension on driven pulley (FTo): FTo =6306.7 N 4. Normal reaction between belt and driven pulley (FNo): FNo = 24367.27 N 5. Frictional force between belt and driven pulley (Ffi): Ffo =4873.4 N 6. Component of normal reaction in axial direction on driven pulley ( Fa1o): Fa1o=23536.98 N 7. Component of frictional force in axial direction on driven pulley ( Fa2o): Fa2o = 1261.3 N 8. Frictional force between shaft and driven pulley (Fa3o): Fa3o =1892.01 N Belt groove angle 30 degree Belt length 925 mm Belt width 30 mm Belt thickness 10 mm
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4519 9. Total axial force on driven pulley (Fao): Fao =26690.29 N 4.3 HYDRAULIC SYSTEM CALCULATIONS 4.3.1 Forward Stroke of Driving (Primary) Pulley: 1. Axial displacement of pulley ( xi ): xi = 11 mm = 11 x 10-3 m 2. Selection of dimensions of hydraulic cylinder: Selecting model A5 for which, ore Pi on diame er = 100mm Rod diameter = 50 mm 3. Pressure for forward stroke ( Pfori ): Pfori = 12.84 bar. 4. Piston velocity during forward stroke ( Vfori ): Vfori = 2.75 x 10 -3 m/s 5. Flow rate of oil during forward stroke ( Qfori ) : Qfori = 1.296 lpm 6. Power requirement during forward stroke( Wfori ): Wfori = 32.63 W 4.3.2 Return Stroke of Driving (Primary) Pulley: 1. Axial displacement of pulley ( xi ): xi = 11 mm = 11 x 10-3 m 3. Axial force during return stroke: Fair = 1191.85 N 4. Pressure for return stroke ( Preti ): Preti = 2.023 bar. 5. Piston velocity during return stroke ( Vreti ): Vreti = 2.75 x 10 -3 m/s 6. Flow rate of oil during return stroke ( Qreti ) : Qreti = 0.97 lpm 7.Power requirement during return stroke ( Wreti ): Wfori = 3.87 W 4.3.3 Forward Stroke of Driven (Secondary) Pulley: 1. Axial displacement of pulley ( xo): Xo = 16.44 mm = 16.44 x 10-3 m 2. Pressure for forward stroke ( Pforo ): Pforo = 33.98 bar. 3. Piston velocity during forward stroke ( Vforo ): Vfori = 4.11 x 10 -3 m/s 4. Flow rate of oil during forward stroke ( Qforo ) : Qforo = 1.94 lpm 5. Power requirement during forward stroke ( Wforo ): Wforo = 129.12 W 4.3.4 Return Stroke of Driven (Secondary) Pulley: 1. Axial displacement of pulley ( xo): xi = 16.44 mm = 16.44 x 10-3 m 2. Axial force during return stroke: Faor = 3153.3N 3. Pressure for return stroke ( Preto ): Preto = 5.35 bar. 4. Piston velocity during return stroke ( Vreto ): Vreto = 4.11 x 10 -3 m/s 5. Flow rate of oil during return stroke ( Qreto ) : Qreto = 1.45 lpm 6. Power requirement during return stroke ( Wreto ): Wforo = 12.38 W 4.3.5 System Parameters: (ⅰ) Maximum working pressure: Pforo = 34 bar = 34 × 105 N/m2 (ii) Maximum flow rate: Q = Qforo = 3.23×10-5 m3/s (iii) Power: kWforo =129.12 W 4.4 DESIGN OF SHAFTS: 4.4.1: Design of Driving (Primary) Shaft: (i) Maximum bending moment: Mi = 169.24 x 103 N-mm (ii) Maximum torque: Ti = 115 x 103 N-mm (iii) Equivalent torque: Tei =288.9 x 103 N-mm Material for shaft : Alloy Steel 35Ni5Cr2 with Sut = 800 N/mm2 & Syt = 500 N/mm2 = 144 N/mm2 = 144 = di = 21.69 mm or 25 mm ⸫ di = 25 mm 4.4.2 Design of Driven (Secondary) Shaft: (i) Maximum bending moment: Mo = 532.91 x 103 N-mm
5.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4520 (ii) Maximum torque: To = 512.2 / 1.2 = 426.8 x 103 N-mm (iii) Equivalent torque: Teo =949.37 x 103 N-mm = 144 N/mm2 = 144 = do = 32.26 mm or 35 mm do = 35 mm Analysis using ANSYS R19.1 Fig 3: Equivalent Stress of Primary sheave 2 Fig. 4 :Total Deformation of Primary Sheave 2 5. CONCLUSIONS Today, only a handful of cars worldwide make use of CVTs, but the applications and benefits of continuously variable ran mi ion can only increa e ba ed on oday’ re earch and development. Considering the specification of the vehicle the ratio for CVT are selected. Further pulley dimensions were calculatedalongwithotherparameters. 3D CAD model of the pulley has been designed. Further hydraulic system for the actuation of CVT is to be designed. Complete analysis of the CVT assembly will be carried out using suitable software REFERENCES 1. D. Kobaya hi, Y. Mabuchi and Y. Ka oh: “A S udy on he Torque Capacity of a Metal PushingV- el forCVT ”SAE Paper No. 980822, in SAE SP –1324, Transmission and Driveline Systems Symposium, pg. 31-39 SAE, 1998. 2. K. Abo, M. Kobaya hi andM.Kuro awa:“Developmentof a Metal Belt Drive CVT Incorporating a Torque Converter for Use with 2-li er Cla Engine ” SAE Paper No. 980823,inSAESP-1324, TransmissionandDriveline Systems Symposium, pg. 41-48 SAE, 1998. 3. S. Sakaguchi, E.Kimura andK.Yamamo o:“Development of an Engine-CVT In egra ed Con rol Sy em”SAEPaper No. 1999-01-0754, in SAE SP-1440, Transmission and Driveline Systems Symposium, pg. 171-179 SAE. 4. N. Hattori, S. Aoyama, S. Kitada and I. Matsuo: “Func ional De ign of a Mo or In egra ed CVT for a Parallel HEV” SAE Paper No. 1999-01-0753, in SAE SP- 144. 5. M.A. Kluger and D.R. Fu ner: “An Overview of Curren CVT Mechani m , Force and Efficiencie ”SAEPaperNo. 970688, in SAE SP-1241, Transmission and Driveline Systems Symposium, pg. 81-88 SAE, 1997.
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