Robotic gearboxes, or simply "robots", were created as a new word in the development of transmissions. They combined all the best that has been done in the history of mechanical and automatic transmissions.
Perhaps robotic gearboxes have not yet become an ideal solution for the development of the transmission of the future, but still they have taken a huge step in this direction.
A robotic gearbox is a manual gearbox with an automatic electronic control unit. From the "mechanics" it inherits reliability and efficiency, and due to the automation of control it receives increased comfort and smoothness of movement. The electronic control unit reads the signals from the input sensors about the state of the car, the speed of rotation of the shaft, the position of the forks and the selector, and using electric or hydraulic servo drives (depending on the model), sends a command to the actuators to change gears.
In robotic gearboxes, the function of both automatic and manual control is implemented. In automatic mode, gear shifting is controlled by an electronic control unit. In manual mode, which is easiest to designate with the word "tiptronic", the driver independently selects the limit on gear shifting automatically and manually adjusts the selector.
Robotic boxes have already had twenty years of history, and throughout this time they have invariably evolved towards a constant complication of the design. Modern robot boxes can be found in a variety of cars - from the budget Scoda Octavia to the supersport "monster" Lamborghini Aventador. All of these, of course, are very different in their design and price of the transmission, but their principle of operation remains the same.
And if in the case of a premium sports car you also acquire the right to absolute reliability, then in budget cars of the middle class, “robots” carried a significant number of both pluses and minuses.
Pros of robot boxes
Robotic gearboxes were created with the idea of increased comfort and efficiency and included a number of advantages of "mechanics" and classic "automatic machines":
- In terms of reliability, "robots" are superior to both CVTs and torque converter automatic transmissions, because their design contains a manual transmission that has been proven over the years - a system that is familiar to every driver and mechanic.
- Robotic gearboxes allow you to seriously save on fuel, in comparison not only with "automatic", but sometimes with "mechanics". In some cases, cars with a "robot" show savings of 30% compared to the same car with a torque converter installed automatic transmission.
- "Robot" requires less oil in comparison with the variator. From 3 to 5 liters versus 7 liters for CVTs. This is also a significant reason for savings.
- The number of gears can vary from the classic six-speed "mechanics" to 7-8 speeds for units from Audi and BMW. Not so long ago, Volkswagen announced the appearance of its DSG robotic gearbox with ten gears.
- Since the “robot” is based on a manual gearbox, the repair of the mechanical part can be carried out in almost any car service. For the auto repairman, it will not be difficult to replace and repair parts of the “robot” box.
- The clutch resource due to the automation of gear shifting is increased by 30-50% in comparison with the "mechanics". The electronic control unit with built-in gearshift algorithms has its own "fool protection" and thus does not allow the clutch to wear out due to the inexperience of the driver.
- The ability to control in manual mode in the city and constant traffic jams is a significant advantage, not allowing the box to wear out beyond measure.
- Shifting gears at a speed of 0.2 seconds for preselective robotic boxes is the norm. Neither the "automatic" nor the average driver on the "mechanics" will demonstrate such a speed.
Cons of robot boxes
It was all about the pros. Now let's talk about the cons, which are also not few and in many respects they determine the final choice of the car owner.
- The electronic control unit is a very capricious unit, afraid of any unnecessary loads and, even more so, unplanned modifications. Chip tuning and flashing the ECU in inexperienced hands could mean the end of the entire clutch. As a rule, drivers do not risk such actions while the car is under official warranty service. In general, control units for robotic gearboxes are amenable to any modifications, but only in experienced hands and for good money.
- The control unit is still the sore point of the checkpoint. With unsuccessful, even official firmware, failures in the ECU program are possible, which lead to braking of the entire clutch and gear failure.
- Manual mode becomes both a plus and a minus. In conditions of busy traffic and rough terrain, it becomes a necessity, even for inexperienced drivers.
- Robotic gearboxes require certain operating rules, including the control of the gas and brake pedals. As a rule, "robots" do not like pressing the gas all the way and, conversely, lightly pressing the brake.
- When driving a car with a “robot”, you should always monitor the temperature of the clutch - overheating dramatically reduces the wear resistance of the box and leads to premature repairs. Therefore, slipping or “launch” can be the last fatal number for a robotic gearbox.
Choose "robot" or not?
Before buying a car with a robotic gearbox, first of all, you should think about whether you need such a transmission option or not.
If this is a budget car, then it should be borne in mind that in conditions of heavy traffic or bad roads, depending on the region of the country, the classic “mechanics” is the preferred option both in terms of wear resistance and cost-effectiveness of repairs. If you still crave comfort and environmental friendliness from your car, you should look towards cars with a preselective robotic gearbox. Now there are a lot of them in the car market, although the main supplier is the Volkswagen concern with a common DSG box. It is installed on VW, Skoda, and Audi. Although now Ford, BMW, Volvo, Fiat and many other manufacturers have demonstrated their preselections.
Robotic gearboxes are quickly taking over a niche in which torque converter gearboxes have felt comfortable for a long time, and soon we will surely see their widespread distribution, including on domestic cars.
Along with the manual transmission, automatic transmission has already become almost standard. At least, this will not surprise anyone. Another thing is a robotic gearbox (RCP) or a robot. It begins to appear on new cars: Chery Indis, Opel Corsa, LADA Priora, etc. Let's figure out what a robot gearbox is, consider its main pros and cons.
In fact, the robot gearbox is an ordinary manual gearbox. Its creation was the desire to provide the driver with maximum driving comfort, and to achieve unpretentiousness in maintenance. Special electronic equipment is installed on the mechanics, by means of which clutch and gear shifting are automated. As a result of the modification, two pedals remained in the passenger compartment. The peculiarity of such an innovation is that the ability to control the speed remains, only its direct switching is already performed by electronics based on the indicators of the sensors.
For example, in a standard gearbox, the clutch is first depressed (all gears are free), then the driver moves the lever to the desired position, which drives the gear at a certain speed. When riding a robot, switching is performed in a slightly different way.
Sectional box robot
The presence of shocks during the change of speed can be attributed to the features of the robotic box. Getting rid of them is quite simple - slow down the engine speed when switching.
When a gear shift is performed, the desired speed is not switched on with the movement of the lever (the driver does not directly control the processes in the box, but only gives a command). What happens next is something like this:
- A specially programmed system recognizes the action of a person;
- The signal is transmitted to the control center;
- The speed and other performance indicators of the car are analyzed using the information received (it is transmitted from sensors and transducers);
- When the system determines the optimal conditions for switching speed, the clutch is automatically squeezed out and the desired gear is transferred to the working position.
As a result, with good software (some can even remember the driving style of the car owner), excellent driving dynamics are achieved.
Robot and machine - what's the difference
It would seem that there should be a minimum of differences, because both boxes are aimed at simplifying and automating gear changes. In reality, an automatic transmission differs from a manual transmission in the same way as from a manual transmission. The main difference between an automaton and a robot is the speed change system.
automatic transmission
In the first case, switching occurs using a torque converter. When the engine speed increases, automatic gear shifting is performed: the previous speed is wedged, and the next one is wedged. This allows almost instantly and imperceptibly for the driver to perform switching.
RKPP
In the robotic version, switching is performed by depressing the clutch and engaging the desired gear (in absolute analogy with mechanics).
As can be seen from the above information, the difference between an automaton and a robot is significant.
Video about the robotic checkpoint
Pros and cons of a robotic box
The focus of many manufacturers on robotic gearboxes speaks of many prospects for their use. Of course, in most models, such gearboxes are installed as an experiment, because drivers are wary of unfamiliar technologies, preferring a mechanic or automatic. But in terms of the combination of convenience, operational life and maintenance costs, robotic models are in the first place.
Pros:
- High reliability. This is due to the similarity with a manual transmission. It is more durable than the CVT and the standard version of the machine.
- Long clutch life. Thanks to the control of its squeezing by an electronic system, the resource is increased by 1/3.
- Less oil. About 3 liters is enough for the robot to work. In the variator, it is required to fill in an average of more than 8 liters. At current prices for automotive oil, significant savings are obtained.
- Manual switching. Many models of robotic boxes allow the driver to switch from automatic to manual mode. This is useful when the car is skidding. Just keep in mind that slipping can knock down the sensors of the system, so resort to it only in case of emergency.
- Fuel consumption. It is close to the minimum value. This is possible thanks to the same manual transmission system.
- Lots of gear. The car can be equipped with a manual transmission with 6 speeds, which has a positive effect on gas mileage and engine performance. When compared with a 6-speed automatic, the cost of work will be several times lower.
Minuses:
- Instability. The tuning of the electronic components responsible for the operation of the robotic box is such a delicate matter that even 2 machines of the same model can differ in operation. But this is only possible if the production of cars with this type of gearbox is only getting better. Companies with experience have already learned how to achieve stability.
- Delay in switching up to 2 seconds. The process of processing information and sending commands to execution can be slightly delayed. As a result, the speed is slower than in automatic transmission.
- Impossibility of setting. This disadvantage does not apply to all robotic models. But there are robots whose control program cannot be adjusted to a certain driving style. For example, you are used to speed, and the box is set to economy (shifting is performed at low revs). In this case, the ride will not be comfortable enough.
- Jerks when switching or starting to move. Such a minus is corrected by changing the program or completely replacing the robot (control unit).
- Software problems. Some manufacturer's transmissions may have problems in the form of firmware glitches that can affect gearshift speed. In some cases, a certain gear may not be included, or all together.
RKPP gear.
At the same time, the robot box is the most modern type among automatic transmissions. Although work on the creation of such a unit was carried out for a long time, successful implementation and introduction into mass production became possible only in recent decades.
In this article, we will look at a robot gearbox, what it is and how it works, as well as what advantages and disadvantages robotic transmissions have compared to other types of gearboxes.
Read in this article
Robotic box: device and principle of operation
So, the box - the robot is actually the usual manual transmission mechanics, where the clutch is disengaged and the gear selection / shifting is carried out not by the driver himself, but by the automation. In other words, the processes in the robot box, which is a mechanical transmission, are simply automated (robotic).
The main advantage of a robot compared to an automatic or CVT is that this transmission is quite simple to manufacture, which reduces the initial cost of the car. Also, a robotic gearbox provides comfort (similar to an automatic transmission), is characterized by high performance, and allows you to achieve fuel efficiency.
Taking into account such features, auto giants everywhere install such gearboxes on their models, both in the budget and in the "top" segment.
- The robotic transmission device is basically a manual transmission that is equipped with separate systems for controlling the clutch, as well as selecting and engaging gears.
This article has been brewing for a long time, because I already have materials about, but I pulled everything about a robotic gearbox. This is because the material turns out to be large, the “robots” are now different and some are not similar to others. And to be honest, this transmission is not quite common, and before its introduction on LADA VESTA, there was quite a bit of information and feedback from real owners. But time is running out, I am closely watching these manual transmissions, more and more cars are beginning to be equipped with them. And right now I have something to show and tell you. As usual, there will also be a video at the end of the article. What are we starting...
Why is there such close attention to this automatic transmission? Yes, everything is simple, it appeared in large quantities from our manufacturer, the VAZ company, on such machines as VESTA and X-RAY. Why exactly a robotic transmission, and there are no CVTs or automatics - I don’t know! Personally, it would be much clearer to me when I can choose the transmission myself, and AVTOVAZ has a lot of experience in installing JATCO automatic machines (on Kalina and GRANTS).
It can be seen that the main shareholder, the Renault-Nissan company, did not want such a competitor (and I will note a fairly high-quality one) as LADA VESTA. Okay, these are my guesses. As usual, let's start - what is it all about?
What is a robotic gearbox?
In short - "ROBOT" (or RKPP) - one of the types of automatic transmissions. Made on the basis of "mechanical boxes", in which the gearshift functions, as well as clutch control are automated. However, not through a “torque converter mechanism” or “two shafts and a belt” (as with opponents). And due to special servos, electronic sensors and other devices that work as robotic assistants (in fact, the name comes from here).
In simple words, certain “servo” (or electric) drives were hung on the usual “mechanics”, which themselves (for you) decide when to shift gears (up or down) or even switch to neutral.
They rely on the data of speed, engine speed, and other sensors (I even read somewhere that they take into account the readings of lambda umbrellas). A makes decisions about switching directly.
Everything is computerized! Without electronic control, the very principle of a robotic gearbox would not be possible.
Types of robotic gearboxes
And here the most interesting is revealed. It turns out that “ROBOTS”, to put it mildly, are not the same. No, I'm not talking about various companies, but about the structure, the technical component. There are only two main types: - single-disk and double-disk (which, in turn, are also divided into dry and wet). Let's take a closer look
Single-disk manual transmission - in fact, this is a classic mechanics with an actuator on it. There is also a clutch disc, a flywheel, a basket, only a servo drive with hydraulic pushers or a fully electric drive is fixed on top, which pulls the clutch foot and shifts gears for you.
It should be noted that there are two types of actuators:
ROBOTS with electronic control (now a fairly common occurrence) here switching takes place using various types of electronic equipment - servos, actuators, "motors", coils, etc. There is practically no oil, attachment systems are often not serviced. It is used by many manufacturers, such as:
- AMT from LADA (VESTA, X-RAY)
- Easytronic from Opel;
-MultiMode from Toyota.
ROBOTS with hydraulic control they switch speeds with the help of hydraulic drives, there are also servo drives, actuators. It’s just that here they work a little differently, there is oil in the actuator system, with the help of it, the control hydraulics work. This whole system is collapsible, it is possible to replace gaskets, high-pressure tanks, oils in it, and simply repair it. You can include boxes of stamps:
- SMG, DCT M Drivelogic by BMW;
- S-Tronic from Audi;
- Senso Drive from Citroen;
- 2-Tronic from Peugeot;
-Dualogic from Fiat.
Double-disc manual transmission - This is a more complex, but also a more advanced version of the ROBOT. Such "boxes" in themselves combine, as it were, two whole. Therefore, there are two clutch discs in one housing. One part is responsible for turning on even gears (2,4,6), the other part is responsible for turning on odd gears (1,3,5).
These two discs, enclosed in one case, can rotate in the air ( dry manual transmission ), prominent representatives:
DSG7 – from VOLKSWAGEN, SKODA
POWERSHIFT - from FORD
DCT - from KIA
However, discs can also rotate in oil ( wet manual transmission ), a prominent representative
DSG 6 - from VOLKSWAGEN (not to be confused with DSG7)
Making, testing, maintaining dual disc robotic gearboxes is VERY difficult! Therefore, not many brands can afford it.
Principle of operation
Well, that the head is not boiling yet? :) Then we continue.
Actually, let's talk about the principles of operation of each of the types.
One clutch disc - everything is very simple. I would even say elementary. For example, I will take again our LADA VESTA. It is based on an ordinary manual transmission (manual transmission VAZ 2180), of course, the body is not one to one, and the shafts are slightly different, but “the fact remains”.
A block of actuators and servos from ZF was hung on it, it is not collapsible and is designed for 10 years of service (according to unofficial data, about 150,000 km should pass).
Clutch, not one to one like on the mechanics, but very similar. Service life is approximately 100 - 120,000 km.
After starting the car, you move the lever to position "A" (on LADA VESTA) or the usual and familiar "D" (DRIVE, as on automatic machines). The actuators imitate the clutch, turn on the gear.
You press the gas pedal, the car starts off (it is important for a single-disk manual transmission, there is no so-called “creeping mode” like on an automatic transmission, there, after switching to mode D, if you release the brake pedal, the car will drive slowly, the ROBOT will stand still).
The higher the speed - the greater the speed, everything is controlled by electronics through the ECU. If you press the brake pedal (speed, engine speed drops), then the gear must be thrown down.
Two clutch discs - the work here is much more difficult. I already have an article about this, you can (so I won’t stop in detail). This ROBOT is no longer so similar to the mechanics. The difference is in the body and actuators. There is also a package of clutch discs (of two pieces) in one housing, an actuator. That's just inside the gearbox itself, several shafts.
When you move the lever to the "D" position, then the actuators close the first clutch pack (including first gear). Pressed on the gas pedal, the car started. However, at the same time, the second clutch pack, that is, the “second”, also starts to work. At the right speed, the "first" turns off and VERY quickly the ROBOT switches to the "second".
Then the first package (which threw off the first gear) switches to the third, the second package switches to the fourth and everything repeats. Of course, it’s quite difficult to explain in words like this, so I’m attaching a short video, we’re watching.
Pros of robotic boxes
On the net you can often find such statements - that robots have no pluses! And it can't be! This is not true, of course there are enough minuses (about them a little lower), now a little about the positive points (for starters single disc variant):
- Vehicle price and production . If you take a ROBOT with one disc, then this is most likely the cheapest automatic transmission, which is included in the price of the car. The difference with a CVT or automatic can reach up to 40,000 rubles.
- Fuel consumption . Oddly enough, but on a manual transmission, it is lower than on a CVT or automatic transmission. In fact, this is a continuation of the mechanics, there are simply no losses due to the torque converter spinning up.
- There is a rollover . This is important for many drivers who are transitioning from manuals. You can either move the lever to the N position yourself, and roll downhill, thereby saving fuel. As well as modern ROBOTS, they can turn off the clutch themselves if you roll down a hill.
Now separately two disc option, there are even more pluses:
- No jolts when shifting . Both uphill and downhill (when you brake)
- Dynamic acceleration . In general, ROBOTS with two disks use the engine efficiency much more (after all, there is no torque converter)
- Fuel economy . Here it is much larger than that of a colleague
- Again, there is a roll .
- Imitation of an automatic or variator . For the driver, there are practically no differences in the switching and modes of this robotic box and opponents (everyone is familiar with the “D”, “N”, “R” and “P” modes)
- There is a "creeping mode" and no rollback back . This is when you turn on "D" and the car slowly crawls forward (even if you do not press the gas pedal).
Overall, the dual disc robotic box is very pleasant to use. However, there is always a “BUT” and there are much more disadvantages here.
Cons of "ROBOT"
Again, we will divide into two camps.
The simplest ROBOT, single-disk:
- Dumb, dumb and dumb again . I have not yet seen a single adequately working mechanism. Not on LADA, not on FIAT, not on TOYOTA. His work needs to get used to, the jolts between gear changes are very obvious. BUT most of all, his thoughtfulness infuriates when you eat in high gear and speed, brake sharply. And as he was on the "fifth", he remained. Step on the gas pedal... it may take 5 to 10 seconds until he realizes that he needs to lower the "speed" and drive normally. Honestly annoying...
- Frost and winter . My friend has a FIAT PANDA, there is a “Dualogic” robotic box, it has a system with hydraulic drives and oil inside. So, it is from severe frost, and this is about - 20, -25 (which is found in almost every region) thickens and does not switch "ROBOT", that is, they started the car and until it warms up, the gear will not turn on. That is corny freezes. Of course, on a manual transmission with a fully electric system, this is not the case (and let's say VESTA does not suffer from this). BUT the fact remains.
- No creep mode. YES in the single-disk version, it is not. That is, you turned on the “D” or “A” mode, stand on a hillock, release the brake carrion, and the car rolls back! This is not an automatic for you, you need to take this into account
- Resource and repair. In general, a single-disk robot is not so expensive to repair! BUT, it will advance already at 100,000 km. Why? I explain. The gearbox itself, “without attachments” is almost eternal, this is for all manufacturers (still “banal mechanics”). However, breakdowns lie precisely in the "mounted". The first weak knot is the clutch - basket - clutch release and flywheel. All this will require repairs closer to 100,000 km, it’s not worth saying that it’s overly expensive, but you will have to pay 10–15,000 rubles for the original (“of course, cheaper). Further, the actuator, if it is hydraulic, then it will require repair and diagnostics also closer to the “100-ke”, and in order to do all this normally, you need good service and about 10-20,000 rubles of money. If you have fully electric “actuators” that are not serviced and repaired, then their service life can be 120 - 150,000 km, and a replacement from 20 to 30,000 rubles (for example, for LADA VESTA costs from ZF, and how they assure that it is not being repaired ... although our craftsmen will get here). It turns out that after 100,000 km, you will give from 20 to 40,000 rubles to repair the robot (not a little).
Complex ROBOTS, two discs:
- Resource. Probably everyone remembers the first DSGs (the hype around them), when their clutches (and there are two of them) could be covered after 40 - 60,000 km. Now, of course, all these bugs have been corrected (after all, the Germans are ahead of the rest here). BUT again, 120 - 150,000 km is almost the maximum limit, and then if you drive normally and do not tear your ROBO from a place.
- Repair and Price. It is difficult to repair, especially if you live somewhere in the outback (you need good diagnosticians). The price will also be far from 20 - 40 thousand, much more, if your "mechatronics" (the actuator for the DSG) breaks down, then repairs can cost a pretty penny (up to 100 thousand rubles), now, of course, there are analogues that are cheaper, but how long will they walk?
I think I will not open America to you if I say that robotic boxes are becoming more and more popular. Some of them, from the point of view of the consumer, are simply magical - they have many steps and quickly sort through them while driving. Others make drivers suffer every day, mercilessly "stupid" at every opportunity.
Let's figure out together what the catch is, why is there a “chasm” between them in terms of driving. Let's start with the fact that robotic gearboxes, in fact, are divided into two types: with one clutch and two.
Robot with two clutches
As a rule, with two clutches, these are complex modern technological gearboxes with a large number of gears and an impressive speed. Sometimes it is less than 0.5 seconds, which practically allows you to achieve accelerations without breaking the thrust. This is ensured thanks to a very interesting line of thought of the designers - on one gearbox shaft there are paired gears, for example, 2, 4, 6, 8. and switching between shafts. This happens extremely quickly, because automatic clutches of a special design open and close, which are completely under the control of fast electronics.
Driving a car with such a box is almost always a thrill for the driver - lightning-fast shifts in conjunction with 6-8 gears allow you to fully unlock the potential of any motor. This means that with good dynamics (depending on the engine), a very small consumption is obtained.
There are three disadvantages of such boxes:
- "Fragility". Yes, they tend to break, due to their very complex design.
- High cost. Everything has to be paid for. The truth is, it's probably worth it.
- Budget class. To meet such “boxes” in inexpensive cars, alas, will not work. Otherwise, the budget class with such a box will automatically move to another price segment.
Single clutch robots
Sadness, but it is with them that most motorists will have to deal. These boxes were built for one purpose - to transfer the adherents of the machine to inexpensive modern small cars, which before that either had no modifications with the machine at all, or a very “tight” old torque converter (classic automatic transmission) was installed there.
They did it. The budget class is the most massive, and having an inexpensive “automatic” box, there is no end to customers.
How is this beauty arranged?
Imagine, we take a standard manual gearbox and “collective farm” to it an actuator that, at the request of the electronics, “squeezes out” the clutch, and the servo engages the desired gear, after which the clutch is closed back by electronics. This is how gear changes happen.
Due to the primitiveness and, in general, the adaptation of a mechanical gearbox, we get the most global cant - the box switches for a very long time, breaking the traction for two or even three seconds, depending on the design of the box and settings. On the road, this is a monstrous surprise, especially if you are driving a car with such a box for the first time.
Having miraculously parted ways, for a long time I spoke a lot of “Armenian” words about myself and the box. Having made an unambiguous conclusion that you need to get used to robots thoroughly, delving into their features. For those who will assume that that car was defective, I will say that over the years I have repeatedly met robotic gearboxes with a similar “character”.
pros
- Relative reliability. The main part of the unit from the mechanical box is reliable. And in the case of a bulkhead, it will not require significant investments.
- Economical. Not as good as dual clutch, but almost on par with manual transmissions. Which is an excellent indicator for an “automatic” cheap transmission.
- Weight. Lightweight, compact. Without problems, they get into a small car, like a manual transmission.
- Price. The cost of robotic boxes is lower than CVTs or classic machines.
Flaws
- Clutch. The clutch is released by the electronics, not “understanding” the wear of the clutch assembly. Adaptation can and should be done, but this does not even happen every MOT. As a result, in some cars, because of this, it is enough for only 20-40 thousand km.
- Works slowly. The sluggishness of this type of boxes is really upsetting. Based on my experience, I think you understand how sad this is.
Results
There is no escape from both types of robotic gearboxes. They both occupied their niches and have the right to life. If you're looking for a progressive, modern, fast gearbox, double clutch is your choice. If you need at least “something” to change gears for you, it will do with one clutch. In any case, the choice is always yours.
- , 10 Nov 2016
