The device and malfunctions of a manual transmission. How it works

The car needs a gearbox, because physical properties engine internal combustion. The engine has a certain maximum speed beyond which it is impossible to enter. In addition, the engine has a rev range, quite narrow, where the torque and power are at their maximum level.

How does a gearbox work?

The gearbox works in such a way that it allows you to change the gear ratios between the engine and the drive wheels when the machine accelerates or slows down. When shifting gears, the engine must be in the range of revolutions of its effective operation.

The gearbox device, if it is, is such that it connects to the engine through. input shaft The transmission rotates at the same speed as the engine. The gearbox device has so many gear ratios in it in order to change the speed of the output shaft. The input shaft is connected to the engine through a clutch - a device that allows you to connect and disconnect the engine from the transmission. The input shaft and gear rotate at engine speed when the clutch is engaged.

The intermediate shaft rotates all gears together. The primary and intermediate shafts are interconnected and rotate together. The next shaft is called the output shaft and is directly connected to cardan shaft and then through the differentials with the wheels of the car. The output shaft rotates as the wheels rotate. The grooves in the output shaft are designed to fix the gear of a certain gear, and then connected from the engine to the drive wheels.

And if it's off and the car is driving freewheeling, then the output shaft rotates inside the gears of the corresponding gears when the gears are not moving, because they are supported on bearings and can rotate freely around the output shaft, even if no gear is engaged.

What is the gearbox made of?

The box is made in such a way that couplings are created to connect the transmission gear to the output shaft, which are connected through splines directly to the output shaft and rotate with it. The clutch is able to slide laterally along the shaft in order to engage with the output shaft - including one of the gears. The clutch engages with the driven gear.

Intermediate shaft turns input shaft from the engine and the intermediate shaft rotates the engaged gear in the selected gear. The rotational energy is then transferred through the clutch to the input shaft and with it the second gear rotates freely on the bearing without engaging with the output shaft.

Gear shifting is a device that every car with an internal combustion engine needs. The need for this mechanism is due to the fact that any engine has a rather narrow speed range, where torque and power reach their maximum. And, in addition, each engine has a so-called “red zone” - a speed limit that must not be exceeded in order to avoid engine breakdowns.

This article will be fully devoted to the subject of the checkpoint, namely, its mechanical variety(MKPP). After all, both the “experienced” driver and the novice motorist need to know the device mechanical box transmission and its working principle. The article will also present graphic schemes Manual transmission, its main malfunctions are considered and advice is given on correct operation this vital mechanism for the car.

Types of gearboxes

In addition to mechanical, there are other types of gearboxes - CVT, and automatic.

The CVT gearbox is stepless. Most important details variator - these are sliding pulleys (there are two of them) and a belt that connects them. The connecting belt in a section has the form of a trapezoid. The main advantage of the variator is Full time job car engine in optimal mode. There are also additional benefits, which include dynamism of acceleration, smoothness of movement and economy. In comparison with the "automatic" ( , automatic transmission gear shift), the variator has a very simple design. But if we compare it with a manual gearbox, then the variator is still inferior to it in terms of dynamics and efficiency.

In addition, the CVT gearbox is almost impossible to combine with powerful motor, as the fragility of the belt will not allow this. Servicing and repairing the variator is enough expensive pleasure, it will be easier and cheaper to replace the gearbox. And one more minus is the need for additional mechanisms for reversing and starting off.

Robotic checkpoint almost no different from mechanical - the torque is also transmitted from the engine to the transmission using the classic "dry" single-plate clutch. But still there is such a nuance: in the robotic box, the processes of gear shifting and on / off are automated. clutch. Therefore, the "robot" is able to greatly simplify the process of driving a vehicle - there is no need to manually and, losing precious time, think about which gear to turn on at a given moment. Also, to the advantages of the “robot” box, you can add its relative cheapness, efficiency and low weight.

However, there are also disadvantages. The robotic gearbox does not work too smoothly, and gear shifting occurs with a significant delay. In addition, at high speed movements, the "robot" can react to switching jerks and jerks. Manual mode it will not help here, since the same electronics “commands” the clutch. If we compare a robotic box even with a simple automatic transmission, then the clarity of the “robot” switching is much inferior to the “automatic”. It should also be remembered that when starting the car with robotic box makes a small rollback. Based on all these disadvantages, manual transmission is traditionally put on the most "budget" car models.

Manual transmission device

Now let's move on to our "hero of the occasion", to whom this material is dedicated - to. As you know, a manual transmission is a mechanism that transmits, converts and changes the direction of torque from the engine flywheel. In the "mechanics" the steps are switched mechanically, respectively - by moving the gear lever. Torque is first transmitted to the output shaft, and then to the wheel drive.

What is meant by the term " stepped transmission"? Traditionally, it determines a stable transfer coefficient (the so-called gear ratio) between the interacting gears of the shafts - driving and driven. This "mechanic" differs from, for example, a variator, where the mentioned coefficient is not tied to the gear ratio and is floating. In other words, the ratio of the number of teeth on the driven gear to the number of teeth on the drive gear gives the gear ratio. These numbers differ at different stages of the checkpoint. The highest gear ratio is obtained by lower rung, and the smallest on the contrary - on the highest.

The general working principle manual transmission quite simple, and the set of its parts is small

A manual transmission can be called relatively uncomplicated. The manual transmission package includes:

• shafts with gears (primary, intermediate and secondary);
• additional shaft with reverse gears;
• crankcase;
• synchronizers;
• directly the gearshift mechanism, equipped with devices for blocking and locks;
• shift lever.

Bearings are installed in the crankcase, in which the gearbox shafts rotate. The shafts are equipped with sets of gears with different numbers of teeth. For noiselessness and smooth gear shifting, synchronizers are used - they equalize the angular speeds of the gears during their rotation. The operation of the gear shift mechanism is to change gears - it is controlled by the driver using a lever. The locking device allows you to keep the transmission from unwanted self-shutdown. The locking device is designed to avoid switching on two gears at the same time.

Stages and shafts manual transmission

As mentioned above, the gear ratio is determined through the ratio of the number of gear teeth that are in interaction. For example: first gear = lower gear = highest gear ratio. All manual transmissions are divided into types according to the number of steps. There are four-, five- and six-speed manual transmissions. Nowadays, the most common “five-step” is a 5-speed gearbox, but a 4-speed one can be found very rarely.

In addition to the number of steps, manual transmissions are also divided into types according to the number of shafts. There are three-shaft and two-shaft boxes. Three-shaft machines are equipped with and rear wheel drive(including heavy trucks), and two-shaft gearboxes are most often installed mainly on passenger cars with front-wheel drive.

Three-shaft gearbox device

The package of the three-shaft gearbox includes:

• drive shaft, also called primary and its gear;
• intermediate shaft with a block of gears;
• secondary shaft (driven), also with a gear block;
• the gearbox housing, called the crankcase;
• synchronizer clutches;
• direct gearshift.

In three-shaft gearboxes, as their name implies, three shafts work - the drive (primary), intermediate and driven (secondary). The drive shaft provides the transmission of torque to the intermediate shaft, with which it is connected using a gear. The intermediate shaft is also equipped with a gear block. The secondary (driven) shaft rotates independently of the primary, although it is located on the same axis with it and also has a block of its gears.

The body of the manual transmission is made of light metal. The entire gearbox mechanism is attached inside the case, grease is also poured there (most often - transmission oil, although nigrol was used in old Soviet-style models).

The location of the shift lever can be different: sometimes the lever is located directly in the box, and sometimes it is mounted on the body. The mechanism responsible for remote gear shifting is colloquially called the "scene".

Two-shaft gearbox device

The package of a two-shaft gearbox includes:

• drive (primary) shaft, equipped with a block of gears;
• driven (secondary) shaft, also with a gear block;
• gear shift mechanism;
• main gear;
• synchronizer clutches;
• differential;
• gearbox housing.

So, this type of manual transmission has only two shafts. In general, the location and purpose of the parts of a two-shaft box is similar to a three-shaft one. The difference is only in the arrangement of the shafts (they stand in parallel) and in the principle of creating a transmission - if in a three-shaft it is created by two pairs of gears, then in a two-shaft one pair works. The two-shaft manual transmission does not have a direct transmission. also in two-shaft boxes not one, but several driven shafts can be used at once.

For transmission reversing both two- and three-shaft boxes use an additional shaft and an intermediate gear. To keep the gear engaged (also for all types of gearboxes), clamps are used. To prevent two gears from being engaged at the same time, a blocking device is provided.

Synchronizers in gearboxes are used for silent gear shifting due to alignment angular velocity gears and shaft. IN standard equipment The synchronizer includes two blocking rings, a clutch, crackers and wire rings. Using a synchronizer, you can alternately turn on the two gears of the secondary (driven) shaft.

The main breakdowns of the gearbox and their causes

1. Oil leakage. Most often it can be associated with damage to seals and seals. Also, the cause may be a loose fastening of the housing cover (crankcase). To get rid of leakage, it is necessary to change the seals and gaskets to new ones and / or tighten the covers.
2. The checkpoint is noisy. Most likely, the noise of the box is associated with a malfunction of the synchronizer. It could also be caused by worn gears. spline connections and/or bearings. In this case, wear parts should be identified and replaced.
3. The gearbox is hard to turn on. This may be due to a breakdown of some of the parts of the switching mechanism. Wear of gears and/or synchronizers is also possible. Check these parts and replace if necessary.
4. Transfers turn off by themselves. Most often this occurs due to a malfunction of the locking device, as well as severe wear of the synchronizers and / or gears. The method of troubleshooting is still the same - replacing the blocking device, gears, synchronizers - depending on which of them the breakdown is associated with.

To checkpoint for a long time served you faithfully - treat her accordingly. Main advice when using the shift lever - be literate in this process. Also, do not forget to change the oil in the crankcase from time to time. If you follow these simple points, the gearbox can last as long as the car itself, without reminding yourself of any malfunctions.

The main part of gearbox breakdowns is connected precisely with incorrect handling of the control lever. Do not pull the lever with quick and sharp movements - such a tough operation may eventually lead to overhaul the entire box, since the switching mechanism and synchronizers will fail very quickly (in fact, the same applies to shafts with gears).

Move the lever smoothly, take mini-pauses in the neutral position - then the synchronizers will work, which will protect the gear from breaking.

Do not forget to periodically check the oil level in the crankcase! Top it up if the need arises. Also, at the right time, you will need complete replacement oil - its terms are indicated in the operating instructions for the machine.

Video - The principle of operation of a manual transmission manual transmission

Conclusion!

And, of course - the classic, always relevant advice: listen to your car! good driver always feels his iron friend and treats him carefully. With this approach, you will not have to repair either the gearbox or other devices in your car.

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The machine consists of a large number of systems. Some of them are intended to provide work electrical system: This accumulator battery and a generator. The second part is basic. It is represented by only three nodes: suspension, engine and gearbox. In this article, we will discuss how the transmission works, what is the scheme of its operation and the features that it has.

Main tasks

There is a gearbox on absolutely any car, regardless of its make, model and year of manufacture. This is not surprising, because the role is really difficult to underestimate, and without it, the connection of the wheel drive and the engine would be very problematic.

To understand why a transmission is needed, it is worth remembering the scheme by which the system works, and what the principle of its operation is based on. Of course, the main link that is the source of mechanical energy is the engine, the operation of which is usually based on the combustion of a certain type of fuel.

The scheme of work is such that forward movement the piston is converted into rotational, which carries out. This shaft is connected to the wheel reducer with the help of a gearbox, which rotates the axle shafts and makes the car move.

Many at this point have a completely logical question: why do we need such a complex scheme, which is based on connecting the wheel drive to the engine shaft through the gearbox? Is it possible to connect directly?

The fact is that a system that has the principle of connecting wheels through a gearbox has several important benefits, allowing the engine and all other components of the car to work more efficiently.

So, it is worth remembering that a system such as a gearbox functions by moving from the engine to the wheels. If this moment were transmitted directly in the system, then with this principle of operation, the rotational speed of the crankshaft and cardan shaft, which connects the gearbox to the wheel gearbox, should be the same. The direct transfer of torque will cause the wheel speed to have a constant ratio to the shaft speed.

With this principle of operation without a gearbox, the car will be very limited in its characteristics, so a change in torque is necessary, depending on the speed. It is the gearbox that does this work, and it depends on it with what torque the engine energy will be transmitted and how it will be used.

Main principle

So, the main task of a car gearbox is to connect the engine and wheels in such a way that the torque remains optimal, and even at extreme speeds engine speed always remained within the normal range.

To do this, firstly, it is necessary to connect the gearbox to the engine and the cardan shaft leading to the wheels. In the simplest case, two shafts serve for this - primary and intermediate. connects with crankshaft engine, and the intermediate one - with the cardan shaft of the car.

These shafts at the gearbox have sets of gears with different size and configuration. In order to change the torque, a lever with a rocker is used, with which the shafts can be shifted and connected using different gears.

So that the shafts, which are in constant contact with each other, do not wear down and do not overheat over time, they are supplied with a lubricant that fills the gearbox housing and stays in it throughout the entire life of the gearbox.

In case of automatic transmission everything is somewhat more complicated: instead of gears, friction clutches appear in it, which, using oil pressure, can be connected to each other in packages and, thus, change the transmitted torque.

The gears have two cones in their design, which, in fact, are a set of gears with a stepless transition between them. Like automatic transmissions, the variator without the help of the driver adjusts the positions of the shafts relative to each other. Due to this, the torque can be adjusted more accurately and smoothly, depriving the driver of any discomfort during control.

Consider how the gearbox is arranged, we will also learn in more detail about the principle of its operation. The engine of the very first cars was directly connected to the drive wheels, which made it easier to care for the car and control, but the power left much to be desired. Modern cars allow you to transfer the energy of the engine to the drive wheels through the transmission, which is done by converting the constant rotation of the engine shaft by the gearbox, and the driver has the ability, depending on the speed he has chosen, to slow down or accelerate the movement of the car.

In addition, the gearbox allows you to change the value tractive effort, which is transmitted to the driving wheels of the machine, change the direction of their rotation and start the engine stationary car with the clutch engaged. You can see how the clutch of a car is arranged on our website.

But its main purpose is to change the torque transmitted from crankshaft engine to the drive wheels in size and direction by engaging gears of different diameters, as well as a long disconnection of the engine from the transmission. Simply put, the gearbox allows you to combine optimal number engine speed with different speed movement. The number of steps depends on the number of pairs of gears engaged in certain combinations.

How does a manual transmission work?

The number of gears is directly related to the ability of the car to adapt to different conditions and overcome obstacles. The composition of the gearbox includes a set of gears (gears) that mesh with each other in various combinations and thereby form several gears, and the gears and gearbox shafts are located inside the crankcase, from which two interconnected shafts emerge - driven and driven. Gears are installed on the driven shaft, moving along it as a result of shifting the gear lever by the driver.

Main part modern cars equipped two-shaft three-way five-speed gearbox gear with constant mesh gears. In the gearbox housing, the primary and secondary shafts with gears and synchronizers are installed on bearings. There is also an axle with an intermediate reverse gear. gears forward are in constant engagement.

One of the gears of each forward gear is mounted on the shaft on bearings, and the torque when the gears are engaged is transmitted through synchronizers located on the shaft on splines. When forward gears are engaged, the input and output shafts rotate in opposite directions, and when reverse gear is engaged, they rotate in the same direction. The reverse gears (driving and driven) are connected through an intermediate gear.

It is mounted on an axle on a bearing and is engaged when the reverse gear is engaged. As a result of these processes, the intermediate gear provides a change in the direction of rotation secondary shaft.

The driver shifts gears with a special mechanism mounted on the gearbox housing. He engages gears with a lever that moves the synchronizer of the gear he has chosen to the corresponding gear with the help of forks. This ensures the transmission of torque from the gear through the synchronizer to the output shaft of the gearbox.

The inclusion of the first gear occurs as a result of moving the synchronizer gearbox to the right along the splines of the output shaft with the help of a fork and connecting it to the driven gear of the first gear, which is mounted on the shaft, on the bearing. The torque from the input shaft is transmitted through the drive gear mounted on it to the driven gear of the first gear and further to the output shaft of the gearbox through the synchronizer. In first gear, the speed of the car decreases, but the torque increases.

Second gear is engaged when the fork moves the synchronizer to the left and connects to the second gear driven gear. The torque from the input shaft to the secondary is transmitted through the second gear drive and driven gears and the synchronizer. When this gear is engaged, the speed of the machine increases, and the torque, on the contrary, slows down.

Third and fourth gears are switched on simultaneously with a fork when the synchronizer is moved along the splines of the secondary shaft in opposite directions, as a result of which it is connected to the driven gear of the third or fourth gear. The torque from the input shaft to the secondary is transmitted through the gears of the third or fourth gear. As a result of the inclusion of these speeds, the speed of the car increases significantly, and the torque does not change.

The gearbox device can also be clearly seen in the next video.