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DESIGN AND DEVELOPMENT OF TRANSMISSION FOR TWO-SEATED

URBAN CAR

MAARUF BIN MUHAMAD

Thesis submitted in 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

DESEMBER 2010
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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 : Supervisor
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 concurently submitted for award of other degree.

Signature
Name : MAARUF BIN MUHAMAD
ID Number : MH08001
Date : 6 December 2010
 v

ACKNOWLEDGEMENTS

I am grateful and would like to express my sincere gratitude to my supervisor

Dr.Sugeng Ariyono for his germinal 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 am truly grateful for his progressive vision
about my training in science, his tolerance of my naive mistakes, and his commitment to
my future career.

My sincere thanks go to all my labmates 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 member engine
research group 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 acknowledge the sincerity of my parents,
who consistently encouraged me to carry on my higher studies. 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 is aim on designing and customizes the transmission from 4 stroke Modenas
Kriss 110cc engine to be used in two seated urban car. Design requirement followed by
the rules of the Eco-challenge marathon race. The suitable gear is to be identified and
selected because of the transmission is decided to use only single gear ratio that suitable
and the power produce must be approximate nearly to the power required to avoid
losses. It‟s important because the design of two seated urban car required the participant
to design and development two seated urban car that have low fuel consumption. The
design will carry out to produce power that approximate enough to the required power
and also have a suitable design for two seated urban car that will be design. In this
thesis the result to use a single gear ratio is chosen. This is because of the result from
the analysis by calculation showed that power produce is near to the power required to
move the car. Then finally this condition can make the car running as efficient as
possible.
 vii

ABSTRAK

Thesis in memfokuskan dalam merekabentuk dan mengubah suai kotak roda gigi
daripada engine 4 lejang Modenas Kriss berkapasiti 110cc untuk disesuaikan dengan
kereta moden yag mempunyai dua tempat duduk. Kehendak rekaan berpandukan
kepada perlumbaan Eco-marathon. Nisbah roda gigi yang sesuai adalah dikehendaki
kerana rekaan kotak roda gigi telah diputuskan untuk menggunakan hanya satu nisbah
roda gigi yag sesuai dan mampu menghasilkn kuasa yang menghampiri kuasa sesaran
pada enjin untuk mengelakkn pembaziran tenaga. Ini adalah penting kerana rekaan
kereta moden dua tempat duduk memerlukan peserta untuk merekabentuk dan
membangunkan kereta moden dua tempat duduk yang jimat dalam penggunan bahan
bakar. Rekaan akan akan menghasilkan kuasa yang menghampiri kuasa sesaran enjin
dan juga mempunyai rekabentuk yang sesuai dan padan dengan kereta moden dua
tempat duduk yang akan dibangunkan. Di dalam thesis ini penggunaan satu nisbah roda
gigi telah dipilih. Ini kerana kajian daripada pengiraan telah mendapati kuasa yang
dihasilkan adalah menghampiri dengan kuasa yang diperlukan untuk menggerakkan
kereta. Dan akhir sekali keadaan ini dapat membolehkan kereta menggunakan kuasa
dengan berkesan.
 viii

TABLE OF CONTENTS

PAGE

SUPERVISOR’S DECLARATION ii
STUDENT’S DECLARATION ii
ACKNOWLEDGEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLE xi
LIST OF FIGURES xii

CHAPTER 1 INTRODUCTION

1.1 Introduction 1
1.2 Problem Statement 1
1.3 Objective 2
1.4 Scopes of study 2
1.5 Flow Chart 3

CHAPTER 2 LITERATURE REVIEW

2.1 Transmission 5
2.2 The Necessity for a Transmission 7
2.3 Resistance to Vehicle Motion 8
2.4 Ratio Span 9
2.5 Engine Torque Rise and Speed Operating 10
2.6 Gear Ratio 11
2.7 Gear Synchronization and Engagement 14
 ix

2.8 Motorcycle Transmission 16

2.8.1 Gears 16
2.8.2 Clutch 17
2.8.3 Drive System 17
2.9 Shell Eco-marathon 2010 18
2.9.1 Urban Concept 18
2.9.2 Energy 19
2.9.3 Vehicle Dimensions 19
2.10 Summary 20

CHAPTER 3 METHODOLOGY

3.1 Introduction 21
3.2 Model Specification 21
3.3 Setting Gear Ratio 22
3.4 Design Concept 22
3.5 Vehicle Resistance and Road Disturbance 23
3.5.1 Aerodynamics Resistance 24
3.5.2 Rolling Resistance 25
3.5.3 Gravitational Resistance 26
3.5.4 Acceleration Resistance 27
3.6 Engine Parameters 28
3.7 Summary 29

CHAPTER 4 RESULTS AND DISCUSSION

4.1 Introduction 30
4.2 Engine Performance 30
4.2.1 Example Calculation of Engine Power 32
4.3 Power Required Result for The Engine 33
4.3.1 Sample Calculation for Power Required 34
4.4 Vehicle Speed and Engine Speed Result 35
4.5 Tractive Efforts Result 37
4.5.1 Example Calculation of Tractive Effort 38
4.6 Transmission Performance Result 40
 x

4.7 Transmission Design 43

4.8 Summary 44

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 45
5.2 Recommendation 45

REFERENCES 47
APPENDICES 48
A Gantt chart of the project 48
B Secondary gear 26 teeth diagram 50
C Primary gear 21 teeth diagram 51
D Synchronizer for engage gear diagram 52
E Bearing diagram 53
F Driver sprocket 14 teeth 54
G Sample calculation for engine torque 55
 xi

LIST OF TABLE

Table No. Title Page

3.1 Gear Ratio for Modenas Kriss 110 23

3.2 Parameter for Two Seated Urban Car Concept 27

4.1 Engine Performance Data Table 32

4.2 Power Required for Flat and Gradient Road Condition Data 34

4.3 Vehicle Speed and Engine Speed for Various Gear Ratios 36

4.4 Tractive Effort Data 39

4.5 Engine Power for Various Gear Ratios 42

4.6 Specification for Two Seated Urban Car 44

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LIST OF FIGURES

Figures No. Title Page

1.1 Flow Chart for The Project 3

2.1 Transmission System for Motorcycle 6

2.2 Vehicle Tractive Resistance and Effort Performance Chart 9

2.3 Engine Performance and Gear Split Chart for an Eight Speed
Gearbox 10

2.4 Simple Gear System In Transmission 12

2.5 Method for Selecting Gear Ratios 14

2.6 Urban Car Design for Eco-marathon 20

3.1 Relationship of power developed and road power required over the
Vehicle‟s speed range 23

3.2 Force Acting on A Vehicle 24

4.1 Graph Engine Performance Torque and Power Versus

Engine Speed 31

4.2 Graph Power Required for Flat Road and Gradient Road
Condition 33

4.3 Graph Engine Speed Versus Vehicle Speed 35

4.4 Graph Tractive Effort for Gear Ratio 37

4.5 Power Required and Power Available to Move The Car 41

4.6 Transmission Design for Two Seated Urban Car 43

 CHAPTER 1

INTRODUCTION

1.1 Introduction

This project is related to Eco-marathon races that need participant to design and
fabricate two seated urban car. This race is the first UMP participation and the first car
(two seated urban car) for UMP. The purpose of the two seated urban car design is to
train student to show their creativity and also apply knowledge that acquired in the
class.

The criteria of two-seated urban car is it must look like a real car that have front
and tail lamp, body shape, side mirror and most important part is the car consume low
fuel. The car also should be able to travel long distance and have basic ability like the
real car on the road.

For this project, one of the methods to achieve low fuel consumption is to
redesign the transmission. Transmission that going to be redesign must be able to
increase the efficiency of the engine power output.

1.2 Problem statement

The transmission to be used in this car is from the 110cc MODENAS engine
that has four ratio of gear. This gear ratio is changed by using clutch mechanism
(centrifugal and wet multiple disc). From common theory, multiple gear ratios will
increase the load of the engine because of the weight from the transmission. Engine
producing power to move the car by transmitting it to the transmission before goes to
 2

tire. This load will occur from the increasing of weight and also the using of clutch
mechanism that can create the heat loss from the engine. This loss can decrease the
efficiencies of the engine.

This point has been used by lot of inventors to improve the fuel consumption by
developing the transmission system. The more efficient transmission system, the more it
can decrease fuel consumption by transfer the torque higher to the rotating device with
high efficiency. Result can see from many type of transmission have been developed
today such as manual transmission, automatic transmission, semi-automatic
transmission, CVT transmission etc. This all development and improvement is about to
decreased fuel consumption by increasing the efficiency of transmission.

1.3 Objectives

The purpose of this project is to determine the correct gear ratio and also to
minimize the loss that occur from the transmission that can affect the efficiency of the
engine that will be used by two seated urban car that wanted it less in fuel consumption.
Beside that this project purpose is also to obtain the data that can be used for further
development of transmission for two seated urban car that has been used in Shell Eco-
challenge races by UMP team in future.

1.4 Scopes of study

In order to achieve the stated objective, the following scopes have been identified:
 The transmission that will be used in this project is from MODENAS 110cc
engine.
 The maximum velocity of the car is estimated from 40km/h to 50km/h.
 The other scope is based on Shell Eco-challenge races rules.
 3

1.5 Flow chart

Start

Literature review gather from journal,

book and other source related to the
project.

Introduction:
Define objective, scope of study and
problem statement

Design requirement such as calculation,

gear ratio and also transmission system

NO
Propose a design by using concept
design selection

Design selection
for the

YES
Suggest improvement for
further research

Report preparation

End

Figure 1.1: Flow chart for the project

 4

From the flow chart project started with proposal of title for final year project
from supervisor and also making a schedule for the meeting. After that, make the
literature review by gather information about design and development transmission for
two seated urban car. Title is related to the Eco-challenge marathon races that need
participant to produce two seated urban car that need to be low fuel consumption. The
rules and specification of the car must be following from Eco-challenge marathon races.

Then make an introduction for the project that included the objective, scope and
problem statement. To choose the better gear ratio and produce efficient, torque
calculation must be from the related formula. Then it followed by finding and defining
design requirement for transmission by calculation to choose the gear ratio that suitable
for the transmission.

Suitable gear ratio is important to the transmission for efficiency. Design is

proposed by concept design selection for select the transmission system design and also
basic concept before goes for the next step. Then make selection from design concept
selection for transmission design. At this state, the transmission design must be choose
correctly and made modification to make the transmission is suitable for the system.
Then make a detail drawing for the transmission design for finalize.

After that make conclusion and suggest improvement for the transmission
design. Finally make a report for the final year project to complete.
 CHAPTER 2

LITERATURE REVIEW

2.1 Transmission

The purpose of the transmission or transaxle is to provide neutral, forward gear

speeds or ranges and reverse. They must be able to provide a gear ratio that is low
enough, when multiplied with the final drive ratio, to increase the engine‟s torque
sufficiently to accelerate the vehicle at the desired rate. The highest gear ratio should
allow the vehicle to cruise at an engine speed that is low enough to save fuel and
decrease noise level. There also need to intermediate ratio spaced so that the engine will
not overrev before a shift or lug after shift. Reverse might be roughly the same ratio as
first since vehicle will be starting from a stop in both cases (Birch T. and Rockwood C.
(2007)).

A transmission is including a first transmission mechanism and a second

transmission mechanism. When a clutch is in an engaged state, the first transmission
mechanism transmits a driving force from the engine to the axle shaft. When a clutch is
in disengaged state, the second transmission mechanism transmits a driving force from
the engine to the axle shaft.
 6

Figure 2.1: Transmission system for motorcycle.

Source: Birch T. and Rockwood C. (2007)

For any given vehicle, transmission gear ratio is selected to satisfy performance
requirements of gradability, fuel economy, acceleration, and ease of operation. Fuel
economy considerations are essential to the selection of gear ratios. Basically too high a
gear ratio causes the engine to run too fast and thus, failing to operate at optimum fuel
efficiency. Otherwise, an extremely low numerical gear ratio will affect vehicle
performance, such as acceleration. Hence, acceleration is also important concern in gear
ratio selection. To maximize acceleration, gear ratios should be selected such that
upshifts occur only when the next higher gear will provide more torque to the drive
wheels (Razzacki S.T., Troy, and MI (US) (2004)).

Providing maximum torque to the drive wheels in each gear requires

consideration of the ratio steps. Wide ratio steps in the lower gears provide for more
fuel efficiency due to less frequent shifting (Razzacki S.T., Troy, and MI (US) (2004)).
However, shifting through wide ratio steps will requires skilful technique otherwise it
can cause a loss in fuel efficiency.
 7

A transmission consist a first transmission mechanism and a second

transmission mechanism. When a clutch is in an engaged state, the first transmission
mechanism transmits a driving force from the engine to the excel shaft. When a clutch is
in disengage state, the second transmission mechanism transmits a driving force from
the engine to the axle shaft (Yasui Y. and Saitama (JP) (2006)).

Usually, a transmission will have multiple gear ratios or simply gears, with the
ability to switch between them as speed varies. This switching may be done manually
by the operator, or automatically. Directional forward and reverse control may also be
provided. Single ratio transmissions also exist, which simply change the speed and
torque and sometimes direction of motor output. In motor vehicle applications, the
transmission will generally be connected to the crankshaft of the engine. The output of
the transmission is transmitted via driveshaft to one or more differentials, which in turn
drive the wheels. While a differential may also provide gear reduction, its primary
purpose is to change the direction of rotation.

There are two types of gear sets used in transmission sliding gears that are in
constant mesh. Both types are used in modern transmissions. The forward gear ranges
are all in constant mesh, with reverse typically being a sliding gear.

2.2 The Necessity for a Transmission

Power from a petrol or diesel reciprocating engine transfers its power in the
form of torque and angular speed to the wheels of the vehicle to move it. The
transmission is used to enable the engine‟s turning effect and its rotational speed output
to be adjusted by choosing a range of under and overdrive gear ratios so that the vehicle
responds to the driver‟s requirements within the limits of the various road conditions.
An insight of the forces opposing vehicle motion and engine performance
characteristics which provide the background to the need for a wide range of
transmission designs used for different vehicle application will now be considered.
 8

2.3 Resistance to Vehicle Motion

To keep the vehicle moving, the engine has to develop sufficient power to
overcome the road resistance power, and to move vehicle from a standstill or to
accelerate a reverse of power in addition to that absorbed by the road resistance must be
available when required.

Road resistance is expressed as tractive resistance (kN). The propelling thrust at

the tyre to road interface needed to overcome this resistance is known as tractive effect
(kN) (Fig.2.2). For matching engine power output capacity to the opposing road
resistance it is sometimes more easy to express the opposing resistance to motion in
terms of road resistance power.

The road resistance opposing the motion of the vehicle is made up of three
components as follows:

 Rolling resistance
 Air resistance
 Gradient resistance
 9

Figure 2.2: Vehicle tractive resistance and effort performance chart.

Source: Heisler H. (2004).

2.4 Ratio Span

Another major consideration when selecting gear ratios is deciding the steepest
gradient the vehicle is expected to climb and the maximum level road speed the vehicle
is expected to reach in top gear with small surplus of about 0.2% gradibility.

The two extreme operating conditions just described set the highest and the
lowest gear ratios. To fix this conditions, the ratio of road speed in highest gear to road
speed in lowest gear at a given engine speed should be known (Heisler H. (2004)). This
quantity is referred to as the ratio span.

Road speed in highest gear

Ratio span =
Road speed in lowest gear (2.1)
 10

2.5 Engine Torque Rise and Speed Operating

Commercial vehicle engines used to pull large loads are normally is designed to
have a positive torque rise curve, that is from maximum speed to peak torque with
reducing engine speed the available torque increases (Fig 2.3). The amount of engine
torque is normally expressed as a percentage of the peak torque from maximum speed
back to peak torque.

Figure 2.3: Engine performance and gear split chart for an eight speed gearbox.

Source: Heisler H. (2004).

 11

The torque rise can be shaped depending upon engine design and taking into
account such features as naturally aspirated, resonant induction tuned, turbocharged,
turbocharged with intercooling and so forth.

A large torque rise characteristic rises the engine‟s operating ability to overcome
increased load if the engine‟s is pulled down caused by changes in the road conditions.
If the torque is rise is small it cannot help as a buffer to supplement the high torque
demands and the engine speed will rapidly fade (Heisler H. (2004)). Frequent gear
changes therefore become necessary compared to engines operating with high torque
rise characteristics. Once the engine speed falls below peak torque, the torque rise
becomes negative and the pulling ability of the engine drops off very quickly.

Vehicle driving technique should be such the engines are continuously driving
between the speed range of peak torque and governed speed. the driver can either
choose to operate the engine‟s speed in range varying just below the maximum rate
power to achieve maximum performance and journey speed or, to improve fuel
economy, wear and noise, within a speed range of between 200 to 400 rev/min on the
positive torque rise side of the engine torque curve that is in a narrow speed band just
beyond peak torque (Heisler H. (2004)). Fig 2.3 showed that the economy speed range
operates with the specific fuel consumption at its minimum and that the engine speed
band is in the most effective pulling zone.

2.6 Gear Ratio

In all gear speeds but one, the power flow from the main drive gear (input) to the
cluster gear and then from the cluster gear to the mainshaft (output). The power passes
through two gear sets. The exception is a 1:1 ratio, where the power flows directly from
the main drive gear to the mainshaft. All the forward gears are normal in constant mesh
so they always rotate at their design speed relative to the engine speed. The gears of the
cluster gear rotate as an assembly. The output gears usually are mounted to the main
shaft so they float or rotate freely. These gears are called speed gears, they completed
the ratio for each gear speed when they become coupled to the mainshaft. The mainshaft
includes synchronizer assemblies for each pair gear speed and can lock the individual
 12

speed gears to the mainshaft. This is done for each shift (Birch T. and Rockwood C.
(2007)).

When choosing the lowest and higher gear ratio, the most important factor to
consider is not just the available engine power but also the weight of the vehicle and
any load it is expected to propel. Another major consideration when selecting gear ratios
is deciding upon the steepest gradient the vehicle is expected to climb and the maximum
level road speed the vehicle is expected to reach in top gear with a small surplus of
about 0.2% grade ability (Heisler H. (2004)).

Figure 2.4: Simple gear system in transmission.

Source: Brain M. (2007).

The method includes selecting gear ratios for a specific application includes
calculating a low gear ratio, and a high gear ratio based upon vehicle parameters and
performance requirements. The total ratio spread is determined by dividing the low gear
ratio by the high gear ratio. Using the total ratio spread, a geometric sequence is created
 13

with a plurality of terms, such that each of the terms respectively represents the ratio
steps between the gears. Lastly, each gear ratio is divided by its respective ratio steps
plus one to fine the gear ratio for the next gear. This method provides and objective
method for selecting gear ratios, such that the steps between each of the ratios are
uniformly progressive (Razzacki S.T., Troy, and MI (US) (2004)).