COMPARISON MANUAL AND CVT TRANSMISSION FOR A CAR UNDER 1 LITER ENGINE MOHAMMAD AZLAN BIN ABDUL AZIZ Report submitted in partial 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 DECEMBER 2010 UNIVERSITI MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING I certify that the project entitled “Comparison Manual and CVT Transmission for a Car Under 1 Liter Engine “is written by Mohammad Azlan bin Abdul Aziz. I have examined the final copy of this project and in my opinion; it is fully adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering. I herewith recommend that it be accepted in partial fulfilment of the requirements for the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Tuan Haji Amirruddin Bin Abdul Kadir Examiner Signature ii 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: LECTURER OF MECHANICAL ENGINEERING 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 concurrently submitted for award of other degree. Signature .................................. Name: MOHAMMAD AZLAN BIN ABDUL AZIZ ID Number: MH07067 Date: 6 DECEMBER 2010 v ACKNOWLEDGEMENTS I am greatly grateful to ALLAH SWT on His blessing for making this project successful. I am grateful and would like to express my sincere gratitude to my supervisor Dr Sugeng Ariyono for his brilliant 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 also sincerely thanks for the time spent proofreading and correcting my many mistakes. My sincere thanks go to all my mates 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 instructor engineer and assistance instructor 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 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 presented about comparison manual and CVT transmission. This thesis deals with analysis on performance of transmission for a car under 1 liter engine. The objective of this thesis is to compare the performance of transmission between manual transmission and CVT transmission. Besides that, the purpose of this thesis is to analyze the performance of the Manual Transmission and the CVT Transmission for a car under 1 liter engine. This thesis also purposes to study the suitability using CVT for a car under 1 liter engine. Manual transmission and CVT transmission have their own advantages and one of that is better in their performance. In performance, there are many category that compared consist of power available, tractive force, fuel consumption and many more. The data used for the analysis is obtained through calculation using specification data that has got from brochure which is downloaded from Toyota’s official web because this model only market at Europe. This model fulfilled this project because it had two types of transmission which is CVT transmission and Manual Transmission. The post-processing method was performed using manual calculation with certain engineering formula and graph is plotted by using assistance software such as Microsoft Excel. The post-processing method to analyze the performance of transmission was performed using the SAE definition. From the results, it is observed that the performance of CVT is better than manual transmission. It is also observed that Manual Transmission is better than CVT in term of fuel consumption for a car under 1 liter engine. Besides that, CVT are suitable to use for a car under 1 liter engine because it gives more power and ride comfort ability. Future work, this comparison between manual transmission and CVT must do in experimental or simulation since CVT technology just begun to blossom to Malaysia. There are many factors that required to do research by experimental especially in transmission’s performance and driveability. vii ABSTRAK Tesis ini membentangkan perbandingan tentang penghantaran manual dan penghantaran CVT. Tesis ini berkaitan dengan analisis terhadap prestasi penghantaran untuk kereta berenjin di bawah 1 liter. Tujuan dari tesis ini adalah untuk membandingkan prestasi penghantaran antara transmisi manual dan transmisi CVT. Selain itu, tujuan dari tesis ini adalah untuk menganalisis prestasi penghantan Manual dan penghantaran CVT untuk kereta berenjin di bawah 1 liter. Tesis ini juga bertujuan untuk mempelajari kesesuaian menggunakan CVT untuk kereta berenjin di bawah 1 liter. Penghantaran manual dan penghantaran CVT memiliki kelebihan mereka sendiri dan salah satu yang lebih baik dalam prestasi mereka. Dalam prestasi, ada banyak kategori yang dibandingkan terdiri daripada kuasa, gaya traksi, penggunaan bahan bakar dan banyak lagi. Data yang digunakan untuk analisis diperolehi melalui perhitungan dengan menggunakan data spesifikasi yang telah didapati dari brosur yang dimuat turun dari Laman web rasmi Toyota kerana model in hanya berada di pasaran Eropah. Model ini memenuhi projek ini kerana mempunyai dua jenis penghantaran iaitu CVT penghantaran dan Transmisi Manual. Kaedah pemprosesan dilakukan menggunakan perhitungan manual dengan rumus tertentu dan graf diplot dengan menggunakan software bantuan seperti Microsoft Excel. Kaedah yang digunakan untuk menganalisis prestasi penghantaran dilakukan dengan menggunakan definisi SAE. Dari hasil, diperhatikan bahawa prestasi CVT lebih baik daripada penghantaran manual. Hal ini juga didapati bahawa Transmisi Manual lebih baik dari CVT dalam hal penggunaan bahan bakar untuk kereta berenjin di bawah 1 liter. Selain itu, CVT sesuai digunakan untuk kereta berenjin di bawah 1 liter kerana memberikan kekuatan lebih dan keselesaan semasa pemanduan. Pada masa datang, perbandingan antara penghantaran manual dan CVT harus dilakukan dalam eksperimen atau simulasi kerana teknologi CVT baru sahaja mula berkembang di Malaysia. Ada banyak faktor yang diperlukan untuk dilakukan kajian secara eksperimen terutama dalam prestasi penghantaran dan kebolehan pemanduan. viii TABLE OF CONTENTS Page SUPERVISOR’S DECLARATION ii STUDENT’S DECLARATION iii DEDICATION iv ACKNOWLEDGEMENT v ABSTRACT vi ABSTRAK vii TABLE OF CONTENTS viii LIST OF TABLES xi LIST OF FIGURES xii LIST OF SYMBOLS xiv LIST OF ABBREVIATIONS xv CHAPTER 1 INTRODUCTION OF THE PROJECT 1 1.1 Introduction. 1 1.2 Problem Statement. 2 1.3 Objectives. 2 1.4 Project Scopes 3 1.5 Methodology and Flow Chart 3 1.6 Structure of Thesis 5 CHAPTER 2 LITERATURE REVIEW 6 2.1 History and Development of Drivetrain. 6 2.2 Continuously Variable Transmission. 8 2.2.1 Introduction of CVT 8 2.2.2 CVT’s Basic Principle. 9 2.2.3 Types of CVT. 10 2.2.4 Epycyclic Gear Train Construction and Description 14 2.2.4 Advantages and Disadvantages of the CVT 15 2.3 Manual Transmission 17 2.2.1 Introduction of Manual Transmission 17 2.2.2 Manual Transmission’s Basic Principle. 19 ix 2.2.3 Advantages and Disadvantages of Manual Transmission 22 2.4 General of Toyota iQ 24 2.5 Summary 25 CHAPTER 3 VEHICLE DYNAMICS PERFORMANCE 26 3.1 Introduction 26 3.2 Vehicle Resistance and Road Disturbances 27 3.2.1 Aerodynamics Resistance. 28 3.2.2 Rolling Resistance. 29 3.2.3 Gravitional Resistance. 29 3.2.4 Acceleration Resistance 30 3.3 Performance of Transmission. 30 3.3.1 TractiveEffort-Speed 30 3.3.2 Power Available 32 3.3.3 Engine-Vehicle Speed 34 3.3.4 Fuel consumption 35 3.4 Parameter of Toyota iQ 1.0 Liter 35 3.5 Summary 36 CHAPTER 4 RESULT AND DISCUSSION. 37 4.1 Introduction 37 4.2 Performance of Power-Torque Engine Toyota 1.0 Liter 38 4.3 Example of Calculation 39 4.3.1 Power Available 39 4.3.2 Tractive Effort 41 4.3.3 Road Wheel Speed 41 4.4 Vehicle Performances Graph and Bar Chart 42 4.4.1 Power Available 42 4.4.2 Tractive Effort 43 4.4.3 Road Wheel Speed 45 4.4.4 Fuel Consumption 46 4.4.5 Carbon Dioxide Emission 47 4.4.6 Peak up of vehicle 48 4.5 Discussion 49 4.5.1 Comparison in Maintenance and Price 49 4.5.2 Compatibility of CVT for A Car under 1 Liter Engine 51 4.6 Summary 52 x CHAPTER 5 CONCLUSION AND RECOMMENDATION 53 5.1 Conclusion 53 5.2 Recommendation 54 REFERENCES 55 APPENDICES 58 A1 Gantt Chart for FYP 1 58 A2 Gantt Chart for FYP 2 59 B1 Technical Data For Toyota iQ 1.0 Liter (CVT) 60 B2 Technical Data For Toyota iQ 1.0 Liter (Manual 61 Transmission) C Table of Power and Torque engine’s performance 62 D1 Table of Tractive Effort versus Vehicle Speed 63 (ManualTransmission) D2 Table of Tractive Effort versus Vehicle Speed (CVT) 64 E1 Table of Power Available for Manual Transmission 64 E2 Table of Power Available for CVT 66 F1 Table of Road Wheel Speed for Manual Transmission 67 F2 Table of Road Wheel Speed for CVT 68 G Table of Fuel Consumption 69 Table of CO2 emission 69 Table of Peak Up of Vehicle 69 xi LIST OF TABLES Table No.