Browse Topic: Transmission fluids
ABSTRACT Traditional engineering concerns such as lubrication and cooling are still present even as vehicle functions become more complex. The established solution to monitor fluid levels has been a sight glass or a dipstick. More complex machines demand continuous knowledge of fluid levels without adding to operator workload. Remote monitoring of vehicle health will become normal and expected by owners and operators of evolving vehicle designs. This dual function fluid level sensor provides both electronic and operator monitoring of vehicle fluids, as well as redundancy in the event of electronic failure. Grouping of sensor components that are considered more likely to fail into one group, aids replacement when necessary. By incorporating a traditional dipstick into a continuous electronic monitoring solution, either method of level monitoring is facilitated
ABSTRACT Thermal management systems (TMS) of armored ground vehicle designs are often incapable of sustained heat rejection during high tractive effort conditions and ambient conditions. The use of a latent heat energy storage system that utilizes Phase Change Materials (PCMs) is an effective way of storing thermal energy and offers key advantages such as high-energy storage density, high heat of fusion values, and greater stability in temperature control. Military vehicles frequently undergo high-transient thermal loads and often do not provide adequate cooling for powertrain subsystems. This work outlines an approach to temporarily store excess heat generated by the transmission during high tractive effort situations through use of a passive PCM retrofit thereby extending the operating time, reducing temperature transients, and limiting overheating. A numerical heat transfer model has been developed based around a conceptual vehicle transmission TMS. The model predicts the
A well-designed cooling system is crucial in construction machines for efficient heat dissipation from vital components, including the Radiator(RAD), Oil Cooler (OC) and Intercooler (IC). The radiator ensures optimal engine performance and longevity by maintaining a stable operating temperature. Oil Coolers preserve hydraulic system efficiency. Inter Coolers optimize engine performance through denser intake air. The robust cooling system enhances system reliability, reduces downtime, avoid overdesigned system, and increases operator safety in demanding construction environments. The size and location of heat exchangers are critical in cooling system design. Using 1D simulation tool KULI for cooling system design offers the benefits of comprehensive system simulation, optimization of thermal management, reduced development time and costs, enhanced system reliability, improved integration with other systems, and real-world testing and validation. The tool enables time and cost-effective
Effective design of the lubrication path greatly influences the durability of any transmission system. However, it is experimentally impossible to estimate the internal distribution of the automotive transmission fluid (ATF) to different parts of the transmission system due to its structural complexities. Hybrid vehicle transmission systems usually consist of different types of bearings (ball bearings, thrust bearings, roller bearings, etc.) in conjunction with gear systems. It is a perennial challenge to computationally simulate such complicated rotating systems. Hence, one-dimensional models have been the state of the art for designing these intricate transmission systems. Though quantifiable, the 1D models still rely heavily on some testing data. Furthermore, HEVs (hybrid electric vehicles) desire a more efficient lubrication system compared to their counterparts (Internal combustion engine vehicles) to extend the range of operation on a single charge. Thus, this paper includes a
This SAE Information Report details some of the equipment and procedures used to measure critical characteristics of automatic transmission fluid (ATF) used in current automatic transmissions. It is intended to assist those concerned with the design of transmission components, and with the selection and marketing of ATFs for the use in passenger car and light-duty truck automatic transmissions. The information contained herein will be helpful in understanding the terms related to properties, designations, and service applications of ATFs
Wet-sump transmissions are widely used in heavy duty and medium duty vehicles. As these transmissions do not have a dedicated forced lubrication system, it is important that the gear train, shafts, and enclosure are designed appropriately so that enough oil splashes to critical locations to ensure sufficient lubrication. The lubrication effectiveness of such transmissions can be studied through detailed tests or numerical simulations. Often, the vehicle, and therefore the transmission, encounters some severe operating conditions, such as climbing on an incline, driving downhill, etc. Studying these conditions through tests is an expensive process and this imposes the need for an analysis first approach. In this paper, the 3D multiphase Volume of Fluid (VOF) method is used to examine two such extreme cases: an 8-degree tilted installation of transmission in a vehicle, and an inclined condition of transmission during a 10-degree uphill climb. By studying the oil volume fraction on gears
This SAE Recommended Practice is intended as the definition of a standard test, which may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering its use. The SAE No. 2 friction test is used to evaluate the friction characteristics of automatic transmission plate clutches with automotive transmission fluid combinations. The specific purpose of this document is to define a µPVT test for the evaluation of the variation of wet friction system low speed slip characteristics as a function of speed, temperature, and pressure. This procedure is intended as a suggested method for both suppliers and end users. The only variables selected by the supplier or user of the friction system are: Friction material Fluid Reaction plates Oil flow (optional) These four variables must be clearly identified when reporting the results of this test. If any of the test parameters or system hardware as described in this document are changed
This document provides a method/procedure for specifying the properties of vulcanized elastomeric materials (natural rubber or synthetic rubbers, alone or in combination) that are intended for, but not limited to, use in rubber products for automotive applications. This document covers materials that do not contain any re-use, recycled, or regrind materials unless otherwise agreed to by manufacturer and end user. The use of such materials, including maximum percent, must be specified using a “Z” suffix. This classification system covers thermoset High Consistency Elastomers (HCEs) only. Thermoplastic Elastomer (TPE) materials are classified using SAE J2558. Silicone Formed In Place Gasket (FIPG) systems such as Room Temperature Vulcanized (RTV) Silicones, and Liquid Silicone Rubber (LSR) systems are classified using ASTM F2468
This SAE Standard provides the testing and functional requirements guidance necessary for a leak detection device that uses any non-A/C refrigerant tracer gas, such as helium or a nitrogen-hydrogen blend, to provide functional performance equivalent to a refrigerant electronic leak detector. It explains how a non-refrigerant leak detector’s calibration can be established to provide levels of detection equal to electronic leak detectors that meet SAE J2791 for R-134a and SAE J2913 for R-1234yf
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal
This SAE Recommended Practice promotes uniformity in the evaluation tests and performance measurements that are conducted on fuel injectors used in low-pressure gasoline engine applications. The scope of this document is limited to electronically actuated fuel injection devices that are utilized in automotive gasoline port fuel injection systems where the fuel supply pressure is normally less than 1000 kPa. Detailed test procedures are provided for determining numerous PFI injector parameters, including, but not limited to, flow curves, leakage, electromechanical performance, fluid compatibility and corrosion susceptibility, durability, the effects of vibration and torsional deflection, thermal cycling effects, and noise. The standardized measurement procedures in this document are all bench tests. Characterization of the fuel spray from a low-pressure gasoline port fuel injector is quite important; however, these spray characterization tests are not addressed in this document, but are
This specification covers performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in road vehicle applications that are: low voltage (0 to 20 VDC) or Coaxial. Incomplete (mechanical) specifications for jacketed twisted pair connectors are also provided. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist-lock connector systems, >20 VAC or DC, or to eyelet terminals. No electrical connector, terminal, or related component may be represented as having met USCAR specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts. If testing is performed by another source, it does not relieve the primary
The gear lubricants covered by this standard exceed American Petroleum Institute (API) Service Classification API GL-5 and are intended for hypoid-type, automotive gear units, operating under conditions of high-speed/shock load and low-speed/high-torque. These lubricants may be appropriate for other gear applications where the position of the shafts relative to each other and the type of gear flank contact involve a large percentage of sliding contact. Such applications typically require extreme pressure (EP) additives to prevent the adhesion and subsequent tearing away of material from the loaded gear flanks. These lubricants are not appropriate for the lubrication of worm gears. Appendix A is a mandatory part of this standard. The information contained in Appendix A is intended for the demonstration of compliance with the requirements of this standard and for listing on the Qualified Products List (QPL) administered by the Lubricant Review Institute (LRI). Appendix A contains a
This SAE Information Report was prepared by the SAE Fuels and Lubricants Technical Committee for two purposes: (a) to assist the users of automotive equipment in the selection of axle1 and manual transmission lubricants for field use, and (b) to promote a uniform practice for use by marketers of lubricants and by equipment builders in identifying and recommending these lubricants by a service designation
The procedures contained in this specification cover the laboratory testing of replaceable halogen incandescent bulbs for use in automotive road illumination. The following tests are intended to be run under the following conditions. New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test The completion of one calendar year, accept as noted in the following Test Schedule Table. Test Title Yearly Physical Dimensions X Mean Spherical Candela (MSCD) X External Visual Examination X Color X Leak/Sealability Through Terminals and Seals X Deflection X Fluid Compatibility Terminal Retention X Resonant Frequencies Aged Resonant Frequency Salt Spray Outgassing Temperatures Requirement Laboratory Life at 14.0 VDC X Luminous Intensity Maintenance X Vibration Durability Shock Aged Vibration Durability Terminal Requirements DRL (SAE J2087
The procedures contained in this specification cover the laboratory testing of miniature incandescent bulbs for use in automotive illumination and signaling applications. The following tests shall be run whenever the following occurs: New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test. The completion of one calendar year as noted in the following Test Schedule Table. Process control data is acceptable. Test Title Yearly Physical Dimensions X Mean Spherical Candela X External Visual Examination X Crush X Thermal Shock X Bayonet Base Retention X Pin Removal X Wedge Base Retention X Lead Wire Bend X Lead Wire Pull X Natural Amber Color X Coated Amber Color Integrated Color Visual Color Point Color Color Maintenance and Coating Durability Amber Coating Chemical Resistance X X X Resonant Frequency Aged Resonant Frequency Salt Spray Wire Loop Pull X Outgassing/Heat Laboratory Life Accelerated Life X Luminous Intensity Maintenance X
Three levels of fan structural analysis are included in this practice: a Initial structural integrity. b In-vehicle testing. c Durability (laboratory) test methods. The initial structural integrity section describes analytical and test methods used to predict potential resonance and, therefore, possible fatigue accumulation. The in-vehicle (or machine) section enumerates the general procedure used to conduct a fan strain gage test. Various considerations that may affect the outcome of strain gage data have been described for the user of this procedure to adapt/discard depending on the particular application. The durability test methods section describes the detailed test procedures for a laboratory environment that may be used depending on type of fan, equipment availability, and end objective. The second and third levels build upon information derived from the previous level. Engineering judgment is required as to the applicability of each level to a different vehicle environment or a
This SAE Recommended Practice is applicable to oil-to-air and oil-to-coolant oil coolers installed on mobile or stationary equipment and provides a glossary of oil cooler nomenclature. Such oil coolers may be used for the purpose of cooling automatic transmission fluid, hydraulic system oil, retarder system fluid, engine oil, etc. This document outlines the methods of procuring the test data to determine the operating characteristics of the oil cooling system and the interpretation of the results
Gearbox power transfer efficiency is a major factor in overall powertrain efficiency of a passenger vehicle. With rapidly changing emission and fuel efficiency regulations, there is a push to increase the gearbox efficiency to improve the overall fuel economy of the vehicle. In case of an existing gearbox, efficiency can be improved by using the low viscosity lubrication oil. Despite a benefit in increasing the gearbox efficiency, lowering down the viscosity of lubrication oil gives rise to few challenges with respect to its performance. One of these challenges is breather performance which defines that transmission oil should not come out of breather pipe in some pre-defined conditions during gearbox operation. As this validation is being carried out on proto parts when the complete system is ready, failure to satisfy the defined criteria for breather performance can lead to multiple trials. This further leads to extended design cycles for launching new passenger vehicles with better
In electric vehicles (EVs), drivetrain lubricants (EV fluids) are often relied upon to aid in cooling the motors. In such cases, the lubricants must provide high cooling performance. They should also improve the efficiency of the transmissions and reduction gearboxes in EV drivetrains. Both requirements can be met by lowering the viscosity of the fluid. This effectively improves the heat transfer coefficient and also helps increase efficiency by reducing churning loss. However, a viscosity that is too low can negatively affect the fatigue life of mechanical parts such as gears and bearings. To solve the issues associated with lower viscosities, we optimized the anti-wear agents, dispersants, and other additives to develop formulations specially designed for EV drivetrains. The result are lubricants that provide excellent extreme pressure properties and protection for drivetrain components despite their lower viscosities. We evaluated performance of the developed lubricants, and it was
This test procedure is intended to apply to hydraulic pump suction filters and strainers used in automotive automatic transmissions that include hydraulic power pumps. The various paragraphs of Section 5 include a variety of tests and alternative tests that are not applicable to all filters and applications, so the engineer must specify which tests are to be performed for a particular application. These test procedures are intended to evaluate filter functional performance characteristics only, durability is not evaluated under this standard. Filter design requirements must be specified by the engineer on the filter assembly drawing, an applicable engineering specification, or summarized on an application data sheet similar to that found in this recommended practice. See Figure 6. Pressure circuit filters, both barrier and system contamination control types, are not covered under this standard. They are similar in design and construction to filters used in many hydraulic and
This SAE Standard covers hose intended for use with automatic transmission cooling system applications. Type A hoses are intended for original equipment or replacement applications while Type B hoses are intended for aftermarket auxiliary cooler applications only. The reference fluid for tests requiring the use of automatic transmission fluid (ATF) shall be Dexron III / Mercon 5 or equivalent ATF that is agreed to by hose manufacturer and customer
This SAE Standard applies to self-propelled, rider operated sweepers and scrubbers as defined in SAE J2130 with maximum machine level surface speeds up to 32 km/h. Machines capable of speeds equal to and greater than 32 km/h are not covered by this document
In recent decades, there has been a growing focus on improving overall vehicle efficiency and fuel economy due to growing customer awareness and more stringent environmental regulations. Effort has been placed on improving the engine efficiency and reducing the losses of the transmission and driveline. One essential component of this process is to correctly size the transmission oil pump as it is one of the main energy consumers in the powertrain. Conversely, the oil pump has a critical mission of ensuring reliable and high quality gear shift as well as supplying lubrication and cooling oil to various components in the transmission. This paper outlines a strategy to systematically understand and quantify the main requirements for sizing the oil pump to ensure adequate performance while minimizing the energy consumption of the pump. The proposed framework is a three-legged approach. The first component identifies the main consumers within the automatic transmission and establishes a
The heat generated by an internal combustion engine must be dissipated to maintain acceptable component temperatures throughout the entire powertrain system under all operating conditions. However, under cold start conditions it is beneficial to retain this available heat to achieve faster warm-up in order to reduce fuel consumption. In modern engines there are several components in the coolant circuit that are used to accelerate the warm-up of sub-system fluids such as the engine oil, transmission oil and axle oil. The magnitude of the fuel consumption reduction will depend on how these rapid warm-up devices are arranged, combined and controlled. This paper describes a methodology that was developed to optimize the distribution of coolant heat in the powertrain system during warm-up. A comparative study can be performed to optimize the arrangement of each heat exchanger in any given powertrain system to minimize cost and time early in development. Different thermal strategies or
In line with Global targets of reducing CO2 Emissions, transportation industry is witnessing a significant shift in focus — from emissions to fuel economy — by regulators, researchers, OEMs, fuels and lubricant manufactures. Improvements in fuel economy can have a significant bottom-line impact for fleets and owner operators alike. There are many paths to take when looking at a program to reduce fuel consumption. These include new engine and transmission designs, new metallurgies, surface finish, coatings, new injection technologies, turbochargers and of course through engine and transmission lubricants. Passenger car engine lubricants are being upgraded time to time and customized for fuel economy and emission compliance benefits as the vehicle technology evolved to meet the emerging regulations. New vehicle technology has shifted surface tribology more towards boundary regime as new designs are compact, offer high operating temperatures and pressures. Fuel Economy (FE) Regulations
The gear lubricants covered by this standard exceed American Petroleum Institute (API) Service Classification API GL-5 and are intended for hypoid-type, automotive gear units, operating under conditions of high-speed/shock load and low-speed/high-torque. These lubricants may be appropriate for other gear applications where the position of the shafts relative to each other and the type of gear flank contact involve a large percentage of sliding contact. Such applications typically require extreme pressure (EP) additives to prevent the adhesion and subsequent tearing away of material from the loaded gear flanks. These lubricants are not appropriate for the lubrication of worm gears. Appendix A is a mandatory part of this standard. The information contained in Appendix A is intended for the demonstration of compliance with the requirements of this standard and for listing on the Qualified Products List (QPL) administered by the Lubricant Review Institute (LRI). Appendix A contains a
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal
This SAE Recommended Practice applies to the use, by automotive service technicians, of generally available leak detection methods to service motor vehicle passenger compartment air conditioning systems
This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report
Automatic transmissions utilize solenoids to manage the flow of transmission fluid throughout the transmission and engage the appropriate clutches during a gear change. Because of the small clearances between sliding interfaces in a solenoid, compatibility between materials and fluids is essential to long-term functionality. The accumulation of films formed from corrosive species on these components can lead to premature failure. Copper (Cu) corrosion strip tests are found in almost all lubricant specifications; however, they do not necessarily provide assurances in the field. Long-duration, powered solenoid soak tests are undertaken to evaluate the long-term functionality of the transmission. The complexity of oil-based corrosion mechanisms, including the temperature dependence of these processes, can be difficult to evaluate even with this advanced level of testing. In this study, the corrosion rates of two Cu-based alloys relevant to solenoid components were evaluated while immersed
In the present article, structural spring characteristics of two different Belleville springs are analyzed to overcome a failure issue in an automatic shift transmission clutch system. The spring design is evaluated through explicit dynamics analysis by finite element modelling and validated by DIN 2093 standard. Automatic shift transmissions that are used in off-highway vehicles are employed with multi-plate wet clutch system to actuate the planetary gears. These clutches are actuated through automatic transmission fluid that are supplied through flow channels. The clutch piston is moved axially by fluid pressure against the clutch pack and Belleville spring thereby transfers torque. Meanwhile, the clutch piston is retracted by the spring force once the fluid pressure is cut off. The spring is designed in such a way that during the energizing mechanism, positive spring stiffness is maintained. It is noticed that the clutch function is obstructed as the spring is inverted to other side
In order to meet Corporate Average Fuel Economy (CAFÉ) regulations and Bharat Stage VI (BS VI) emission regulations, Indian auto original equipment manufacturers (OEMs) are adopting low viscosity engine/axle/transmission oils to achieve overall fuel efficiency gain. Attaining fuel economy by reducing oil viscosity is already established for passenger car motor oils (PCMOs) but is in its initial phase for heavy-duty diesel engine oils (HDDEOs). Now SAE 15W-40 is the most widely used viscosity grade by volume for HDDEO. In India, a large number of old vehicles meeting BS II, BS III and BS IV norms exists and require sustainable strategy to reduce fuel consumption, as well as overall greenhouse gas emissions. In this paper, authors discussed the development of low viscosity heavy duty diesel engine oil in 10W-30 viscometrics meeting API CH4 specification. Fuel economy credential of the developed product was carried out on a chassis dyno w.r.t. the reference oil in “Delhi Bus Driving Cycle
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