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Geared Continuously Variable Transmissions (CVTs)
This Is The World's First Geared CVT and It Will Blow Your Mind - Ratio Zero Transmission
A Geared CVT is a type of transmission that combines the features of a traditional Continuously Variable Transmission (CVT) and a set of gears. Traditional CVTs, such as those with a belt and pulley system, allow the vehicle to smoothly adjust engine speed and power output over a continuous range of ratios. A Geared CVT, however, incorporates a set of gears (typically planetary gears) into the system to combine the benefits of both traditional gears and CVT technology.
How Geared CVTs Work
1. **Continuous Variable Transmission (CVT) Principle**: - Traditional CVTs use a belt-and-pulley system to adjust the gear ratio between the engine and the wheels. As the vehicle accelerates, the system automatically adjusts to maintain the optimal engine speed (RPM), providing smooth power delivery without the stepped shifts found in traditional automatic transmissions. 2. **Incorporating Gears**: - In a geared CVT, instead of relying solely on pulleys, planetary gears or other gear mechanisms are used to complement the continuous variability of the CVT system. These gears help manage the power transfer more efficiently, often in combination with the CVT belt system. - **Planetary Gearsets**: These are the most common type of gears used in geared CVTs. A planetary gearset consists of a central "sun" gear, surrounded by "planet" gears that revolve around the sun gear, and an outer "ring" gear that encircles the planet gears. This setup allows the transmission to provide a wide range of gear ratios without the fixed steps found in traditional manual or automatic transmissions. 3. **The Combined Functionality**: - The geared CVT adjusts continuously to maintain the ideal engine speed for efficiency and performance while using gears to provide additional control over the torque transfer and power output. The combination of gears and the CVT system allows for: - **Enhanced Power Delivery**: The system can provide more consistent and precise power delivery across a wider range of driving conditions. - **Better Efficiency**: The geared system helps optimize the engine’s power, reducing fuel consumption, especially in hybrid vehicles where efficiency is critical. - **Smooth Transitions**: Like a traditional CVT, the geared CVT can maintain a smooth transition without the abrupt shifting typical of traditional gearboxes.
Key Components of a Geared CVT
- Planetary Gearset: As mentioned, planetary gears are used to modulate the gear ratios smoothly. The gearset typically includes:
- Sun Gear: The central gear connected to the engine.
- Planet Gears: The set of gears that rotate around the sun gear and engage with the ring gear.
- Ring Gear: The outermost gear that works with the planet gears.
- Variable Pulley System: Some geared CVTs still use a variable pulley system to adjust the drive belt's position, providing additional flexibility for changing the ratio.
- Hydraulic System: Most geared CVTs use a hydraulic system to control the pressure and movement of the pulleys and gears, ensuring smooth transitions and proper operation.
Advantages of Geared CVTs
- Efficiency: By combining the benefits of CVTs and geared systems, geared CVTs can provide more efficient power transfer, optimizing engine speed and fuel consumption.
- Smooth Acceleration: The vehicle experiences smooth, uninterrupted acceleration without the “shift shock” or jerky movements typical of traditional automatic transmissions.
- Improved Performance: The combination of gears and CVT elements allows the transmission to handle a wide range of power demands efficiently, which is particularly beneficial in hybrid or electric vehicles.
- Reduced Mechanical Loss: The use of gears, especially planetary gears, can help reduce friction and mechanical loss compared to traditional CVTs, improving overall performance.
Applications of Geared CVTs
- Hybrid and Electric Vehicles:
- Geared CVTs are particularly popular in hybrid vehicles, where efficiency is paramount. They help manage the transition between electric motors and internal combustion engines, ensuring smooth and efficient power delivery.
- Automotive:
- Car manufacturers like Toyota and Honda use geared CVTs in their hybrid models to combine the benefits of both systems for enhanced fuel efficiency and performance. The Toyota Prius and Honda Insight are examples of cars using geared CVTs.
- Motorcycles and Scooters:
- Some motorcycles and scooters use geared CVTs to enhance acceleration and maintain optimal engine speed, providing smoother rides and better fuel economy.
- Heavy Equipment and Industrial Applications:
- Geared CVTs are also used in certain types of industrial machinery and heavy equipment to manage power output efficiently, especially in situations where load handling and variable speeds are required.
Challenges of Geared CVTs
- Complexity: Geared CVTs are more complex than traditional CVTs, combining both gearing and belt mechanisms. This can lead to more maintenance needs and higher manufacturing costs.
- Size and Weight: The inclusion of planetary gears and other components can make geared CVTs bulkier and heavier than belt-driven CVTs, which may limit their use in smaller vehicles or applications where weight is a crucial factor.
- Cost: Due to their complexity and advanced design, geared CVTs can be more expensive to produce, making them less cost-effective than simpler transmission technologies in some cases.
Conclusion
Geared CVTs represent a significant advancement in transmission technology, combining the smoothness and fuel efficiency of traditional CVTs with the power handling and precision of geared systems. They are particularly useful in hybrid vehicles, where both smooth performance and efficiency are crucial. Despite their complexity and higher costs, geared CVTs are a promising solution for modern automotive and industrial applications where efficiency and performance are key.
Manufacturers of Geared CVTs
- JATCO Ltd.
- JATCO is a leading manufacturer of CVTs, and they produce geared CVTs for automotive applications, including those that combine planetary gears and CVT elements for better performance, particularly in hybrid and electric vehicles.
- Honda Motor Co., Ltd.
- Honda develops its own geared CVT systems, particularly for its hybrid vehicles, combining gear-based CVT technology to improve power delivery and fuel efficiency.
- Toyota Motor Corporation
- Toyota integrates geared CVTs in some hybrid vehicles, such as the Toyota Prius, combining traditional CVT technology with geared systems to improve overall performance, especially in hybrid powertrains.
- Aisin Seiki Co., Ltd.
- Aisin, a subsidiary of Toyota, manufactures a variety of transmissions, including geared CVTs for both automotive and industrial applications. Their systems use planetary gears and advanced mechanical elements for improved efficiency.
- BorgWarner Inc.
- BorgWarner produces advanced transmission systems, including geared CVTs for automotive and commercial vehicle applications, combining CVT and gear-based technologies for enhanced performance.
- ZF Friedrichshafen AG
- ZF manufactures geared CVT systems, especially for hybrid and electric vehicles, combining continuous variable technology with geared elements to optimize performance and efficiency.
- Ficosa International
- Ficosa develops geared CVTs for vehicles requiring higher performance and efficiency, particularly in hybrid applications.
- Magna International
- Magna works on geared CVTs for hybrid and electric vehicles, integrating CVT and gear-based systems to balance performance, efficiency, and driving dynamics.
- Bosch
- Bosch develops geared CVT systems for hybrid vehicle applications, helping to optimize fuel efficiency, performance, and emissions compliance.
- Hyundai Motor Group
- Hyundai develops geared CVTs for hybrid vehicles, combining CVT technology with advanced gearing systems to improve driving performance and fuel efficiency.