Gear Ratio Optimization of Manual Transmission for Passenger Vehicle Using 1D Simulation Cycle and Statistical Analysis

Abstract

Nowadays, the global greenhouse emission becoming much worse, in lines with the increase of vehicle production which is one factor that leads to greenhouse gas emission. The properly matched engine transmission in vehicle system design is important in improving vehicle performance and fuel economy. Thus, the basic purpose of this research is to design and develop 1D vehicle physics model for powertrain matching and fuel economy prediction towards lower carbon emission vehicle and to evaluate and optimize transmission gear ratios to improve vehicle performance and fuel economy using statistical analysis. The subject of the study is a Proton Iriz 1.6L with 5-speed manual transmission. The vehicle is modelled in GT-Suite in order to predict the vehicle performance and fuel economy. The baseline results are compared with the actual testing data with the correlation of each parameter, performance and fuel economy which resulted less than 3% tolerance different. The optimal selection of gear ratio are determine by the Taguchi method while each gear ratio significance toward full transmission set are calculated using ANOVA. Fuel consumption is calculated through the simulation with the aid from prediction of Taguchi Method. The result gather from GT-Suite simulation shows an improvement of 1.79% for 0-100 km/h speed and 5.56% for NEDC fuel economy compared to the baseline model. This computerize method will reduce significantly greater in real life cost, reduce the time in real testing and less computing time, also increase the productivity of the researcher and engineers