How does a robot on a car work? Operating principle of a robotic gearbox. Starting the climb, overcoming it, descending

Robotic gearbox (common name: robot box) is a manual transmission in which the clutch release and gear shift functions are automated. Name " robotic gearbox"indicates that the driver and driving conditions form only the input information for the control system, and the operation of the gearbox is controlled by an electronic unit with a specific control algorithm.

The robotic transmission combines the comfort of an automatic transmission with the reliability and fuel efficiency of a manual transmission. At the same time, the “robot” is for the most part much cheaper than a classic automatic transmission. Currently, almost all leading automakers equip their cars with robotic gearboxes, installing them on the entire line of models from small to premium class.

Robotic gearbox design

Robotic gearboxes differ in design, however, the following general device of this unit can be distinguished - a manual gearbox with a clutch and gear control system.

Automated transmissions use a friction type clutch. This may be a separate disc or a package of friction discs. Progressive in the design of the gearbox is the so-called. double clutch, which ensures transmission of torque without interrupting the power flow.

The design of the robotic gearbox is based on a manual gearbox. In production, mainly ready-made technical solutions are used. For example, automatic transmission Speedshift from Mercedes-Benz is built on the basis of the 7G-Tronic automatic transmission by replacing the torque converter with a friction multi-plate clutch. At the base of the box SMG BMW has a six-speed manual transmission equipped with an electro-hydraulic clutch.

Robotic boxes can have an electric or hydraulic clutch and gear drive . In an electric drive, the executive bodies are servomechanisms (electric motor and mechanical transmission). The hydraulic drive is carried out using hydraulic cylinders, which are controlled by electromagnetic valves. This type of drive is also called electrohydraulic. In a number of designs of “robots” with an electric drive (Easytronic from Opel, Durashift EST from Ford) uses a hydromechanical unit with an electric motor to move the clutch master cylinder.

The electric drive is distinguished by low operating speed (gear shift time 0.3-0.5 s) and lower energy consumption. The hydraulic drive requires constant maintenance of pressure in the system, which means high energy costs. But on the other hand, it is faster. Some hydraulically driven robotic gearboxes found in sports cars have impressive shift speeds: Ferrari 599GTO - 0.06c, Lamboghini Aventador - 0.05c.

These qualities determine the scope of application of “robots” with electric drive on budget cars, and with hydraulic drive on more expensive cars. The following gearbox designs have an electric drive:

• Allshift from Mitsubishi;
• Dualogic from Fiat;
• Durashift EST from Ford;
• Easytronic from Opel;
• MultiMode from Toyota;
• SensoDrive from Citroen;
• 2-Tronic from Peugeot.

A fairly large number of robotic boxes are equipped with a hydraulic drive:

• ISR(Independent Shifting Rods) by Lamborghini;
• Quickshift from Renault;
• R-Tronic from Audi;
• Selespeed from Alfa Romeo;
• SMG from BMW.

The robotic gearbox is controlled by an electronic system that includes input sensors, an electronic control unit and actuators. Input sensors monitor the main parameters of the gearbox: input and output speed, position of the gear forks, selector position, as well as oil pressure and temperature (for hydraulic drive) and transmit them to the control unit.

Based on sensor signals, the electronic control unit generates control actions on the actuators in accordance with the programmed program. In its work, the electronic unit interacts with the engine management system, the ABS (ESP) system. In robotic boxes with hydraulic drive, the control system additionally includes a hydraulic control unit, which provides direct control of hydraulic cylinders and pressure in the system.

The actuators of the robotic gearbox, depending on the type of drive, are electric motors ( electric drive), electromagnetic valves of hydraulic cylinders ( hydraulic drive).

The main disadvantage of a robotic gearbox is the relatively long gear shift time, which leads to jerks and dips in the vehicle dynamics and, accordingly, reduces the comfort of driving the vehicle. A solution to this problem was found in the use of a gearbox with two clutches, which ensured gear shifting without interrupting the power flow.

The double clutch allows you to select the next gear when the gear is engaged and, if necessary, engage it without interrupting the operation of the box. Therefore, another name for a robotic gearbox with two clutches is preselective gearbox(from preselect - pre-select).

Another advantage of the dual clutch transmission is the high speed of gear shifting, which depends only on the speed of the clutches ( DSG from Volkswagen - 0.2c, DCT M Drivelogic from BMW – 0.1c). The “robot” with two clutches is also compact, which is important for small cars. Along with this, one can note the increased energy consumption of the box (especially with a “wet” clutch). Relatively high gear shift speeds combined with continuous transmission of torque make it possible to achieve excellent acceleration dynamics of the vehicle and fuel economy.

Currently, dual clutch is used in many robotic gearboxes:

• DCT M Drivelogic from BMW;
• DSG from Volkswagen;
• PDK from Porsche;
• Powershift from Ford, Volvo;
• Speedshift DCT from Mercedes-Benz;
• S-Tronic from Audi;
• TCT from Alfa Romeo;
• Twin Clutch SST from Mitsubishi.

Even the magnificent Ferrari 458 Italia is equipped Doppelkupplungsgetriebe (dual clutch transmission). All of the listed robotic gearboxes use a hydraulic clutch and gear drive. And only one gearbox today has an electric drive device, this EDC (Efficient Dual Clutch) from Renault (gear shift time 0.29s).

The pioneers in the mass use of dual-clutch transmissions are Volkswagen and Audi, which have been installing DSG and S-Tronic robotic transmissions in their cars since 2003. Box S-Tronic is an analogue of the DSG box, but unlike it, it is installed longitudinally on the axle on rear- and all-wheel drive vehicles.

On an automated box DCT M Drivelogic The control system implements the Drivelogic function, which provides eleven gear shift programs. Six programs are manual shift programs, and five are automated shift programs. This function allows you to adapt gear changes to the driving style of a particular person. Essentially, this gearbox is an adaptive gearbox.

Operating principle of a robotic gearbox

The robotic gearbox can operate in two modes: automatic and semi-automatic. In automatic mode, the electronic control unit, based on input sensor signals, implements a specific algorithm for controlling the box using actuators.

All robotic gearboxes have a manual (semi-automatic) gear shift mode, similar to the Tiptronic automatic transmission function. Operation in this mode allows you to sequentially change gears from low to high and vice versa using the selector lever and (or) steering wheel paddles. Therefore, in a number of information sources, a robotic transmission is called sequential gearbox(from sequensum - sequence).

Modern cars are equipped with new types of transmissions, including a robotic gearbox. To understand the main points related to its operation, you need to understand what a robotic gearbox is.

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What is a robotic gearbox?

A robotic gearbox on a car means something between a manual transmission and an automatic transmission. In fact, a robotic gearbox is a “mechanics” equipped with an automatic clutch and the ability to change gears. The operation of this type of unit does not depend on the driver, but on the functioning of the control electronic module. While driving, the driver only needs to correctly transmit incoming data to ensure proper operation of the gearbox.

Robotic gearbox device

Schematic structure of the structural components of manual transmission

To understand what it is, you need to understand the structure of the unit. Additional elements intended for squeezing the clutch, as well as switching and selecting speeds, are called actuators.

The robotic transmission is equipped with its own control system, made in the form of a control unit, as well as several controllers. These sensors are designed to interact with the block. A robotic gearbox is fundamentally different from traditional automatic transmissions and CVT transmissions.

Robot gearboxes, like mechanical ones, are equipped with a clutch. ATF gear oils are not used in these types of units.

Depending on the car manufacturer, the robotic transmission can be equipped with one or two clutches:

• if there is only one clutch, then it is a single-disk unit;
• if two, then the transmission is considered preselective.

The main components of the robotic unit:

1. The checkpoint itself.
2. Actuators or servos. Designed for squeezing the clutch and activating speeds.
3. The control module, which is a microprocessor unit. Used to process and transmit commands.
4. External controllers. The number of sensors may vary depending on the machine manufacturer.

checkpoint

We recommend understanding the structure of the robotic unit in more detail using the example of a six-speed gearbox equipped with two clutches. The unit is designed as a manual gearbox, but is equipped with two drive pulleys. One of these elements is installed inside the other. The outer pulley has an internal cavity into which the inner component is installed. The outer pulley contains the gears for driving the second, fourth and sixth speeds, and the inner pulley contains the gears for the first, third, fifth and reverse gears.

Each shaft of the robotic gearbox is equipped with a separate clutch.

Actuators or servos

Actuator devices can be electrical or hydraulic. The electric type of elements is made in the form of an electric motor with a gearbox, and the hydraulic type is considered a hydraulic cylinder. The rod of the latter is connected to the synchronizer device. The main purpose of the actuator elements is to mechanically move the synchronizer components, as well as activate and deactivate the clutch.

Control module

The control module is a microprocessor unit on which external controllers are installed. These sensors are involved in the electronic engine control system of the machine. The transmission sensor interacts with controllers from the power unit and other systems, for example, ABS. The control module can be combined with a microprocessor engine control unit, but the transmission will operate according to its own algorithm.

The Carvizor channel spoke in detail about the structure and design features of manual transmission.

Features of a robotic gearbox

The electric clutch drive operates via an electric motor as well as mechanical speed. The operation of the hydraulic drive is based on special cylindrical devices, which are controlled by an electromagnetic valve. Sometimes a robotic unit can be supplemented with an electric motor, which is used to move cylindrical elements and is designed to support the functioning of the hydromechanical module. This device, equipped with a drive, is characterized by a long speed switching, which can be up to half a second.

Compared to a hydraulic device, the unit does not require constant support of the required pressure level to operate. In some Opel models, hydraulic units are characterized by a fast speed switching cycle, providing switching in 0.06 seconds. But such robots are usually installed on sports cars.

Working principle of robot gearbox

Scheme of functioning of the robotic unit

The robotic unit works like a mechanic - to start driving and change gears, the driver needs to depress the clutch pedal. The procedure for activating this mechanism is performed through an actuator device that receives an impulse from the control module. After a signal is given, the unit slowly rotates the gear unit.

If the transmission is equipped with two clutches, then the first one is initially activated. After this, the actuator device for selecting and activating the speed brings the synchronizer unit to the first speed gear. This leads to its blocking on the shaft and the beginning of rotation of the secondary pulley. When the car starts moving, the driver presses on the gas. If the transmission is single-disc, the next speed will be activated after a certain period of time. As a result, a so-called time gap appears.

To prevent the occurrence of a time delay and reduce the gear shift time, the unit is equipped with a second clutch and another shaft. This led to the creation of the preselective box. When the first gear is engaged, the second is ready to be activated because the second clutch is already engaged. When the unit receives a signal from the control module, it quickly switches from first speed to second.

Subsequent switching to higher and lower speeds while driving is performed in the same way. The time interval when switching is minimal. Any over-thrust is excluded, there is also no failure of engine thrust and other nuances. As a result, the car drives dynamically, and the fuel consumption savings are maximum. Functioning in automatic mode is achieved through regular analysis of the microprocessor module of pulses supplied from external controllers.

When receiving signals and sending them, the microprocessor takes into account:

• the amount of load on the power unit;
• driving speed;
• the position in which the gas pedal is located.

Robotic boxes have the ability to manually change speeds; this feature can be called an imitation of a hydromechanical automatic machine. Some types of units allow locking when overspeed is activated.

Block diagram of the functioning of the I-Shift robotic system on Honda cars

Operating modes

The microprocessor module can operate in several modes:

1. Sport. Typically, it is activated when driving on the highway, when the car is driving steadily at high speed.
2. City mode. Activated when driving around the city or standing in a traffic jam.
3. Economy Allows maximum fuel savings. But the driving speed will be minimal.

How to learn to drive with a robotic gearbox? Main control features

To prevent transmission malfunctions, you need to know how to use the robot, namely:

• how to warm up the unit;
• how to start movements correctly;
• how to use the transmission when operating a car in city mode.

Warming up the robotic gearbox and operating features

Many car manufacturers claim that robotic units do not need to warm up. But in this matter, it is necessary to take into account the temperature of the working fluid in the lubrication system, as well as how the oil behaves in frosty conditions. Some types of consumables thicken at low temperatures and accumulate at the bottom of the unit. According to the standard, the warm-up process consists of starting the engine and waiting 2-3 minutes. When warming up the car, you do not need to touch the gearshift lever.

If the car is in a garage, then you need to drive it out calmly and smoothly to avoid jolts and jerks. When warming up, you need to monitor the number of revolutions; ideally, their number will be minimal and will be about 1 thousand per minute. The unit should also be warmed up in the summer, thanks to this all the components of the robot will be properly lubricated. Warming up will prevent rapid wear and tear of the unit components.

Main operating features that will increase the operating life of the unit as a whole:

1. Avoid slipping when driving in cold weather. This will lead to rapid wear of the actuators and components. Regular slipping will cause the unit to miscalibrate.
2. Experts do not recommend frequent driving on heavily snow-covered surfaces. The vehicle may get stuck, which will ultimately cause slippage.
3. It is recommended to use products equipped with studs as winter tires. When installing regular tires on wheels, there is a risk of slipping on ice.
4. During long downtimes of several days or more, it is recommended to set the gearbox selector to position E. The engine must be turned off.
5. If the road condition is poor, experts advise starting to drive in second gear, but not accelerating too much.

Alexey Rykov spoke about the basic principles of controlling a robotic gearbox using the example of the Lada Granta.

Rules for the correct start on a robot box

Owners of cars equipped with robotic gearboxes should take into account that some vehicles do not have the additional option of starting assistance. In particular, we are talking about starting to move on a hill, uphill. Therefore, it is important to learn how to get started correctly. The starting procedure is carried out in the same way as on a car with a mechanical unit.

More information about getting started:

1. The parking brake lever must be raised.
2. The gear lever is set to mode A.
3. The driver easily, effortlessly presses the gas.
4. At the same time, the parking brake lever is released.

If, when you start driving outside, there is sub-zero temperature and high humidity, the box selector can be moved to position M1. The force on the gas pedal must be acceptable so that overslip does not occur. If the machine is equipped with a gyroscope, then when selecting the automatic mode, the microprocessor of the unit itself will select the required speed and switch. This will allow you to switch speeds down. If the driver is experienced, then, taking into account the situation, he can set the M mode when fixing the set gear.

If the speed limit is initially set, then it is not recommended to change the speed of movement. The engine speed should be between 2500 and 5000 per minute, but not beyond this range. When you start driving downhill, the transmission selector is set to mode A and the handbrake lever is released.

Operation of a robotic gearbox in urban environments

Regular use of the vehicle in city traffic and traffic jams can lead to rapid wear of transmission components. To prevent this, when stopping the car, you should move the gear lever to mode N. Then the parking brake is activated and the engine is stopped. If the stops are short-term, for example, in traffic jams, then the neutral mode does not need to be turned on; it is enough to stop when the lever is set to mode A. If the car sits in a traffic jam for more than one minute, then the engine will need to be stopped.

Vasily Kostin spoke about the intricacies of using machines with an installed robot.

Advantages

Advantages of robotic units:

1. Reliability of the unit design as a whole. The device is based on a mechanical component, which has undergone numerous tests and been studied by specialists. Thanks to this, this type of gearbox is better in reliability than conventional automatic transmissions and CVTs.
2. Operating a vehicle with a robotic unit installed allows you to save fuel. If the gearbox and engine of the car are not worn out, then fuel savings can be up to 30%.
3. Refilling a robotic unit requires less lubricant, on average no more than three liters. For comparison, about seven liters are poured into CVT boxes. This advantage allows you to save money.
4. The number of gears in robots corresponds to the number of speeds in mechanics.
5. Due to the fact that the basis of the gearbox is the mechanical part, this allows for simple repairs. Many specialists have skills in such repairs, which cannot be said about CVT units. Most common problems can be resolved on your own with the right approach.
6. The service life of the clutch system is approximately 40% longer than that of manual transmissions. This is not only about saving money, but also about safety.
7. When operating a car in urban conditions, the manual gear shift function allows you to start driving without load on the unit.

Flaws

Robotic gearboxes have not only advantages, but also disadvantages; they are given in accordance with reviews by the owner of cars with manual transmission:

1. The main disadvantage of a manual transmission is problems in programming the transmission. It may be difficult for a car owner to reprogram the software in order to increase the dynamics of the car and save unit resources. Therefore, difficulties arise in adjusting the transmission for a specific driving style. The driver will need time to get used to the way the car operates for convenient operation.
2. Low activation speed and slow response of the unit. This is due to the costs of programming the device. This problem is typical for many automatic transmissions.
3. When driving in city conditions and traffic jams, as well as on rough roads, the driver should switch to manual control mode. Otherwise, the elements of the clutch system will wear out faster. This is reflected in the service life of the unit as a whole.
4. When changing gears, jerks and jolts are felt. Not on all units, but on many. This is because the throttle is not released before the speed change occurs. To eliminate this problem, you can not fully depress the gas pedal.
5. When driving uphill, the clutch may disengage. The problem is related to overheating of the transmission unit. If the car is moving uphill, it is recommended to switch to manual control.

The problem with reprogramming can be solved by replacing the microprocessor firmware, but this must be done when the warranty period expires.

The HPC channel presents a real negative consumer review about the operation of a robotic unit in a car.

The difference between a robotic gearbox and an automatic one

The main differences between robotic transmissions and automatic units:

1. Design features. The robot is a mechanical unit equipped with a microprocessor control device. Automatic transmissions have their own device. It also includes an electronic module, but there is no mechanical component in the machines.
2. Automatic transmissions outperform robotic units in terms of speed shifting. Also, on automatic transmissions the switching procedure is smoother.
3. Robotic devices have a manual switching option. On automatic units there is no possibility of manual control.
4. Cars equipped with a robotic unit consume less fuel. Refilling them requires less lubricant.
5. The procedure for repairing and servicing robotic gearboxes will cost the consumer less than an automatic transmission.

Relevance of robot boxes in Russia

Russian car manufacturers almost never install robotic units on their products. In 2015, the management of the VAZ automobile concern announced that Lada Priora car models would be equipped with robotic gearboxes. The total weight of the device is approximately 35 kg. The unit itself is adapted to domestic roads, as well as weather conditions characteristic of the Russian climate.

For example, automatic machines may refuse to start a car engine if the temperature drops below -25 degrees. Robotic units will be able to function effectively and start internal combustion engines at -40 degrees. The manufacturer AvtoVAZ provides a three-year warranty on the gearbox, but claims that on average the device will last about ten years. This step was taken by the concern's representative office to increase sales of Lada Priora cars.

Today, among domestic cars, robotic gearboxes are installed only on Lada Grants and Priora.

The official Lada channel presented a video clip about the production of robotic units for Lada Granta cars.

Tips for choosing a robotic gearbox

Before purchasing a vehicle with a manual transmission, you need to collect as much information as possible about the functioning of a specific type of transmission. It is recommended to study consumer reviews, since some versions of robots have “glitches” that are characteristic of the entire line. In particular, you need to know about the time interval when changing gears. It is better to give preference to options in which the switching procedure is performed as quickly as possible.

When choosing a car, you need to take into account the individuality of the device. Identical transmissions may differ from each other. Problems associated with the operation of the unit can often be removed by flashing the microprocessor unit.

Basic malfunctions in the operation of robots

Symptoms that may indicate a problem with the device:

1. An alarm indicator appeared on the control panel. This could be a Check Engine light or a special symbol indicating problems with the transmission.
2. While driving, the driver hears extraneous sounds. An uncharacteristic whine or hum may indicate problems with the transmission.
3. There is no response when pressing the gas. The engine speed does not increase or increases, but the speed does not increase.
4. An oil puddle appears under the car. This indicates a leakage of consumable fluid from the unit.
5. The clutch system slips.
6. When the driver presses on the gas and does it smoothly or when changing gears, a push or jerk appears.
7. The transmission unit itself stops functioning, the car stops and does not move.

Most problems are caused by incorrect operation of the microprocessor device. If we talk about mechanical problems, most of them are associated with wear and tear of the component elements. Such parts usually cannot be repaired and must be replaced.

Mechanical problems:

• wear of the fork designed to select speed;
• The rolling bearing devices wear out, which can cause a hum.

Photo gallery

Photos of robots from different automakers are shown in this section.

Video “How to prevent rapid failure of a robotic gearbox”

User JoRick Revazov talked about things that cannot be done with a robotic unit on a car.

Modern cars are increasingly equipped with robotic gearboxes. In everyday life, such boxes are also called “robots”. The very name “robotic gearbox” indicates that the driver’s actions, taking into account the vehicle’s driving conditions, generate “input information” for the electronic unit of the box (robot), which, through embedded algorithms, controls the operation of the entire unit. The main advantage of robotic gearboxes is that these units effectively combine the comfort and ease of use of a conventional automatic transmission with the reliability and fuel efficiency of an ordinary manual transmission. In addition, as a rule, a robotic gearbox is significantly cheaper than a traditional automatic gearbox. Today, “robots” are installed both on expensive premium models and on cars in the mass and even budget segments.

The robotic gearbox is capable of operating in automatic and semi-automatic modes. For the driver, the operation of a robotic gearbox will be practically indistinguishable from the operation of a conventional automatic transmission. When a certain speed is reached, the electronic unit, based on incoming signals from input sensors, provides the desired algorithm for the operation of the box using actuators. In addition, any robotic gearbox has a manual gear shift function called. True, unlike conventional “mechanics”, when manually shifting, the “robot” lever does not need to be set to a specific position defined for a particular gear. Shifting in manual mode is done sequentially from low to high gear and vice versa by simply rocking the selector forward or backward. Sometimes a robotic gearbox, due to the feature of sequential gear shifting in manual mode, is also called sequential (sequensum). For some types of robotic gearboxes, steering wheel paddles are additionally provided, with which you can change gears without taking your hands off the steering wheel.

Robotic gearbox design

Robotic gearboxes from different manufacturers may vary slightly in design, but the general principle of operation of such units is the same - any robotic gearbox is a manual gearbox, which is equipped with a system that controls gears and clutch.

Robotic gearboxes use a friction clutch mechanism. For this, a separate disc or a set of friction discs can be used. Many modern robotic gearboxes are equipped with a dual clutch system, which ensures transmission of torque with a constant flow of power. Considering that the basis of any robotic gearbox is a mechanical unit, manufacturers, as a rule, use ready-made solutions. So, for example, the well-known Speedshift unit, produced at Mercedes-Benz facilities, is built on the basis of the 7G-Tronic gearbox, in which the torque converter is replaced with a friction-type multi-plate clutch. And to create the Bavarian SMG robotic gearbox, a six-speed mechanical unit was used, modified with a clutch with an electro-hydraulic drive.

It is noteworthy that the “robots” can have both hydraulic and electric drives for gears and clutches. The executive units of the electric drive of the box are servomechanisms (mechanical transmission with an electric motor). The hydraulic drive of the robot box is carried out using hydraulic cylinders controlled by electromagnetic valves. This type of drive is often called an electrohydraulic drive. Some robotic transmissions equipped with an electric drive, such as Durashift, installed on a number of Ford models, use a hydromechanical unit equipped with an electric motor that moves the clutch master cylinder.

Electrically driven robotic boxes are usually installed on inexpensive models of mass brands. After all, the electric drive, although characterized by low energy consumption, cannot provide high speed operation - gear changes range from 0.3 to 0.5 seconds. The hydraulic drive system in the box requires constant pressure, which is achieved by higher energy consumption. Hydraulically driven robots are much faster - hydraulically driven robotic boxes are often installed even on sports cars.

Control of the “robot” is provided by an electronic system responsible for turning on and operating the control unit, input sensors and actuators. Basic parameters such as speed, selector lever position or the condition of the gear forks, as well as oil temperature and pressure (for a hydraulic drive system) are read by sensors and transmitted to the control unit. Then the electronic unit, based on the embedded program, causes the necessary effects on the executing mechanisms. It is worth noting that in a robotic gearbox with a hydraulic drive, the control system is supplemented with a unit that ensures the operation of hydraulic cylinders and ensures the required level of pressure.

Depending on the type of drive, the role of the actuators of the robotic gearbox is performed by electric motors or electromagnetic valves, which are equipped with hydraulic cylinders.

Double clutch robotic gearbox

Over the past couple of years, robotic gearboxes with a dual-clutch system have become widespread. The fact is that the main disadvantage of a standard robotic gearbox is the rather long time it takes the unit to change gears. This often causes dips in dynamics and jerking during an active driving style, which negatively affects the comfort level of the entire trip as a whole. This negative feature scares off a considerable number of potential car enthusiasts from the prospect of purchasing a car equipped with a robotic gearbox. The solution to the problem was the use of a double clutch system, which eliminates the interruption of the power flow at the moment of gear shifting. The double clutch makes it possible to select the required gear while the previous gear is engaged, and, if necessary, engage the next gear without interrupting the operation of the gearbox. Due to this design characteristic, double-clutch transmissions are called preselective gearboxes.

Another important advantage of dual-clutch transmissions is their speed when changing gears. Here, the speed of transition from one gear to another depends solely on the speed of the clutches. Thus, DSG “robots” from Volkswagen spend no more than 0.2 seconds on switching, and DCT M Drivelogic units produced by BMW – only 0.1 second. In addition, the “robot”, equipped with two clutches, is a very compact unit, which is especially important for small city runabouts.

Differences between a “robot” and an “automatic machine”

An inexperienced motorist may not find the differences between cars equipped with automatic and robotic transmissions. After all, in the interiors of such cars there are no clutch pedals, and the gear selectors look almost the same. But in fact, from a technical point of view, these units differ significantly from each other. Moreover, the robot’s design is even more similar to a manual transmission. Unlike a “robot” or a standard manual transmission, the main components of an automatic transmission are a gearbox and a torque converter, which ensures smooth gear shifting. It is the torque converter that performs the clutch function of a conventional manual transmission, which is also equipped with a manual transmission. Thus, the “robot” is a manual gearbox, in which an electronic unit is responsible for the timeliness of gear shifting. And the switches themselves are made automatically, through hydraulics and electronic control.

Advantages and disadvantages of robotic gearboxes

Assessing the pros and cons of robotic gearboxes, it is worth noting that a “robot” is more convenient than a manual transmission, because here you do not have to constantly operate the shift lever, and the absence of the need to depress the clutch pedal significantly reduces driver fatigue. Compared to automatic transmissions, robotic boxes provide greater fuel efficiency and, as a rule, have less weight. The fuel consumption of a car with a manual transmission is close to the fuel consumption of a car with a manual transmission. The cost of a robotic gearbox is also lower compared to an automatic transmission.

As for the shortcomings, the main ones were mentioned above - these are noticeable jerks and jerks when changing gears, characteristic of budget cars equipped with “robots”. Few people will be pleased with long pauses when changing from one gear to another. In addition, when starting to move uphill, a car with a manual transmission, like a car with a manual transmission, may roll back a little.

However, for the sake of objectivity of the picture, it is worth noting that all of the listed shortcomings have been eliminated on units with two clutches. Robotic gearboxes of this type could be considered optimal units, if not for their high price.

There are several automobile transmissions in the world. The most popular are manual transmission and automatic. At the moment, many popular manufacturers have begun to use a robotic version in their new products. In the article we will look at what it is - a robotic gearbox, what reviews it receives and whether it has advantages and disadvantages.

Box characteristics

The robot's gearbox is essentially mechanical, it just has an additional automatic clutch and gear shift built into it. Accordingly, the operation of the transmission is completely dependent not on the driver, as in other options, but on the electronic controlled unit. The driver only needs to correctly transmit incoming information for the transmission to operate correctly.

Device

We will look at which gearbox is better, automatic or robot, a little later; first we need to know the device of the new invention. The automated gearbox received a friction type clutch. This is a package of disks, or a built-in separate mechanism. The most reliable and durable design can be called the one that has a double clutch. Volkswagen Golf became the first car in the world to be equipped with a robotic gearbox. Reviews about the operation of the device were quite good, everyone noted a good response from the electronics, as well as ideal functionality during overclocking. At the same time, the power flow was not interrupted. This is achieved by using a double clutch. In this case, switching speeds takes no more than 1 second. When working on Russian roads, unfortunately, the service life of such a gearbox is reduced by at least half.

Peculiarities

The clutch drive can be electric or hydraulic. In the first case, it should be noted that there is an electric motor and a mechanical transmission. The second type of drive operates through the operation of special cylinders, which are controlled by an electromagnetic valve. In some cases, the robotic gearbox, the variator of which is well designed, is equipped with an electric motor. It moves the cylinders and is also designed to maintain the operation of the hydromechanical unit. A similar device that has a drive of this type is distinguished by the duration of the gear shift speed. As a rule, it varies from 0.3 to 0.5 seconds. However, when compared with hydraulic analogues, the system will not need to constantly maintain a certain pressure. A striking example of such a car is the Opel; the robotic gearbox on this car generally pleases many drivers.

Hydraulic gearboxes have a fast cycle, which provides gear changes in a time of 0.05 to 0.06 seconds. That is why such a transmission is most often used on racing cars and supercars. Examples are Ferrari and Lamborghini. On cars that belong to the budget class, such a gearbox cannot be supplied to a service station, even as an additional option.

How does a checkpoint robot work?

Most of the mechanisms are regulated by special intelligent robot gearbox units. What it is? Thanks to this, that is, the operation of the electronic system, it is possible to monitor all the necessary parameters for the gearbox. The sensors also analyze the position of the transmission, oil pressure and other parameters for transmission to the main unit. After this, the electronics will generate all the necessary actions that should be performed. In the form of short signals, they will be sent to the electric drive and electric valves, respectively, this will allow the gearbox to quickly but smoothly shift.

Operating modes

The design of the automatic variator and the robotic gearbox remains unclear to many. This device works on mechanical principles. However, if the user wishes, it can be switched to automation. After a person switches to the appropriate mode, the electronic unit will be blocked. The latter will begin to analyze the algorithm itself. The driver only needs to press the gas pedal and monitor what is happening on the road. Quite often in traffic jams, judging by the reviews, the robotic gearbox becomes indispensable. If the mode is manual, the driver will be allowed to independently change gears from low to high, and vice versa. Control can be carried out using a conventional gear lever.

Relevance of the box in Russia

Unfortunately, domestic manufacturers practically do not use robotic gearboxes to create cars. Many drivers don’t know what it is. However, in 2015 it was announced that VAZ cars belonging to the Priora series would be equipped with a robot. This box weighs about 35 kg, and it is fully adapted to Russian roads and weather conditions. For example, if the old automatic transmission did not make it possible to start the car at temperatures below 25 degrees, then the robot can show good performance even if this mark drops to -40. The warranty period for the robotic box is 3 years, but the manufacturer stated that the average service life is 10 years. This is how the company wanted to achieve a return to popularity for the Priora series cars.

Advantages

The robot gearbox has received very good reviews. Let's consider its main advantages. Many people say that it is convenient when the gearbox has all the advantages of an automatic and manual transmission. Accordingly, a person, working with a car, can receive impressions of the operation of an automatic transmission. But at the same time, he doesn’t have to worry about wasting too much fuel.

The main advantage of such a gearbox is efficiency. According to users, the design has software that rationally determines torque. And if compared with an ordinary person, electronics do not get nervous, do not get tired, do not become depressed, and are not affected by physical activity. That is why the robotic gearbox has become widespread in the world market.

At the moment, such a transmission is equipped in cars of classes A, B, C. It should be noted that the Toyota Corolla also received a robot gearbox. This device is also installed on the German Volkswagen Amarok. Moreover, this “German” can be bought in this configuration both on the Russian and European markets.

However, this is not an exhaustive list of advantages; there are several more. Judging by the reviews, this transmission is highly reliable. Replacing the mechanisms will be required only after completing a run of 250 thousand km. Often the clutch that needs to be repaired is one that does not withstand heavy loads very well, especially when it comes to driving in difficult areas. The cost of a robotic box is much less than a standard machine. Moreover, the robotic gearbox is very unpretentious in maintenance. Oil is the only thing that must be changed every 60 thousand kilometers.

Weight Features

The weight of the box is quite an important issue. In this parameter, the transmission performs better than the automatic, since it is much lighter. The curb weight of such a box for passenger cars will be no more than 50 kg, while the weight of an automatic transmission only starts from this mark and reaches 100 kg in maximum positions. Accordingly, with a robot the car will be lighter, that is, the shock absorbers, wheels and engine do not experience heavy load.

Flaws

We have already looked at what an automatic robot box is, and we have also discussed the advantages of a machine running on such a device. However, it also has its drawbacks. You should find out which ones. For example, the main disadvantage is the speed of gear shifting. Because of this, a lot of pressure can be placed on the car, especially if a person is stuck in a traffic jam. Often the car accelerates with jerks, which is more suitable for sporty driving. That is why for all lovers of quiet driving, the manufacturers of such gearboxes install a special mode. And if this problem can be dealt with, then the safety of driving on slopes in such a car is a rather pressing issue.

The robotic gearbox does not receive constant signals from the engine. That is why it can often turn off, and accordingly, the car will roll down the slope. But, fortunately, judging by the reviews, few people found themselves in such a situation. In general, taking into account all the negative aspects, this box can still be called one of the best.

Automakers strive to find optimal technical solutions when designing various vehicle components. As a result, new design innovations appear. An example is the evolution of the transmission. Now you can see various options for gearboxes that successfully compete with each other. There are mechanical, automatic, robotic gearboxes or continuously variable transmissions.

In the article we will find out what a robotic gearbox is, what advantages and disadvantages it has compared to other types of transmission. After all, not only our mood, but also safety on the road often depends on the degree of comfort of driving a car.

Let's start with the fact that a robot is a It's a mechanic, where the gears are changed and the clutch is released automatically. If we take, for example, the robotic Toyota Corolla, which has been produced since 2007, then it has a robotic gearbox - this is one-on-one mechanics, in which the usual gearshift lever and clutch were removed and instead of them special servos - actuators - were installed. It follows from this that the driving characteristics of the car will be in many ways similar to that of a conventional manual, but you won’t have to change gears yourself.

The work of these gearboxes is to receive information from the driver in digital form, and then, having processed it correctly and quickly, translate everything into mechanical manipulation of gears and shafts. To control the gear selection, instead of the usual lever, which is connected by cables or rods to the gearbox, a lever is used - a joystick, which only indicates the desired gear to the electronics. The electronic control unit (ECU) is responsible for the logical part.

Appearance of the robot control lever on a Toyota Corolla

Taking into account user reviews, we note that this type of automobile gearboxes has most of the advantages of an automatic transmission and combines the economy and reliability of automobile “mechanics”. For the buyer, the robot will be cheaper than a classic automatic machine, which means there is an additional positive argument in their favor.

Most popular automakers produce models in various price segments with robotic transmission units installed on them. Even in the budget segment, Renault released a car with a “robot” on board in 2016.

How does a robotic box work?

The robotic gearshift unit in most cars is based on a manual transmission. In this case, manipulations with switching between stages are carried out by special structural add-ons, which are called servos. In some sources, these switches are called actuaries. One of them is engaged in turning the clutch on/off, and the mission of the second is to physically move the gears in the box. This means that their work helps to get rid of the clutch pedal inside the car.

Appearance of the robot clutch actuator

Not all drive designs are created equal. Engineers have created two varieties of them. In the first case, operation is maintained using electricity, and in the second case, hydraulics are responsible for the smoothness and speed of switching. Usually reviews are not always clear, so we will describe both options.

1. A popular device is electric drive. This design is less expensive and can be installed even on budget class cars. The control is based on an electric motor with a gearbox and an actuator.
2. IN hydraulic system Gear shifting is carried out using cylinders pushed by the force of solenoid valves. The principle of operation in this case is similar to the classic “automatic machine”. The second name for such devices is “electro-hydraulic drive”. The design is more expensive than a conventional electric drive, but this is compensated by the speed of switching between gears. Also, the driver does not feel any sudden dips. The block is installed on more expensive cars.

All operations are managed by a built-in computerized unit. It monitors the engine speed, the current speed of the car, receives information from the ABS, anti-skid system and issues commands to the actuator.

Clutch device in a robot

The first “robots” in cars were installed with one clutch. The experiment turned out to be controversial. A sufficient number of shortcomings of this design have been revealed. As a result of developments, double-clutch gearboxes appeared. Let's take a look at these types of boxes and how they work.

Robot device with two clutches

1. One clutch. The gearbox is based on two shafts: primary and secondary. The primary (drive) shaft receives rotation from the engine. It is separated from the engine by the clutch. From the secondary (driven) shaft, rotation is transmitted to the wheels through gears. At the command of the electronics, the first servo drive disengages the clutch, and after the break, the second one moves the synchronizers in the same way as a driver would do with a lever on a manual gearbox. However, the electronics “protect” the clutch, and the power gap often becomes noticeable in the cabin (the effect of passengers “nodding their heads” when traction is temporarily lost).
2. Two clutches. The designers tried to reduce the effect of the negative impact of traction failures using a double clutch. As a result, designs emerged that were collectively called DCT (Dual Clutch Transmission). Later, the Volkswagen concern developed six-speed DSG (Direkt Schalt Getrieb) gearboxes. This abbreviation, which was simply a trademark, became synonymous with all dual-clutch boxes, just as the word “copier” came into use not as a trademark, but as a paper copy. The DSG design has two input shafts, one of which is located inside the other. Both shafts are connected to the motor using individual clutches. The “smart” gearbox, when starting the car in motion, engages first gear, but at the same time the gear for second gear engages on the second shaft. The second shaft waits for its clutch to close and simultaneously open with the first gear. This saves switching time and ensures smooth transitions between stages. There is a second name for such boxes - “preselective” (predicting choice). For example, for Golf cars, the switching time of the robotic gearbox is only 8 milliseconds.

Engineers, improving the design of the double clutch, have developed two varieties of this unit. In the first case, it was decided to leave the clutch environment air (“dry” type), and in the second case, working fluid was poured into the assembly (“wet” type). For drivers who prefer an aggressive driving style and sharp, deep presses on the gas pedal, a dry clutch will often overheat, which will lead to its rapid failure.

To reduce the negative impact on the clutches, the block is filled with oil. A negative effect also appeared due to slippage and a slight loss of power at this time, but the unit began to withstand more severe loads. This had a positive effect on its durability.

Most leading automakers, including Fiat, BMW, Ford, and Mitsubishi, have preselective transmissions in their arsenal. An indicator of its prospects is that even Porsche recognized the appropriateness of this design, because the company uses only proven and promising models. Developments in this direction continue.

Pros and cons of a robotic gearbox

Benefits include:

1. The design of the units is based on time-tested manual transmissions. Due to this, the overall reliability of the unit increases, which is higher than that of CVTs.
2. The occupied volume in the engine compartment is significantly less than that of classic automatic transmissions; therefore, the oil consumption during operation for this box will be lower than that of analogues.
3. The performance of the clutch, especially the wet type, is 25-30% higher in “robots”.
4. Also, the difference between a robotic gearbox and an automatic one lies in the cost of production and repair of this unit, which speaks in favor of “robots” rather than “automatic machines” and CVTs.
5. Most modern robotic-controlled gearboxes have the ability to change gears manually, which is similar to Tiptronic in automatic transmissions.
6. The weight of the robot box is significantly less than the automatic transmission. This gives advantages when installed on small-sized cars, where weight even of several tens of kilograms plays a significant role.
7. Fuel consumption on cars equipped with “robots” is comparable to consumption on manual transmissions and less than that of other designs, all other things being equal.

Disadvantages include:

1. There are designs with robotic gearboxes in which the delay between gear changes reaches two seconds. This applies to electrical switches. When driving like this, dynamics are lost and discomfort for the driver may occur.
2. The use of hydraulic drives to speed up shifts increases the speed between switching on a stage to 0.05 s. However, this design significantly increases the cost of the entire assembly. Brake fluid, used as a working fluid, must be kept under high pressure at all times, which takes away some of the power from the engine. Hydraulics become more efficient in powerful or premium cars.
3. Cheaper models do not provide adaptive adjustment of the automation to the driving style of the car owner.
4. Preselective models are still quite expensive to repair. Although the mechanical part is very reliable, just like simple mechanics, with unfinished ECU firmware and imperfect clutch design, premature wear of the latter often occurs. And all the “attached” equipment of the robot (clutches, ECUs, actuators) costs a lot of money. Therefore, when buying a used car, you should check the robot with special care and find out the dates of its last service, look at the receipts for the work performed.

But still, most of the positive factors quite easily cover all the negative aspects. Therefore, in order to enjoy all the “advantages” of robots, it is necessary to choose new design options in which the main disadvantages are minimized or completely eliminated.

Conclusion

The process of final improvement of robotic boxes has not yet arrived. Engineers are striving to make the design more reliable and faster, and by some measures they are succeeding. At the same time, cars with “robots” are already finding their fans.