37 Overdrive considerations

Power is essential to propel a vehicle because it is a measure of the rate of doing work, that is, the amount of work being developed by the engine in unit time. With increased vehicle speed, more work has to be done by the engine in a shorter time.

The characteristic power curve over a speed range for a petrol engine initially increases linearly and fairly rapidly. Towards mid-speed the steepness of the power rise decreases until the curve reaches a peak. It then bends over and declines with further speed increase due to the difficulties experienced in breathing at very high engine speeds (Fig. 3.26).

A petrol engined car is usually geared so that in its normal direct top gear on a level road the engine speed exceeds the peak power speed by about 10 to 20% of this speed. Consequently, the falling power curve will intersect the road resistance power curve. The point where both the engine and road resistance power curves coincide fixes the road speed at which all the surplus power has been absorbed. Therefore it sets the maximum possible vehicle speed.

By selecting a 20% overdrive top gear, say, the transmission gear ratios can be so chosen that the engine and road resistance power curves coincide at peak engine power (Fig. 3.26). The undergearing has thus permitted the whole of the engine power curve to be shifted nearer the opposing road resistance power curve so that slightly more engine power is being utilized when the two curves intersect. As a result, a marginally higher maximum vehicle speed is achieved. In other words, the engine will be worked at a lower speed but at a higher load factor whilst in this overdrive top gear.

If the amount of overdrive for top gear is increased to 40%, the engine power curve will be shifted so far over that it intersects the road resistance power curve before peak engine power has been obtained (Fig. 3.26) and therefore the maximum possible vehicle speed cannot be reached.

Contrasting the direct drive 20% and 40% overdrive with direct drive top gear power curves with respect to the road resistance power curve at 70km/h, as an example, it can be seen (Fig. 3.26) that the reserve of power is 59%, 47% and 38% respectively. This surplus of engine power over the power absorbed by road resistance is a measure of the relative acceleration ability for a particular transmission overall gear ratio setting.

A comparison of the three engine power curves shows that with direct drive top gear the area in the loop made between the developed and opposing power curves is the largest and therefore the engine would respond to the changing driving conditions with the greatest flexibility.

If top gear is overdriven by 20%, as shown in Fig. 3.26, the maximum engine power would be developed at maximum vehicle speed. This then provides the highest possible theoretical speed, but the amount of reserve power over the road resistance power is less, so that acceleration response will not be as rapid as if a direct drive top gear is used. Operating under these conditions, the engine speed would never exceed the peak power speed and so the engine could not 'over-rev', and as a result engine wear and noise would be reduced. Benefits are also gained in fuel consumption as shown in Fig. 3.26. The lowest specific fuel consumption is shifted to a higher cruising speed which is desirable on motorway journeys.

Indulging in an excessive 40% overdrive top gear prevents the engine ever reaching peak power so that not only would maximum vehicle speed be reduced compared to the 20% overdrive gearing, but the much smaller difference in power developed to power dissipated shown on the power curves would

—„—I . _____ r__J_I_I_L—_L---—.1. ...I ..I-1-1-1—

0 20 40 60 SO 100 120 140 160 110 200 220

Vehicle speed (km/h)

Fig. 3.26 Effect of over and undergearing on vehicle performance severely reduce the flexibility of driving in this gear. It therefore becomes essential for more frequent down changes with the slightest fall-off in road speed. A further disadvantage with excessive overdrive is that the minimum specific fuel consumption would be shifted theoretically to the engine's upper speed range which in practice could not be reached.

An analysis of matching an engine's performance to suit the driving requirements of a vehicle shows that with a good choice of undergearing in top gear for motorway cruising conditions, benefits of prolonged engine life, reduced noise, better fuel economy and less driver fatigue will be achieved. Another major consideration is the unladen and laden operation of the vehicle, particularly if it is to haul heavy loads. Therefore most top gear overdrive ratios are arrived at as a compromise.

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