Heat Treatment Issue Drop in FTQ More rework

Heat Treatment Issue: Drop in FTQ More rework (dark green) then normal 1

Heat Treatment: Increase in H 2 of 4 th gear Spectra of 1800 transmissions are shown in a density display: Orders bottom to top, units left to right. The amplitude of the 2 nd harmonic of 4 th gear (order 130) increased by 10 d. B starting at about unit 600 in the spectral display. The root cause was a new heat treatment furnace which had to be optimized. New oven First optimization 2

Increase in H 1 of 6 th gear The increase in the 6 th gear H 1 gear mesh energy is still acceptable in the vehicle: No reject due to fixed limit. Optimization is under way 3

Nick on 6 th gear input shaft Time history of crest value in 6 th gear drive for 1784 transmissions on test stand P 2 Crest of synchronous channel gives sensitive nick detection Crest = Peak/RMS for computed for each revolution and each shaft, Maximized over the ramp One unit exhibits a crest value of 11. 5 and has a nick on the input shaft in 6 th gear 4

Non-shaved final drive. SK 3 over limit The ghost order due to missed shaving operation is identified on the synchronous channel of the final drive output channel. The root cause is not visible in the Mix spectrum only 5

Harmonic sum catches geometry defect H 1 H 2 H 3 H 4 H 5 H 6 Although the individual harmonics are below the limit curve, the single value Sum Of Harmonics = H 1+H 2+H 3+H 5+H 6+H 7 catches the defect. 6

Spectral defects Grinding problem on 5 th gear input shaft Pitch error on 3 rd gear input shaft 7

Order Track Limits Transmission with limits on Order Tracks on main gear mesh components Pinion Drop H 1 Mesh Bevel Gear H 1 Mesh Limits are manually controlled but could be learned as well 8