HE ease of driving a car equipped with an
automatic transmission makes automatics the overwhelming
favorite of American motorists. But while the Hydra-Matic
4T40-E transmissions moving down the final assembly line at a
General
Motors factory in Windsor, Ontario, may be simple to use,
they are far from simple to design and build. Flipped upward
like cast-aluminum cornucopias, the partly assembled
transmission bodies are fed a harvest of gears, chains,
springs, electronics and wires. Exactly how the pieces come
together to shift gears is something of a mystery even to the
people who make the transmissions, which are soon to be
installed in Chevrolet Cavaliers, Oldsmobile Aleros and other
cars. When asked about the specifics of the torque converter,
the link between the transmission and the engine, the plant's
engineering manager, Don Wright, laughed. "As for how it
works, you'll have to ask someone else,'' he said. "I'm the
guy who knows how to make them."
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But what sets the 4T40-E apart from older models is not the
intricacy of its mechanical and hydraulic systems. Rather it
is a box tethered to the transmission by a wire. Inside, a
sophisticated microprocessor uses special software to replace
the electromechanical systems that once controlled automatic
transmissions.
By moving to electronic controls, transmission makers have
not only been able to introduce new features - like additional
gear ratios and transmissions that adapt to different driving
styles - but have also narrowed the efficiency and performance
gap between automatics and manual transmissions.
Mark Gilmore, the director of transmission development at
G.M.'s Powertrain division, acknowledged that the
all-mechanical automatics that were being produced by the
company when he joined it in 1977 probably deserved their
popular pejorative name, "slush buckets." But today, he said,
there is legitimate debate on how they compare with manual
transmissions. "I think we're now certainly very close with
automatics," he said.
Whether manual or automatic, transmissions perform two
basic jobs. At low speeds, they allow the drive shaft that
powers the wheels to rotate at a lower rate than the engine's
drive shaft. Doing that creates the force, known as torque,
needed to accelerate the car. At higher speeds, the situation
reverses. To prevent the engine from running inefficiently,
the transmission creates a final drive shaft rotational speed
that is higher than the engine drive shaft's rate. The first
automatic and semiautomatic transmissions appeared in the
years before World War II, but they were largely experimental
and not particularly successful. "They provided acceleration
that could best be described as stately," said Bob Casey,
curator of transportation at the Henry Ford Museum and
Greenfield Village in Dearborn, Mich.
Then in 1939, the first G.M. Hydra-Matic appeared, and it
became available on Oldsmobiles during the next year. It used
a hydraulic system to make gear changes based on a complex set
of factors, including the vacuum pressure of the engine's
exhaust manifold, the car's speed and the engine throttle
setting, all measured mechanically. Various springs opened and
closed hydraulic pistons to shift gears. "It was just insanely
complicated, yet the transmissions became extremely reliable,"
Mr. Casey said.
One of Mr. Gilmore's first jobs as a junior engineer at
G.M. was to adapt transmissions to different engines by
changing their springs and pistons. "I used to carry a little
suitcase around filled with hardware," he said. Eliminating
that fiddly process was one reason that G.M. and other
transmission makers started looking at electronics. It also
quickly became apparent that electronics offered ways to boost
performance.
Automatic transmissions, like manual ones, need to uncouple
themselves from the engine when shifting. Rather than use a
mechanical clutch - basically two abrasive discs that press
against each other - the torque converter makes its coupling
between the engine and the transmission with hydraulic fluid.
When a car is accelerating, fluid couplings can boost
engine torque. But at higher speeds they put the "slush" into
slush box.
The obvious solution, introducing a mechanical connection
that kicks in at highway speeds, was difficult without
electronic controls.
The first G.M. transmission to have all of its gear changes
controlled by electronics did not appear until 1989.
Transmission software has become so sophisticated that it
can now determine if a car is climbing a hill - a situation
that often baffled transmissions in the past - and study
drivers' patterns to see if they prefer sporty acceleration or
sedate but economical driving. "Our goal is to have the
customer not even realize the transmission is doing a whole
lot of things," Mr. Gilmore said.