Robotic gearbox: what is it, differences from automatic transmission, pros and cons

There are 4 types of gearboxes (gearboxes). The share of cars with a robotic gearbox, classic automatic and CVT on the roads is constantly growing, because more and more motorists are abandoning manual mechanics. Transmissions that operate without human intervention are constantly being improved. Their quality, speed of reaction to road events, smoothness of actions become better, and any trip is more comfortable.

It is much more convenient with a robotic gearbox.

What is a robotic gearbox

A robotic gearbox (RMG, or robot) is part of a vehicle’s transmission. Sometimes it is confused with an automatic transmission, but they are different from each other. Manual transmission consists of a manual transmission, automatic switches of electric or hydraulic type (actuators) and a control unit for these switches (ECU). That is, the box itself is mechanical; only the control of its operation is automatic.

For the driver, the manual transmission looks almost like an automatic transmission. There is no gearshift lever at hand (on some models there is a selector knob instead), and there are no clutch pedals underfoot. While driving, gears are switched automatically.

Comparison of two gearboxes: what is the difference between a robot and an automatic machine

This block summarizes the comparative results of the topic: “Which gearbox is better, automatic or robot?”

The table below shows the differences between robot and automatic gearboxes.

Type of differences	Robot	Machine
Constructive	Mechanical box with electronic control unit	Torque converter, planetary gearbox, valve body
Functional	Availability of manual switching function	Manual switching
Price	Darling in TO	Low cost service
Consumer	Low consumption of fuels and lubricants	Large amounts of oil and fuel consumption

Now it will be easier for a novice car owner to choose between these two types of automatic transmission. The next block provides some advice from experienced car owners and mechanics on choosing one or another device if the car enthusiast has already taken a step towards one of the types.

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The design and principle of operation of an automatic transmission

How it works

The manual transmission, equipped with a clutch disc connected to the engine flywheel, is controlled by a robot. The algorithm incorporated by the developers into the ECU reacts to sensor readings by sending commands to the servos.

It looks like this:

the driver presses the gas pedal;
engine speed increases, the car accelerates;
upon reaching the values specified in the program, the clutch actuators and shift forks are activated;
upshift occurs.

If the driver continues to accelerate, then at the next programmed engine speed and driving speed, the ECU again gives a signal and the actuators change gear again.

By the same principle, during braking, gears are switched from high to low. High-performance processors make it possible to create complex programs that simulate human behavior in different situations. And the more complex they are, the more dynamic and comfortable the ride.

Features of manual transmission

Operation of a robotic gearbox.
The gear shift drives on robots are equipped with either electric motors or a piston hydraulic system. But they perform the same task - they move the synchronizers of the secondary shaft gears and depress the clutch.

The main difference is that hydraulics work faster and smoother. But it is more expensive to produce, so mainly high-class cars are equipped with such manual transmissions. The most popular is DSG from the German concern Volkswagen.

The ECU for the boxes is made both separate and combined with the internal combustion engine control unit. The latter option is most appropriate if the robot's control algorithm takes into account the readings of the same systems as engine control, for example ABS or ESP.

Types of drives and how to use them

We got to the heart of the robotic transmission design, namely the clutch drive system and gear shift mechanism. There can only be two systems for now:

Hydraulic drive. It operates using electrically controlled hydraulic cylinders. This means that for the drive system to operate correctly, it is necessary to constantly maintain pressure in the hydraulic system, and this, of course, is a loss of energy to drive the additional pump. However, the response speed of hydraulic robots is amazing. On some sports car models, the response speed can reach 0.06 seconds.
Electric drive. This type of drive is slower, but simpler and the most inexpensive. That is why it is used most often in inexpensive cars. The electric drive operates using servomechanisms, and this determines the low speed of gear shifting, but the energy consumption of the internal combustion engine is much less for such a drive.

The only problem with a robotic transmission before the advent of double clutch was considered to be the lack of information from the clutch. When a person independently controls the clutch, he feels the moment the discs close and can control the process so that the switching is smooth and soft. Also, when switching at speed, there could be dips.

Clutch device in a robot

Robotic boxes based on the method of interaction with the engine are of two types:

single-disc;
double-disc (use two clutches, activated alternately).

A single-disc box is no different from a mechanical one. It has a primary and secondary shaft.

The primary is connected to the clutch disc. The secondary shaft transmits torque directly to the wheels. Both shafts interact through gears of different diameters. Switching occurs at the moment when the gear selected for the desired gear on the secondary shaft is locked. In manual transmissions, this is done by electric manipulators that receive a signal from the ECU. Hydraulic manipulator drives on single-disk boxes are used extremely rarely.

Double-disc ones have two driving input shafts, each of which is connected to its own clutch disc. One shaft is responsible for even gears, and the second for odd and reverse gears. This technical solution made it possible to make the inclusion of the selected gear smoother. The drive synchronizers operate alternately. At the moment of transition on one shaft from 1st to 2nd gear, the ECU already gives a signal to prepare to engage 3. Therefore, they are also called preselective, i.e. with preliminary selection. As a result, the switching process itself is accelerated to 0.2 seconds or less.

Some manufacturers configure the operation of actuators and algorithms in such a way that the robot functions no worse than a human.

Operating modes

The driver's control of the gearbox comes down to selecting a mode using the selector:

Neutral is designated "N". In this mode, the engine runs, but no torque is transmitted to the wheels. Turn it on before driving, after stopping, and during long-term parking.
Forward movement is indicated by "A/M", "E/M" or "D". Having turned on this mode, release the brake pedal and press the gas pedal. The car moves forward, automatically switching gears depending on acceleration or braking.
Manual control is designated "M". The car moves forward, the driver independently changes gears by pressing the steering wheel paddles or selector to the “+” or “-” positions. In this case, the switching occurs only by one stage.
Reverse movement is indicated by “R”. By selecting this mode, you can drive backwards.
Some manual transmissions may have “winter” and “sport” modes.

The concept of a robotic gearbox.

There are also some peculiarities when driving, which the driver must get used to, otherwise he will end up in unpleasant situations.

This is the following:

Driving in automatic mode requires roads with good hard surfaces. If you drive into mud in the summer and deep, loose snow in the winter, you run the risk of stalling. The algorithm will begin to issue erroneous commands, and transmissions will not be switched on correctly. Such situations increase the wear of parts and mechanisms, which increases the risk of breakdowns.
The gas pedal must be pressed smoothly; under no circumstances should it be pressed to the floor. It is necessary to monitor the engine speed, recording the moments of gear shifting, and avoid over-throttle.
If your car does not have a hill start assist function, you need to do the same as when using a manual transmission - use the parking brake to prevent rolling back.
When stopping for long periods (more than 60 seconds) at a red light or in a traffic jam, you need to switch the selector to the “neutral” position.
For a long stop in a parking lot, first move the selector to “neutral”, then turn on the parking brake, then release the brake pedal and turn off the engine.
Each manufacturer indicates how often the ECU needs to be recalibrated based on mileage (also called initialization or training). This must be done due to wear on the clutch disc. The procedure should be carried out every 10,000-15,000 km.
In winter, at low air temperatures, warming up the box takes exactly as long as it takes to warm up the engine.

The main differences between manual transmission and automatic transmission

Both types of transmission perform the same function - they free the driver from the need to change gears while the car is moving.

But due to the fact that these are structurally different mechanisms, they differ from each other in operation and maintenance:

In an automatic transmission, ATF is part of the working mechanism. Manual transmissions contain oil to lubricate mechanical components, but it is several times less in volume. In addition, it needs to be changed much less often.
A car with a robot is more dynamic in motion and consumes less fuel. Because the weight and dimensions of an automatic transmission exceed those of a robot, and gear shifts in a manual transmission occur faster.
It’s much more comfortable to drive a car with an automatic transmission, because the gears shift smoothly, and a robotic gearbox cannot dampen jerks as much.
The wear of the friction clutches is slower than the wear of the clutch disc.
On a robotic box, you can switch to manual control. It is not complete, because switching is carried out only to one position and it is impossible to switch, for example, from 2 to 4 immediately. But the automatic transmission does not give the driver such an opportunity.

Summarize

Many people ask me: “ Seryoga, would you take a ROBOT? Shall we say DSG? “It’s a difficult question, probably, I haven’t yet matured to manual transmission (and to VAGs too), although I can’t say anything against it, many people like it.

If we take double-disc manual transmissions (DSG, POWERSHIFT, DCT), they are really not bad in use, dynamics, fuel economy and ride comfort. BUT they are still new! Further, when the time comes for repairs, many VERY STRONGLY with them, asking themselves the question - “why did I take this device”?

In general, if you drive up to 100 -120,000 km and then change cars, then why not?

Single-disc ROBOTS will cause you more discomfort in everyday driving, especially for people who have moved from an automatic transmission or CVT (although a person gets used to everything). But it is cheap to use, once every 100-150,000 km you pay 20,000 rubles and move on.

Personally, I like a regular classic automatic transmission, change the oil every 60 thousand kilometers, operate it correctly , and you won’t have any grief.

Now the video version, for those who are too lazy to read, watch it.

This is where I end my materials, I think I helped you with your choice, sincerely your AUTOBLOGGER.

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Advantages and disadvantages

Robotic gearboxes have become widespread due to their advantages. However, they also have disadvantages, which it is better to know about before buying a car in order to be prepared for them.

Scheme of operation of the SensoDrive system.

Advantages:

The acceleration time to 100 km/h, with other parameters being similar, is almost no different from the acceleration time with a manual transmission.
Fuel consumption is comparable to that of cars with manual transmission and up to 30% lower than on models with automatic transmissions.
The clutch disc wears out more slowly than with manual shifting.
The robot works more accurately than a human, so the shafts and gears of the box will wear out less and last longer than in manual mechanics.
The cost of repairs and maintenance is on average lower than that of an automatic transmission.

Negative points:

While driving, jerking and jerking may be felt when shifting gears.
The algorithm embedded in the ECU does not have a human reaction to situations that arise while driving. Therefore, errors may occur when it is necessary to urgently accelerate or brake.
To make a decision, the robot needs longer gears, and to maintain dynamics, a more powerful engine is needed.
If there is no hill assist system, then when starting to move uphill, the car may roll back.
Impossibility of flashing the control unit. The gear shift algorithm is a manufacturer's development and cannot be adjusted.
Traffic in traffic jams has a bad effect on the components and mechanisms of the box, leading to their early destruction.

Advantages and disadvantages of the “automatic machine”

If we talk about the advantages of automatic systems, they include:

Easier and simpler controls.
Reduced load on the engine (this advantage becomes more obvious when compared with a manual transmission, where more engine revolutions are required to change speed).
Reduced loads on the chassis of the car.

The disadvantages include:

Higher fuel consumption.
Poor acceleration dynamics (when compared with manual transmission).
Reduced efficiency.
Higher oil consumption.
Slow gear changes.
There is a risk of the car rolling away if the car is on a slope.

Thus, an automatic transmission is in many ways better than a manual transmission, but the robotic system is actively stepping on the heels of the automatic transmission.

Symptoms of a problem

Like any mechanism, a robotic box is subject to wear and tear during operation and can break. Malfunctions are divided into mechanical and control unit . Each has its own manifestations.

Signs of mechanical failure:

slipping while driving on a flat, hard road surface indicates wear of the clutch disc;
if the gears do not shift, this may indicate a breakdown of the actuators;
extraneous noise while driving can be caused by a number of reasons, and to identify a breakdown, components and mechanisms should be diagnosed;
increased jerking during gear shifting may occur due to wear and destruction of gear connections on the gearbox shafts, wear of the gear selection forks;
The Check Engine light on the instrument panel indicates the need for computer diagnostics.

Signs of errors in the ECU:

the robot’s operating mode is disrupted, gear shifts occur incorrectly and at the wrong time;
jerking when shifting gears becomes stronger;
when the selector selects the forward or backward driving position, the car does not move;
The Check Engine light comes on.

To figure out why the trouble arose, you need to carry out correct diagnostics using special equipment.

Relevance of the box in Russia

Cars with robotic gearboxes are in good demand among our car enthusiasts. Surveys show that the share of Russians willing to buy a car with a manual transmission ranges from 15-20%. It should be noted that the share of those who want to use a classic machine is still 2 times higher.

In large cities, solvent segments of the population choose automatic transmissions because of a more comfortable ride and much fewer problems associated with operation in conditions of frequent traffic jams. Moreover, the prices for an automatic machine and a good preselective unit are at the same level. But, if the price of fuel continues to rise, many will prefer a car with a manual transmission (as it is cheaper to operate), especially when trips are not limited to the work-home route.

conclusions

The robotic gearbox is becoming increasingly popular among car enthusiasts. Ford also comes with this new device. It should be noted that such a transmission is very convenient, functional and at the same time unpretentious. Unfortunately, not all cars work with it yet, but often for an additional fee you can change the gearbox to this one. If there are any concerns that unforeseen situations may arise, then you can read reviews of a car equipped with such a transmission and understand whether this option is suitable for you or not. As a rule, many drivers are completely satisfied with their choice. That is why when buying a car it is better to pay attention to such models.