© zf getriebe gmbh rematec 2011 vortragender/speaker günter herth zf-getriebe gmbh saarbrücken...
TRANSCRIPT
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ReMaTec 2011
Vortragender/Speaker
Günter HerthZF-Getriebe GmbHSaarbrückenGermany
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Drivelinde Technology | Automatic Transmission, Manual Transmission and Dual Clutch Transmission Strategic Business Areas
The new 8-speed transmission model line
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ZF-Getriebe GmbH SaarbrückenFactory 1 Saarbrücken
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Technological leap from 5- to 6-speedautomatic transmission
?
Generation 1
Generation 2
En
gin
e t
orq
ue
[N
m]
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Results of brainstorming and product conception
More gears are able to create an added value to the costumer.
8-speed-systems have an optimized cost-value ratio.
During the product conception the Lepelletier wheel set has also been taken into consideration. Result: this system has not really benefits compared to the second generation of 6-speed-transmissions. The degree of efficiency is even smaller compared to the 6-speed.
Ambitious aim of ZF: Introduction of a 8-speed transmission generation with a great added value to the costumer, in particular concerning fuel consumption.
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A B C DE
F
ZF 8 HP design based on Lepelletier principle (Prototype)
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Objectives 8HP…
fuel consumptionemissions
control of variability
cost
- 6 %
modulardesign
- 20 %
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6 HP TÜ
Pump
Operating point
Lock-up clutch
Engine torque
8 HP..
- 6 %
- Spread- No. of gears
- Open clutches- Gearset efficiency- Optimized lubrication
oil
- Vane cell pump
- Better torsion damping
Reduction of fuel consumption and technical solutions
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- 6 %
4-speed
- 5 %
6-speedFirst gen.
3-speed
- 2 %
5-speed 6-speedSecond gen.
8-speed
- 3 %
- 6 %
Fuel consumptions savings
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8 HPprduct family
8 HP 90
8 HP 45
8 HP 70
8 HP 30
8 HP 55
8 HP 55 A
8 HP 90 A
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Transmission section 8HP70
Gearset 1
Gearset 4
Gearset 3
Gearset 2
Clutch D
Clutch C
Clutch E
Brake A
Brake B
Drive
Vane pump
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ten8-Gang
Gang A B E C D FL F
1
2
3
4
5
6
7
8
R1
F
Gang A B C D E
1
2
3
4
5
6
7
8
R
BA
C
E
D
A
C DB
E
GWK
Drag losses from 4 open shift elements and one free wheel
8 HP
= open shift element
Tranmission schema 8 gear ZF / AW
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gearbrake clutch ratio gear
stepA B C D E
1
2
3
4
5
6
7
8
4,70
3,13
2,10
1,67
1,29
1,00
1,50
1,49
1,26
1,30
1,29
1,19
7,05Overall
R
0,841,25
-3,30
0,67
BA
C
E
D
RS3RS2RS1 RS4
82 3 4 5 6 71
Transmission schema 8HP
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Disk brakes ( A and B )
Piston chamber B2Piston chamber B1
Return spring(Cup spring) Brake
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Multiple disk clutch ( E, C und D )
Baffle plate Cub spring Pistons Clutch pressure
Dynamic pressure balance via the lubricating oil passage
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Automatic transmission 8HP70
Break Clutch Planetary gearset
Output flangeMechatronicsOil screenVane pump (DFZ)
Converter design:Turbine torsion damper with
Two dampersOne damper
Planetary gearset
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modular design (kits) starting elements
Hybridcompatible
Options 8HP.. starting elements
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Hydrodynamic Cooled Clutch
Hydrodynamic Cooled Clutch
Integrated starting clutch
Integrated starting clutch
Basis 3-line converter
Basis 3-line converter
HybridHCC integrated
HybridHCC integrated
Crankshaft-starter generator
Crankshaft-starter generator
Options starting elements
OptionsOptions
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4-wheel torsen
integrated
4-wheel hang-on
4-wheel ToD integrated
Options 8HP… 4W-drive
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Pump
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Double hub vane cell pump
Drive via a rolling toothed chain that is easy to rotate into overdrive directly from the converter neck.
Supply volume at 14.7 cm3/revolution
Pressure and suction canals are linked directly to hydraulic control with tubing travelling an unimpeded route for the best possible flow.
Suction flow charging from the main pressure valve improves the efficiency factor even more.
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Installation space comparison IZP / FZP
b = 14 mm b = 23.5 mm
d = 9
6 m
m
d = 4
7 m
m
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Overall efficiency factor oil pump
Engine rotation speed [rpm]
Ove
rall
eff
icie
ncy
[%
]
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Torque converter
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Challengecurrent development trends in the drive train
On the engine side, a reduction in displacement, weight, installation space... (Downsizing) is causing greater irregularity (e.g. 4 instead of 6 cylinders)
Downshifting (driving under high load at low rotational speed)
With the newest converter generation, which is used in the 8HP, ZF is already well equipped for the future.
In the same applications, we have a better decoupling factor than with the preceding generation by up to a factor of 5
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3-line converter
For ZF it is the first time to use a three-line converter in passenger cars
The third control line, together with the separately sealed piston chamber, makes it possible to better adjust the converter bridging clutch (WK) than with a 2-line system.
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Converter construction kit
NW:=neue Wandlergeneration
Converter Transmission
ZDW = two damper converterTTD = turbine torsion
NW = new converter generation
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Torque converterTyp NW 235 RH - 4GWK / TTD
1 housing / outer disk carrier WK(n_mot)2 Chamber for WK(converter bridging clutch) 3 WK piston4 Torsion damper5 Clutch pack for WK Lined disk and outer disks
6 Converter housing7 Turbine8 Pump 9 Guide wheel10 Free wheel from the guide wheel11 Line 1 and 2 (pumps and turbine chamber)12 Line 3 (Chamber for pressure charging the WK)13 Inner disk carrier WK
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Special ZF hybrid solutions
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Parallel hybrid – output classesZF Transmission
HIS
8 HP
EM
IAB
8P
K0
E-pumpHIS
8 HPEM
Installed electrical output 3-5 kW 4-20 kW 30-120 kW
Voltage 14-42 V More than 42 V 144-600 V
Fuel consumption reduction 3-5% About 15% 15-30%
1 start-stop (all)-/generator function (mild + full hybrid)
2 Recuperation
3 Boosting
4 Electrical starting
5 Purely electrical drive
Mild hybridMicro hybrid Full hybrid
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Savings potential for the hybrid performance classes
Full hybrid systems offer the greatest savings potential.
Measured against their lower purchase costs, this savings from micro and mild hybrids can also pay off for drivers or fleet operators.
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Why parallel hybrid?
ZF is conceptually oriented to the parallel hybrid in the passenger car sector.
Most affordable solution with the greatest customer benefits
The parallel hybrid drive is comparably cost effective to produce, since it gets along with just one electric motor
Only moderate electrical output in driveline necessary
High installation space efficiency compared to power-split hybrid transmissions because only one electrical motor is required
Higher efficiency
Modularity advantage
Various versions can be built upon available automatic transmissions as an “add-on module”
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Definition of name for converter hybrid transmission (mild hybrid)
Converter – hybrid transmission:
x HP xx HNumber of gears
SizeHydrodynamic starting element
Hybrid
Planetary design
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ZF mild hybrid
Example: mild hybridBMW Gen. 1.5: 8HP70H = Standard transmission with e-motor
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Definition of name for (full) hybrid transmission
Hybrid transmission (without converter):
x P xx HNumber of gears
Size
Hybrid
Planetary design
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ZF full hybrid
BMW Gen. 2.0: 8P70H Standard transmission with e-motor; brake B is the starting element
Audi MLB : 8P55AF H = Front longitudinal transmission including all-wheel drive and front axle differential between engine and e-motor ; brake B is the starting element
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ZF full hybrid concept
EM
IABK0
E-pumpK0
combustion engine
E-motor
IAE
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8P70H BMW Gen. 2 (full hybrid)Transmission schematic
Gear
Brake Clutch Ratioi
Gearratiostep
A B C D E
1
2
3
4
5
67
8
4.696
3.1302.104
1.667
1.285
1.000
1.50
1.49
1.26
1.30
1.29
1.19
7.05 Total
R
0.8391.25
-3.275
0.667
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Summary
ZF focuses on hybrid drive
ZF focuses on parallel hybrid solutions
ZF is pursuing economical solutions with rather small e-motors
ZF is stronger due to a partnership with CAS*
ZF is active with all its important customers on the hybrid issue
ZF already develops generation 3.0 as a plug-in Hybrid. „In 2014 every vehicle manufacturer must have a hybrid plug-in car in his portfolio who wants to sell cars in China.
*Continental Automotive Systems
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Thank you very much for your attention
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The End