Transmission Technology Trends – Competition fuels the future · Transmission Technology Trends...

Transmission Technology Trends –

Competition fuels the future

Patrick Lindemann

Schaeffler Symposium 2014 Patrick Lindemann 1

Global Warming


CO2 reduction

CO2 Legislation Worldwide

90

110

130

150

170

190

210

230

250

270

2000 2005 2010 2015 2020 2025

China: 117 g/km

in 2020

EU: 95 g /km

in 2020

Japan: 105 g/km

in 2020

USA:

109 g/km

in 2025

Source: icct 2013

Light vehicles

in g/km CO2

Proposed target

Enacted target

USA: incl. light duty vehicles


CAFE vs. Footprint

Our Car Today

29 %

Heat loss

4%

Charge cycle

8 %

Engine friction

3 %

Accessories

17%

Wheels

On the basis of Nizzola

.

100 %

Fuel energy

Engine

Drivetrain 34 %

Exhaust gas heat

Fuel economy chain of a combustion engine

5 %

Transmission

& driveline

Schaeffler Symposium 2014 4


Damper is enabler for engine technology

Transmission Technology Trends –


Patrick Lindemann



The Contestants



US

Selection Criteria:

Start-stop Capability


Manual Transmission


Motivation for clutch automation

￭Main driver in the past: Comfort and robustness

￭Additional driver for today / future: Fuel efficiency

￭MT with strong Disadvantage!

Extended Start/Stop

functions (Sailing) Hybrid capability

Assistance- and

comfort functions Misuse protection


Fuel saving potential of Start/Stop and Sailing

Without automation, sailing potential can not be tapped!

NEDC WLTP

Fue

l con

sum

ption

in l/1

00

km

5.5

5.0

4.5

4.0

Fuel consum

ption in l/1

00km

5.5

5.0

4.5

4.0

Basis w/o start/stop With start/stop Sailing

-6.1 %

-2.6 %

-6.1 %

Simulation result (2.0l Diesel)


Options for clutch automation

ECM CbW MTplus

2-pedal design

Actuator with high

dynamic

Shift intention sensor

3-pedal design

Actuator with high

dynamic

Pedal load emulator

3-pedal design

Actuator with reduced

dynamic

——


Key activities for Clutch by Wire

Compact force emulator device

￭ Space neutral unit with integrated

position sensor

￭ Optimal pedal load by new spring

system

Flexible actuator concept

￭ Tailored for upgrading manual

transmission to CbW

￭ Modular with high add-on capability

Basic actor

Hydraulic module

Mechanic module

Position sensor

Spring set


Key activities for MTplus

Actuator unit design

￭ Detailing of final architecture

￭ Study cost-benefit ratio

Demonstrator vehicle

￭ Study of operating handling and

feedback on foot actuation

￭ Study of extended functionality

(sailing, comfort, misuse protection)

Master cylinder

Slave cylinder

Electric motor

Spindle driver


Functionality of clutch automation

CO2 Potential Assistance Protection Comfort Safety

Sailing

Recuperation

Electric launch & creeping

Hybrid capability

Automated launch and creeping

Autonomic drive

Engine stall

Resonance drive

Clutch Pedal load assist

Collision protection

Emergency break

Longer gear ratios

MT

plu

s

Drive w/o clutch pedal

EC

M

Traction control

eClutch during shift

Impact

Optimal pedal load

Slip control

Anti judder

Anti jerking

Cb

W


Fuel saving potential of automated launch

Heat dissipation in clutch during vehicle launch (measurement) O

ccu

rre

nce

in %

15

10

5

0

Manual launch

0

Energy in kJ

50 100 150 >200


Fuel saving potential of automated launch

Heat dissipation in clutch during vehicle launch (measurement)

Reduced energy level due to automated launch can be used to adjust gear ratios

Reduction of gear ratios by 10 % can lead to fuel saving of 5.6 % (NEDC) / 2.5 % (WLTP)

Simulation result (2.0l Diesel)

Occu

rre

nce

in %

15

10

5

0

Manual launch

Automated launch

0

Energy in kJ

50 100 150 >200


Double Clutch Transmission


DCT as an Efficient Basis for a Full Hybrid System

● First production application!

2014 Schaeffler Symposium

> 20 % improved

fuel efficiency!

2004 mild hybrid-demonstrator 2006 full hybrid-study

14 % improved

fuel efficiency!

Excellent efficiency of the dry DCT!

No disconnecting clutch necessary!

No additional axial space required!


DCT as an Efficient Basis for a Full Hybrid System

● First production application!

2014 Schaeffler Symposium

> 20 % improved

fuel efficiency!

2004 mild hybrid-demonstrator 2006 full hybrid-study

14 % improved

fuel efficiency!








i-DCD Driveline (85.6mpg)

Source: "Internal Press research"


180 Nm

370 Nm

Hydrostatic clutch

actuator HCA Gear actuator

Modular Approach Clutch / Actuation


Wet Double Clutch System with CSC

370 Nm


1

2

3

4

5

6

7

8

Tra

nsm

issio

n p

rod

uctio

n in

mill

ion p

er

ye

ar

0

Database: IHS + Schaeffler Project Knowledge / Dec. 2013

wet

dry

"Dry or Wet" or "Dry and Wet"?

2006 2008 2010 2012 2014 2015 2007 2009 2011 2013

200 W


Clutch actuator

Gear actuator

Ave

rag

e p

ow

er

co

nsu

mp

tio

n in

W

0

30

60 Dry DCT

A

Dry DCT

B Dry DCT

C

Wet

DCT Dry

DCT

2007 2010 2011 2013

Modular and Efficient Actuator Technology


… the Powertrain of Tomorrow - Requirements

Efficiency

Ratio spread

Comfort

Performance

Weight

Space

Cost

Start-stop capability

Hybridization capability

Engine

Input shaft

1,000

2,000

0 0 4 8

Time in s

Sp

ee

d in

rp

m


Facing

Geometric optimization of parts and assembly

Compensation function

Anti-judder control system

Further Potential for Launch and Creeping


Facing





25

50

75

100

Tribological system damping

0

Standard facing

Optimized facings

RCF1o, B8040

Excitation Damping

Next generation

Double clutch

facings e.g. B9000

Cu

mu

lative

fre

qu

en

cy in

%


Facing






Efficiency

Ratio spread

Comfort

Performance

Weight

Space

Cost

Start-stop capability -

Hybridization capability

… the Powertrain of Tomorrow - Requirements


The Planetary Automatic Transmission


The CVT


Customer acceptance

DCT

Sporty

CVT

Smoooth

Planetary AT

Have to pull

out Stumps

International Customer Clinic:

What is your favorite Transmission


Transmission Production

10

20

30

40

50

60

DCT

CVT

AT

Tra

nsm

issio

n p

rod

uctio

n in

mill

ion

pe

r ye

ar

0

2013 2017 2022

Worldwide

Database: IHS + Schaeffler Project Knowledge / Dec. 2013

Prediction is very hard, especially about the future

” ‟

Yogi Berra

1925 –

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