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ReMaTec 2011

ReMaTec 2011. Vortragender/Speaker Günter Herth ZF-Getriebe GmbH Saarbrücken Germany. Drivelinde Technology | Automatic Transmission, Manual Transmission and Dual Clutch Transmission Strategic Business Areas. The new 8-speed transmission model line.

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ReMaTec 2011

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  1. ReMaTec 2011 Vortragender/Speaker Günter Herth ZF-Getriebe GmbH Saarbrücken Germany

  2. Drivelinde Technology | Automatic Transmission, Manual Transmission and Dual Clutch Transmission Strategic Business Areas The new 8-speed transmission model line

  3. ZF-Getriebe GmbH SaarbrückenFactory 1 Saarbrücken

  4. Technological leap from 5- to 6-speedautomatic transmission ? Engine torque [Nm] Generation 2 Generation 1

  5. 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.

  6. ZF 8 HP design based on Lepelletier principle (Prototype) F A B C D E

  7. - 6 % fuel consumptionemissions modulardesign cost Objectives 8HP… control of variability - 20 %

  8. - 6 % Reduction of fuel consumption and technical solutions 6 HP TÜ - Spread- No. of gears Operating point • Open clutches- Gearset efficiency- Optimized lubrication oil Engine torque - Better torsion damping Lock-up clutch Pump - Vane cell pump 8 HP..

  9. Fuel consumptions savings 3-speed 4-speed 5-speed 6-speed First gen. 6-speed Second gen. 8-speed - 6 % - 2 % - 5 % - 3 % - 6 %

  10. 8 HPprduct family 8 HP 90 A 8 HP 90 8 HP 70 8 HP 55 A 8 HP 55 8 HP 45 8 HP 30

  11. Transmission section 8HP70 Gearset 1 Brake B Gearset 2 Brake A Gearset 3 Gearset 4 Clutch D Drive Vane pump Clutch C Clutch E

  12. = open shift element Tranmission schema 8 gear ZF / AW A B GWK D 8 HP E C D C B A 8-Gang E F Drag losses from 4 open shift elements and one free wheel

  13. A B D E C RS1 RS2 RS4 RS3 brake clutch ratio gear gear step A B C D E 4,70 1 1,50 3,13 2 1,49 2,10 3 1,26 1,67 4 1,30 1,29 5 1,29 1,00 6 1,19 0,84 7 1,25 0,67 8 Overall R -3,30 7,05 Transmission schema 8HP 4 1 2 3 5 6 8 7

  14. Disk brakes ( A and B ) Piston chamber B2 Piston chamber B1 Return spring (Cup spring) Brake

  15. Multiple disk clutch ( E, C und D ) Cub spring Pistons Baffle plate Clutch pressure Dynamic pressure balance via the lubricating oil passage

  16. Automatic transmission 8HP70 Planetary gearset Break Clutch Planetary gearset Converter design: Turbine torsion damper with Two dampers One damper Vane pump (DFZ) Mechatronics Output flange Oil screen

  17. Options 8HP.. starting elements modular design (kits) starting elements Hybridcompatible

  18. Options starting elements Options Basis 3-line converter Hydrodynamic Cooled Clutch Integrated starting clutch Crankshaft-starter generator HybridHCC integrated

  19. Options 8HP… 4W-drive 4-wheel torsen integrated 4-wheel hang-on 4-wheel ToD integrated

  20. Pump

  21. 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.

  22. Installation space comparison IZP / FZP d = 96 mm d = 47 mm b = 14 mm b = 23.5 mm

  23. Overall efficiency factor oil pump Overall efficiency [%] Engine rotation speed [rpm]

  24. Torque converter

  25. 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 Challengecurrent development trends in the drive train

  26. 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.

  27. Converter construction kit Converter Transmission ZDW = two damper converter TTD = turbine torsion NW:=neue Wandlergeneration NW = new converter generation

  28. Torque converterTyp NW 235 RH - 4GWK / TTD 6 Converter housing 7 Turbine 8 Pump 9 Guide wheel 10 Free wheel from the guide wheel 11 Line 1 and 2 (pumps and turbine chamber) 12 Line 3 (Chamber for pressure charging the WK) 13 Inner disk carrier WK 1 housing / outer disk carrier WK (n_mot) 2 Chamber for WK (converter bridging clutch) 3 WK piston 4 Torsion damper 5 Clutch pack for WK Lined disk and outer disks

  29. Special ZF hybrid solutions

  30. Parallel hybrid – output classesZF Transmission EM 8 HP HIS Micro hybrid Mild hybrid Full hybrid

  31. 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.

  32. 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”

  33. Definition of name for converter hybrid transmission (mild hybrid) Converter – hybrid transmission: x HP xx H Number of gears Hybrid Size Hydrodynamic starting element Planetary design

  34. ZF mild hybrid Example: mild hybrid BMW Gen. 1.5: 8HP70H = Standard transmission with e-motor

  35. Definition of name for (full) hybrid transmission Hybrid transmission (without converter): x P xx H Number of gears Hybrid Size Planetary design

  36. 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

  37. ZF full hybrid concept E-motor EM K0 IAB IAE K0 E-pump combustion engine

  38. Gear ratio step Ratio i Brake Clutch Gear A B C D E 4.696 1 1.50 3.130 2 1.49 2.104 3 1.26 1.667 4 1.30 1.285 5 1.29 1.000 6 1.19 0.839 7 1.25 0.667 8 Total R -3.275 7.05 8P70H BMW Gen. 2 (full hybrid)Transmission schematic

  39. 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

  40. Thank you very much for your attention

  41. The End

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