8-speed - Sussex Auto Parts
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Transcript 8-speed - Sussex Auto Parts
ReMaTec 2011
Vortragender/Speaker
© ZF Getriebe GmbH
Günter Herth
ZF-Getriebe GmbH
Saarbrücken
Germany
The new 8-speed
transmission model line
© ZF Getriebe GmbH
Drivelinde Technology | Automatic Transmission, Manual Transmission and Dual Clutch Transmission Strategic Business Areas
KT/KT-A, Juni 2011
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ZF-Getriebe GmbH Saarbrücken
Factory 1 Saarbrücken
Technological leap from 5- to 6-speed
automatic transmission
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Generation 2
Generation 1
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Engine torque [Nm]
?
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 6speed-transmissions. The degree of efficiency is even smaller compared to the 6speed.
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Ambitious aim of ZF:
Introduction of a 8-speed transmission generation with a great added value to the
costumer, in particular concerning fuel consumption.
ZF 8 HP design based on Lepelletier
principle (Prototype)
A
B
E
C
D
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F
Objectives 8HP…
cost
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modular
design
- 20 %
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control of
variability
-6%
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fuel consumption
emissions
Reduction of fuel consumption and
technical solutions
6 HP TÜ
Engine torque
Lock-up clutch
- Better torsion
damping
Pump
- Vane cell pump
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-6%
- Open clutches
- Gearset efficiency
- Optimized lubrication
oil
8 HP..
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Operating point
- Spread
- No. of gears
Fuel consumptions savings
3-speed 4-speed
5-speed
6-speed 6-speed
First gen.
8-speed
Second gen.
-6%
-2%
-5%
-6%
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-3%
8 HP
prduct family
8 HP 90 A
8 HP 90
8 HP 70
8 HP 55 A
8 HP 55
8 HP 30
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8 HP 45
Transmission section 8HP70
Gearset 1
Gearset 2
Gearset 3
Brake B
Brake A
Clutch C
Drive
Clutch E
Vane pump
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Clutch D
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Gearset 4
Tranmission schema 8 gear ZF / AW
B
D
8 HP
E
A
B
1
2
3
4
5
6
C
7
8
8-Gang
F
B
D
A
E
Gang
A
1
2
3
4
5
B
Drag losses from 4 open shift elements and one free
wheel
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E
C
D
FL
F
8
R1
E
6
7
D
R
C
C
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A
Gang
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GWK
= open shift element
Transmission schema 8HP
A
B
D
E
C
brake
A
B
C
clutch
D
E
ratio
1
4,70
2
3,13
3
2,10
4
1,67
5
1,29
6
1,00
7
0,84
8
0,67
R
-3,30
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RS4
RS3
gear
step
1,50
1,49
1,26
1,30
1
2
3
4
5
6
7
8
1,29
1,19
1,25
Overall
7,05
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gear
RS2
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RS1
Disk brakes ( A and B )
Return spring
(Cup spring)
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Brake
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Piston chamber B2
Piston chamber B1
Cub spring
Pistons
Clutch pressure
Dynamic pressure balance via the
lubricating oil passage
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Baffle plate
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Multiple disk clutch ( E, C und D )
Automatic transmission 8HP70
Break
Planetary gearset
Clutch
Planetary gearset
Converter design:
Turbine torsion
damper with
Vane pump (DFZ)
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Oil screen
Mechatronics
Output flange
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Two dampers
One damper
Options 8HP.. starting elements
modular design (kits)
starting elements
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Hybrid
compatible
Options starting elements
Options
Basis
3-line converter
Hydrodynamic Cooled
Clutch
Integrated starting
clutch
Hybrid
HCC integrated
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Crankshaft-starter
generator
Options 8HP… 4W-drive
4-wheel
torsen
integrated
4-wheel
hang-on
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4-wheel ToD
integrated
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Pump
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.
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Suction flow charging from the main pressure valve improves the efficiency
factor even more.
Installation space
b = 14 mm
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b = 23.5 mm
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comparison IZP / FZP
Engine rotation speed [rpm]
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Overall efficiency [%]
Overall efficiency factor oil pump
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Torque converter
Challenge
current 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.
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In the same applications, we have a better decoupling factor than with the
preceding generation by up to a factor of 5
3-line converter
For ZF it is the first time to use a three-line converter in passenger cars
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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.
Converter construction kit
Converter
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NW:=neue
NW = new converter generation
Wandlergeneration
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ZDW = two damper converter
TTD = turbine torsion
Transmission
Torque converter
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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
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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
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Typ NW 235 RH - 4GWK / TTD
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Special ZF hybrid solutions
Parallel hybrid – output classes
ZF Transmission
Micro hybrid
Mild hybrid
Full hybrid
EM
8 HP
EM
8P
8 HP
K0
HIS
HIS
IAB
E-pump
Installed electrical output
3-5 kW
4-20 kW
30-120 kW
Voltage
14-42 V
More than 42 V
144-600 V
3-5%
About 15%
15-30%
Fuel consumption reduction
2 Recuperation
3 Boosting
4 Electrical starting
5 Purely electrical drive
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1 start-stop (all)-/generator
function (mild + full hybrid)
Savings potential for the hybrid
performance classes
Full hybrid systems offer the greatest savings potential.
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Measured against their lower purchase costs, this savings from micro and
mild hybrids can also pay off for drivers or fleet operators.
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
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Various versions can be built upon available automatic transmissions as an “add-on
module”
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Modularity advantage
Definition of name for converter hybrid
transmission (mild hybrid)
Converter – hybrid transmission:
x HP xx H
Number of gears
Hydrodynamic starting element
Hybrid
Size
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Planetary design
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Example: mild hybrid
BMW Gen. 1.5: 8HP70H = Standard transmission with e-motor
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ZF mild hybrid
Definition of name for (full) hybrid
transmission
Hybrid transmission (without converter):
x P xx H
Number of gears
Size
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Planetary design
Hybrid
ZF full hybrid
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Audi MLB : 8P55AF H = Front longitudinal
transmission including all-wheel drive and
front axle differential between engine and emotor ; brake B is the starting element
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BMW Gen. 2.0: 8P70H Standard transmission
with e-motor;
brake B is the starting element
ZF full hybrid concept
E-motor
EM
combustion
engine
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E-pump
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K0
IAE
IAB
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K0
8P70H BMW Gen. 2 (full hybrid)
Clutch
C
D
E
Ratio
i
1
4.696
2
3.130
2.104
1.667
3
4
5
6
7
8
R
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Brake
A
B
1.285
1.000
0.839
0.667
-3.275
Gear
ratio
step
1.50
1.49
1.26
1.30
1.29
1.19
1.25
Total
7.05
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Gear
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Transmission schematic
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*
*Continental Automotive Systems
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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.
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ZF is active with all its important customers on the hybrid issue
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Thank you very much
for your attention
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The End