1. No category

New Features for more efficient
Manual Transmissions with
additional Customer Benefit
14th International VDI Congress, Friedrichshafen, 2014-06-24
Wulf Leitermann, Matthias Brosi, Rafael Prellezo
New Features for more efficient Manual Transmissions with additional Customer Benefit
Agenda
1. Global Manual Transmission Market
2. Future Market Requirements for Manual Transmissions
3. New Features for more efficient Manual Transmissions
− Increased overall Spread and Number of Gears
− Reduction of parasitic Losses
− Automated Clutch
4. Next Generation Inline Manual Transmission Family
5. Summary
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© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
1. Global Manual Transmission Market
1. Global Manual Transmission Market
Global manual transmission volumes will increase. Inline
manual transmission market is shrinking and moving from
passenger cars to light commercial vehicles.
Light Vehicle Production < 3,5 t (Passenger Cars and Light Commercial Vehicles)
RWD MT Light Commercial Vehicle Production < 3,5 t; > 250 Nm
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RWD MT Passenger Car Production < 3,5 t; > 250 Nm
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
2. Future Market Requirements
for Manual Transmissions
2. Future Market Requirements for Manual Transmissions
Further improvements of manual transmissions is requested.
Additional functions under consideration, due to customer
acceptance and on-costs.
New design features requested:
Overall spread > 7,5
Oil management
Significantly reduced parasitic losses in
all components
Gears
Bearings
Seals
Additional design features optional:
Functional aspects considered as
standard:
7-speed gear set
Shiftability according specific OEM DNA
Automated clutch
Fulfillment of NVH targets
All features have to consider best cost efficiency
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© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
3. New Features for
more efficient Manual Transmissions
3. New Features for more efficient Manual Transmissions
Increased overall spread is the major
contributor to reduce fuel consumption
and emissions
down speeding in higher gears
3 … 4 %, depending on engine and
vehicle application
Improvement for WLTC slightly higher
than for NEDC
relative fuel
consumption [%]
Increased overall spread reduces fuel consumption, but
effects transmission and powertrain attributes.
100,0
Phi = 6,3
95,0
Phi = 7,5
90,0
WLTC
But high overall spread effects drivability and design attributes:
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Feature
Challenge
Approach
Increased gear steps
Driving maneuvers @ low speed
7-speed gear set
Down-speeding
Tractive effort decrease @ high speed
Engine characteristic
Increased center distance
Transmission weight
Adjusted design philosophy
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
3. New Features for more efficient Manual Transmissions
Reduction of splash loss directly correlates to complexity
of chosen technical solution.
Splash losses
without vs. with oil shield
75
50
-54%
100
-40%
relative splash
losses [%]
Passive Oil Management:
Oil shield separates gear set from oil sump
Controlled oil flow
Reduced oil volume
Significantly reduced splash losses and
oil temperature
w/o oil shield
with oil shield
25
0
Active Oil Management:
Dry sump lubrication by scavenge pump and
injection lubrication
Further reduced splash losses
but, higher
• complexity
• weight
• costs
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relative energy
loss reduction [%]
1000 1/min
3500 1/min
Energy loss reduction
passive vs. active oil management
100
75
passive
50
active
25
0
NEDC
WLTC
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
3. New Features for more efficient Manual Transmissions
Further improvement on component level are possible, but to
some extent cost-benefit outcome questionable.
Component
Measure
Gear set
Low loss gear design
Coating
Bearings
Smaller bearings, due to
reduced axial and radial
forces
Reduces drag torque
Synchronizer Reduced number of
cones
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Oil
Reduction of viscosity
Seals
Optimized sealing lip
design and reduced
preload
Manual transmission is a very mature
system
all efficiency improvement measures to
be reflected against
- Cost
- Customer benefit
- End customer acceptance
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
3. New Features for more efficient Manual Transmissions
Automated clutch system could improve MT functionality
and fuel efficiency
Automated clutch system features and
advantages:
Add-on automated clutch system
components:
Sailing possible for MTs
CO2 reduction in WLTC ca. 7%
in real life even higher
Clutch actuator + position sensor
Stop-and-go assist
Clutch pedal + position sensor
Control unit (pot. integrated in ECU)
Launch control
Drivetrain protection
NVH improvement by clutch micro slip
Base for MT hybrids!
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© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
3. New Features for more efficient Manual Transmissions
Automated wet clutch concept based on GETRAG DCT
technology will offer further advantages.
Fully integrated automated wet clutch concept
based on GETRAG modules:
Wet clutch using DCT components
Pump actuator carry-over from DCT
Oil suction and cooling based on DCT design
features
Clutch control using DCT software modules
Advantages of integrated wet clutch system:
Better controllability of wet clutch system
Higher robustness against high energy events
Significantly reduced inertia and weight
Usage of mass production components and
controls
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© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
4. Next Generation Inline MT Family
4. Next Generation Inline Manual Transmission Family
Volatile market and technical requirements needs to be
addressed in the next generation inline MT concept
Variety of technical
requirements
Segmented inline MT
market
250 … 800 Nm
Premium passenger cars
Different mission profiles
(sport car vs. LCV)
Sport cars
LCV
Number of gears
(6 vs. 7-speed)
Overall ratio spread
Volatile inline MT volumes
Shrinking volumes for
premium passenger cars
Increasing global volumes
for light commercial
vehicles (LCV)
?
Fuel efficiency
Common requirements for all applications
Best shiftability
NVH optimized
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Flexibility for different
applications and
innovations
Low product costs
Best reliability
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
4. Next Generation Inline Manual Transmission Family
New flexible inline MT architecture supports huge variety of
customer requirements.
Major design features:
One center distance for all variants
Overall spread > 7,5 feasible
Reduced axial and radial loads
Low loss gear design
Carry over components MT/DCT
Best shiftabilty and NVH
Optimized design costs
New design and manufacturing approach:
Mid and high torque derivatives by
adjusted gear width
Axial flexibility of bearings position and
shift system provided
Common base of MT and DCT without
negative effects on:
•
Weight
•
Complexity of MT and DCT
Protected options:
7-speed gear set module
Active oil management
Mid and high torque gear sets
Fuel efficiency measures
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© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24
5. Summary
5. Summary
New and optimized functionality for manual transmission is
feasible and base for GETRAGs new flexible MT architecture
Major contributors for fuel efficiency improvement are
•
Increased overall spread for down-speeding potentially 7-speed gear set needed
•
Automated clutch to enable sailing
Improvements on component level (oil management, low viscosity oil, low loss gear
design …) are feasible
Due to cost sensitivity of manual transmissions each optimization has to be crosschecked regarding cost-benefit outcome and could be different for specific applications
or markets
Technically meaningful features like 7-speed or automated clutch has to be checked
against end customer expectation and acceptance
GETRAG could offer a new flexible manual transmission architecture, which reflects
optimized functionality. New functions are optional.
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© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Wulf Leitermann, Matthias Brosi, Rafael Prellezo
2014-06-24