Transmission Technology Trends –
Competition fuels the future
Patrick Lindemann
Global Warming
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Patrick Lindemann
CO2 reduction
CO2 Legislation Worldwide
Light vehicles
in g/km CO2
270
Proposed target
Enacted target
USA: incl. light duty vehicles
250
230
210
190
170
China: 117 g/km
in 2020
USA:
109 g/km
in 2025
150
130
Japan: 105 g/km
in 2020
110
EU: 95 g /km
in 2020
90
2000
Source: icct 2013
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Patrick Lindemann
2005
2010
2015
2020
2025
CAFE vs. Footprint
Our Car Today
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Fuel economy chain of a combustion engine
17%
Wheels
100 %
Fuel energy
5%
Transmission
& driveline
.
3%
Accessories
8%
Engine friction
4%
Charge cycle
29 %
Heat loss
On the basis of Nizzola
Engine
Drivetrain
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34 %
Exhaust gas heat
Damper is enabler for engine technology
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Patrick Lindemann
Transmission Technology Trends –
Competition fuels the future
Patrick Lindemann
Competition fuels the future
The Contestants
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Schaeffler Symposium 2014
Patrick Lindemann
Competition fuels the future
The Contestants
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Patrick Lindemann
Competition fuels the future
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Schaeffler Symposium 2014
Patrick Lindemann
Competition fuels the future
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Schaeffler Symposium 2014
Patrick Lindemann
Competition fuels the future
Selection Criteria:
US
Start-stop Capability
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Patrick Lindemann
Manual Transmission
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Patrick Lindemann
Motivation for clutch automation
Extended Start/Stop
functions (Sailing)
Hybrid capability
Assistance- and
comfort functions
Misuse protection
￭ Main driver in the past: Comfort and robustness
￭ Additional driver for today / future: Fuel efficiency
￭ MT with strong Disadvantage!
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Fuel saving potential of Start/Stop and Sailing
5.5
-6.1 %
5.0
4.5
4.0
WLTP
Fuel consumption in l/100km
Fuel consumption in l/100 km
NEDC
5.5
-2.6 %
-6.1 %
5.0
4.5
4.0
 Basis w/o start/stop
 With start/stop
 Sailing
Simulation result (2.0l Diesel)
Without automation, sailing potential can not be tapped!
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Options for clutch automation
ECM
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CbW
MTplus
 2-pedal design
 3-pedal design
 3-pedal design
 Actuator with high
dynamic
 Actuator with high
dynamic
 Actuator with reduced
dynamic
 Shift intention sensor
 Pedal load emulator
 ——
Schaeffler Symposium 2014
Patrick Lindemann
Key activities for Clutch by Wire
Mechanic module
Flexible actuator concept
￭ Tailored for upgrading manual
transmission to CbW
￭ Modular with high add-on capability
Basic actor
Hydraulic module
Position sensor
Compact force emulator device
￭ Space neutral unit with integrated
position sensor
￭ Optimal pedal load by new spring
system
Spring set
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Key activities for MTplus
Demonstrator vehicle
￭ Study of operating handling and
feedback on foot actuation
￭ Study of extended functionality
(sailing, comfort, misuse protection)
Master cylinder
Actuator unit design
Spindle driver
￭ Detailing of final architecture
￭ Study cost-benefit ratio
Electric motor
Slave cylinder
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Functionality of clutch automation
ECM
Drive w/o clutch
pedal
CbW
Optimal pedal load
Slip control
Traction control
MTplus
eClutch during
shift
Impact
Anti jerking
Longer gear ratios
Sailing
Recuperation
18
Anti judder
Engine stall
Electric launch &
creeping
Automated launch
and creeping
Resonance drive
Hybrid capability
Autonomic drive
Clutch
Pedal load assist
Emergency break
CO2 Potential
Assistance
Protection
Comfort
Safety
Schaeffler Symposium 2014
Patrick Lindemann
Collision protection
Fuel saving potential of automated launch
Heat dissipation in clutch during vehicle launch (measurement)
Occurrence in %
15
10
 Manual launch
5
0
0
50
100
Energy in kJ
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150
>200
Fuel saving potential of automated launch
Heat dissipation in clutch during vehicle launch (measurement)
Occurrence in %
15
10
 Manual launch
 Automated launch
5
0
0
50
100
150
>200
Energy in kJ
 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)
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Double Clutch Transmission
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Patrick Lindemann
DCT as an Efficient Basis for a Full Hybrid System
 Excellent efficiency of the dry DCT!
 No disconnecting clutch necessary!
 No additional axial space required!
2004 mild hybrid-demonstrator
 14 % improved
fuel efficiency!
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2006 full hybrid-study
 > 20 % improved
fuel efficiency!
Patrick Lindemann
2014 Schaeffler Symposium
● First production application!
DCT as an Efficient Basis for a Full Hybrid System
 Excellent efficiency of the dry DCT!
 No disconnecting clutch necessary!
 No additional axial space required!
2004 mild hybrid-demonstrator
 14 % improved
fuel efficiency!
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Schaeffler Symposium 2014
2006 full hybrid-study
 > 20 % improved
fuel efficiency!
Patrick Lindemann
2014 Schaeffler Symposium
● First production application!
i-DCD Driveline (85.6mpg)
 Excellent efficiency of the dry DCT!
 No disconnecting clutch necessary!
 No additional axial space required!
Source: "Internal Press research"
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Modular Approach Clutch / Actuation
Hydrostatic clutch
actuator HCA
180 Nm
370 Nm
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Gear actuator
Wet Double Clutch System with CSC
370 Nm
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"Dry or Wet" or "Dry and Wet"?
Transmission production in million per year
8
7
6
5
wet
4
3
dry
2
1
0
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
Database: IHS + Schaeffler Project Knowledge / Dec. 2013
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Patrick Lindemann
200 W
Modular and Efficient Actuator Technology
Average power consumption in W
60
Clutch actuator
Gear actuator
Dry DCT
A
Dry DCT
B
30
Wet
DCT
Schaeffler Symposium 2014
Dry
DCT
0
2007
28
Dry DCT
C
Patrick Lindemann
2010
2011
2013
… the Powertrain of Tomorrow - Requirements
Efficiency
Ratio spread
2,000
Speed in rpm
Comfort
Performance
Weight
Space
Engine
1,000
Input shaft
Cost
Start-stop capability
0
Hybridization capability
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0
4
Time in s
8
Further Potential for Launch and Creeping
 Facing
 Geometric optimization of parts and assembly
 Compensation function
 Anti-judder control system
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Schaeffler Symposium 2014
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Further Potential for Launch and Creeping
 Facing
 Geometric optimization of parts and assembly
 Compensation function
Cumulative frequency in %
100
 Anti-judder control system
Optimized facings
RCF1o, B8040
75
50
Next generation
Double clutch
facings e.g. B9000
Standard facing
25
0
Damping
Excitation
Tribological system damping
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Further Potential for Launch and Creeping
 Facing
 Geometric optimization of parts and assembly
 Compensation function
 Anti-judder control system
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Schaeffler Symposium 2014
Patrick Lindemann
Further Potential for Launch and Creeping
 Facing
 Geometric optimization of parts and assembly
 Compensation function
 Anti-judder control system
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Schaeffler Symposium 2014
Patrick Lindemann
… the Powertrain of Tomorrow - Requirements
Efficiency
Ratio spread
Comfort
Performance
Weight
Space
Cost
Start-stop
capability
Hybridization capability
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Patrick Lindemann
The Planetary Automatic Transmission
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Patrick Lindemann
The CVT
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Customer acceptance
International Customer Clinic:
What is your favorite Transmission
DCT
Sporty
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CVT
Smoooth
Planetary AT
Have to pull
out Stumps
Transmission Production
Transmission production in million per year
60
50
40
30
20
DCT
10
CVT
AT
0
2013
2017
Worldwide
2022
Database: IHS + Schaeffler Project Knowledge / Dec. 2013
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Schaeffler Symposium 2014
Patrick Lindemann
‟
Prediction is very hard,
especially about the future
”
Yogi Berra
1925 –