– Transmission Technology Trends Competition fuels the future Patrick Lindemann
Transmission Technology Trends – Competition fuels the future Patrick Lindemann Global Warming 1 Schaeffler Symposium 2014 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 2 Schaeffler Symposium 2014 Patrick Lindemann 2005 2010 2015 2020 2025 CAFE vs. Footprint Our Car Today 3 Schaeffler Symposium 2014 Patrick Lindemann 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 4 Schaeffler Symposium 2014 34 % Exhaust gas heat Damper is enabler for engine technology 5 Schaeffler Symposium 2014 Patrick Lindemann Transmission Technology Trends – Competition fuels the future Patrick Lindemann Competition fuels the future The Contestants 7 Schaeffler Symposium 2014 Patrick Lindemann Competition fuels the future The Contestants 8 Schaeffler Symposium 2014 Patrick Lindemann Competition fuels the future 9 Schaeffler Symposium 2014 Patrick Lindemann Competition fuels the future 10 Schaeffler Symposium 2014 Patrick Lindemann Competition fuels the future Selection Criteria: US Start-stop Capability 11 Schaeffler Symposium 2014 Patrick Lindemann Manual Transmission 12 Schaeffler Symposium 2014 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! 13 Schaeffler Symposium 2014 Patrick Lindemann 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! 14 Schaeffler Symposium 2014 Patrick Lindemann Options for clutch automation ECM 15 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 16 Schaeffler Symposium 2014 Patrick Lindemann 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 17 Schaeffler Symposium 2014 Patrick Lindemann 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 19 Schaeffler Symposium 2014 Patrick Lindemann 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) 20 Schaeffler Symposium 2014 Patrick Lindemann Double Clutch Transmission 21 Schaeffler Symposium 2014 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! 22 Schaeffler Symposium 2014 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! 23 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" 24 Schaeffler Symposium 2014 Patrick Lindemann Modular Approach Clutch / Actuation Hydrostatic clutch actuator HCA 180 Nm 370 Nm 25 Schaeffler Symposium 2014 Patrick Lindemann Gear actuator Wet Double Clutch System with CSC 370 Nm 26 Schaeffler Symposium 2014 Patrick Lindemann "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 27 Schaeffler Symposium 2014 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 29 Schaeffler Symposium 2014 Patrick Lindemann 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 30 Schaeffler Symposium 2014 Patrick Lindemann 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 31 Schaeffler Symposium 2014 Patrick Lindemann Further Potential for Launch and Creeping Facing Geometric optimization of parts and assembly Compensation function Anti-judder control system 32 Schaeffler Symposium 2014 Patrick Lindemann Further Potential for Launch and Creeping Facing Geometric optimization of parts and assembly Compensation function Anti-judder control system 33 Schaeffler Symposium 2014 Patrick Lindemann … the Powertrain of Tomorrow - Requirements Efficiency Ratio spread Comfort Performance Weight Space Cost Start-stop capability Hybridization capability 34 Schaeffler Symposium 2014 Patrick Lindemann The Planetary Automatic Transmission 35 Schaeffler Symposium 2014 Patrick Lindemann The CVT 36 Schaeffler Symposium 2014 Patrick Lindemann Customer acceptance International Customer Clinic: What is your favorite Transmission DCT Sporty 37 Schaeffler Symposium 2014 Patrick Lindemann 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 38 Schaeffler Symposium 2014 Patrick Lindemann ‟ Prediction is very hard, especially about the future ” Yogi Berra 1925 –
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