– iTC Innovative solutions for torque converters pave the way into the future
iTC – Innovative solutions for torque converters pave the way into the future Markus Steinberger Father of the torque converter Hermann Föttinger 1877 - 1945 1 Schaeffler Symposium 2014 Markus Steinberger First TC in mass production 74 Years of TC. Everything invented? 2 Schaeffler Symposium 2014 Markus Steinberger Rumor has it… Torque Converter 1940-? 3 Schaeffler Symposium 2014 Markus Steinberger What is a torque converter? • Launch device • Clutch • Torsional vibration isolator • Continuously variable transmission 4 Schaeffler Symposium 2014 Markus Steinberger The main torus function • Launch device Performance Customer success decided by Cost 5 Schaeffler Symposium 2014 Efficiency Markus Steinberger Comparison: launch efficiency Engine speed Engine speed Speed to reach desired launch torque Friction losses Hydrodynamic losses Time Time Wet or dry clutch 6 Schaeffler Symposium 2014 Markus Steinberger Trans. Engine Trans. Engine Torque ratio amplifies to launch torque Torque converter TC has up to TWICE the efficiency of a friction clutch Engine speed Engine speed Comparison: launch efficiency Time Hydrodynamic losses Time Torque converter Friction clutch 7 Schaeffler Symposium 2014 Markus Steinberger TC innovation since the last Symposium New during Symposium 2010 • TC as a launch device • Limited damper performance 8 Schaeffler Symposium 2014 Markus Steinberger Goal from Symposium 2010 TC innovation since the last Symposium New during Symposium 2010 • TC as a launch device • Limited damper performance 9 Schaeffler Symposium 2014 Markus Steinberger Production during Symposium 2014 • • • • True launch-and-lock Superior damper performance Cylinder deactivation 6 to 3 cylinders More than 30° damper travel and CPA TC innovation - piston State of the art piston connection Schaeffler piston riveting • Eliminates riveting connection • Fewer components • Saves space 10 Schaeffler Symposium 2014 Markus Steinberger TC innovation - piston Leaf springs Piston assembled deflected rivet formed riveted to cover 11 Schaeffler Symposium 2014 Markus Steinberger TC innovation - flange State of the art damper hub Schaeffler net formed flange • Fewer components • Reduced weight • Simplified design 12 Schaeffler Symposium 2014 Markus Steinberger TC innovations Schaeffler friction material Pendulum damper Piston bushing 13 Schaeffler Symposium 2014 Markus Steinberger TC innovation recognition 14 Schaeffler Symposium 2014 Markus Steinberger Global sales: cars with automatic transmissions Globally sold AT vehicles in Millions 60 50 40 Automatic transmissions with torque converter 30 20 10 Automatic transmissions without torque converter 0 2013 15 Schaeffler Symposium 2014 2015 Year Markus Steinberger Source: IHS 2020 Innovation “ ...Everything that can be invented has been invented. ” Charles H. Duell Commissioner of the US Patent Office 1899 16 Schaeffler Symposium 2014 Markus Steinberger What's next? The Symposium is about the FUTURE, not the PAST. 17 Schaeffler Symposium 2014 Markus Steinberger Simple idea Integrate turbine and piston TM 18 Schaeffler Symposium 2014 Markus Steinberger iTC function Clutch disengage o Pressure separates turbine and impeller o Flow enters at stator shaft o Complete liftoff at very low release pressure 19 Schaeffler Symposium 2014 Markus Steinberger Clutch release force TM iTC function Clutch apply o Turbine applies towards impeller o Flow direction opposite of typical TC 20 Schaeffler Symposium 2014 Markus Steinberger Apply pressure TM Clutch apply force Bernoulli effect and iTC Force from pressure difference Resulting clutch force " For an inviscid flow, an increase in the speed of the fluid occurs simultaneously with a decrease in pressure." Reaction force Lift Low oil velocity, Daniel Bernoulli higher 1700 - 1782 pressure 21 Schaeffler Symposium 2014 Markus Steinberger High velocity, low pressure Low velocity High oil velocity, lower pressure Clutch engagement measurement speed in rpm impeller speed smooth engagement 3000 2000 1000 smooth release turbine speed pressure in bar 0 clutch pressure 2.0 1.5 1.0 0.5 0.0 0 5 10 time in s 22 Schaeffler Symposium 2014 Markus Steinberger 15 20 Clutch drag check Clutch forced to stay open Clutch drag comparison TM 1. Run characteristic as iTC 2. Block iTC function 3. Re run test 4. Compare results Blocked iTC function with additional bearing for test 23 Schaeffler Symposium 2014 Markus Steinberger Clutch drag measurement No difference in torque converter characteristic No drag measurable 12 2.5 10 2.0 8 Blocked iTC 1.5 6 1.0 4 K-factor (stiffness) 0.5 2 iTC 0.0 0 0.0 0.2 0.4 Speed ratio 24 Schaeffler Symposium 2014 Markus Steinberger 0.6 0.8 1.0 K-factor in 100 rpm/Nm½ Torque ratio 3.0 Note from my old Friend 25 Schaeffler Symposium 2014 Markus Steinberger iTC advantages TM More space for damper (CPA in front wheel drive) Impeller thrust washer Reduced mass and inertia No turbine bearing Simpler, more compact design 26 Schaeffler Symposium 2014 Markus Steinberger Dry weight comparison iTC design Damper torque in Nm Current production Damper angle in ° 13.1 kg 27 Schaeffler Symposium 2014 Markus Steinberger 10.7 kg iTC advantages Simplified damper inputs (modular design) 28 Schaeffler Symposium 2014 Markus Steinberger TM iTC advantages No weld behind friction surface (hot spots) Improved clutch stability due to thrust Blades stiffen friction surface Improved TC efficiency due to smaller gap 29 Schaeffler Symposium 2014 Markus Steinberger TM Torque converter evolution TM Value Innovation Next generation 2014 new production 2010 new production 31 Schaeffler Symposium 2014 Markus Steinberger Multi function integrated torque converter Impeller clutch TM Lockup clutch 32 Schaeffler Symposium 2014 Markus Steinberger Design layout Impeller clutch TM Lockup clutch Vent to sump between bushing and seal Low to high pressure controlled Low or high pressure not controlled 33 Schaeffler Symposium 2014 Markus Steinberger Idle disconnect TM Lockup clutch Impeller clutch Open Open Sump TC port Lockup port 34 Schaeffler Symposium 2014 Markus Steinberger Launch and drive with open TC TM Lockup clutch Impeller clutch Open Closed Open Sump TC port Lockup port 35 Schaeffler Symposium 2014 Markus Steinberger Lockup clutch at touch point TM Lockup clutch Impeller clutch Open Closed Sump TC port Lockup port 36 Schaeffler Symposium 2014 Markus Steinberger Lockup clutch applied TM Lockup clutch Impeller clutch Closed Open Closed Sump TC port Lockup port 37 Schaeffler Symposium 2014 Markus Steinberger Lockup clutch at touch point TM Lockup clutch Impeller clutch Closed Open Closed Sump TC port Lockup port 38 Schaeffler Symposium 2014 Markus Steinberger TC mode TM Lockup clutch Impeller clutch Open Closed Sump TC port Lockup port 39 Schaeffler Symposium 2014 Markus Steinberger Idle disconnect TM 40 Schaeffler Symposium 2014 Markus Steinberger Lockup clutch Impeller clutch Open Closed Open mTC benefits TM mTC use o Overcome turbo lag of turbo charged engines o Reduce start drag of small engines 41 Schaeffler Symposium 2014 Markus Steinberger iTC modularity Damper technology Multi function technology TM TM 42 Schaeffler Symposium 2014 Markus Steinberger iTC benefits o Reduced space, mass and inertia o Enables CPA in FWD package o More TC functionality possible (variable K-factor, idle disconnect, …) Product Focus o Modern automatic transmissions o Front and rear wheel drive 43 Schaeffler Symposium 2014 Markus Steinberger iTC ‟ ...Everything that can be invented ...Everything that can be invented has been invented. been invented. has ” Charles H. Duell Commissioner of the US Patent Office 1899 44 Schaeffler Symposium 2014 Markus Steinberger
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