transmission_technology_international_变速器技术2010-06_(1).pdf

AN ENGINE TECHNOLOGY INTERNATIONAL PUBLICATION JANUARY 2010 What s new ZF and Porsche s all new seven speed DCT unit Hyundai s innovative six speed automatic Who is leading the way in hybrid concepts Fran ois Gougeon director of engineering for transmissions projects Renault J rgen Greiner head of product development ZF Dr Harald Maelger global OEM manager Afton Chemical Roger Stone engineering director Torotrak Gear change Find out what the future holds for the global transmissions industry INTERVIEWS COVER STORY 24 DUAL IN THE CROWN With the market facing big changes top ranking execs from the leading transmissions players gaze into the future to predict which gearbox technologies will win and lose 02 NEWS The latest developments from the world of transmissions including a new CVT from Jatco 04 ZF AND PORSCHE DCT Developed for Porsche ZF s new seven speed box is one of the lightest and most compact DCTs around 06 HYBRID TRANSMISSIONS TTi travels the world to discover the leading innovations in hybrid transmissions 10 HYUNDAI AUTOMATIC Having created its fi rst six speed transmission the South Korean OEM has joined an exclusive club 12 OEM INTERVIEW FRAN OIS GOUGEON With the aim of being one of Europe s greenest car makers Renault s director of engineering for transmissions has DCT development on his mind 16 SUPPLIER INTERVIEW J RGEN GREINER In a rare media outing ZF s product development chief speaks openly on what the future holds for suppliers with smaller research and development budgets 20 SUPPLIER INTERVIEW DR HARALD MAELGER For many lubrication remains the unsung hero of modern powertrains Afton Chemical s global OEM manager discusses what s next for this technology 32 SUPPLIER SPOTLIGHT TOROTRAK Roger Stone the new engineering director at Torotrak tackles questions about the company s key technologies and reveals his plans for the future 48 LAST WORD TTi catches up with Bernd Matthes president of BorgWarner Transmission Systems in the USA CASE STUDIES 34 Brave new world 36 Eco friendly evolution 37 Optimization of gearbox analysis 38 Total driveline analysis 40 Transmission control 43 Torque talk 46 Innovative springs CONTENTS01 January 2010 Transmission Technology International 12100616 24 02 TRANSMISSIONS NEWS INDUSTRY UPDATE BorgWarner confi rms Chinese car maker deal China s largest vehicle maker First Automotive Works FAW is to benefi t from turbochargers and exhaust gas recirculation EGR valves supplied by BorgWarner The components will be installed in various cars and light commercial vehicles manufactured by the Chinese OEM while BorgWarner s proven turbocharging technology will be employed on newly developed 1 3 liter and 2 liter gasoline engines which are to be used in the compact and midsize car segment BorgWarner is also supplying the EGR valve for the 3 liter diesel power unit that FAW installs in its light commercial vehicles All three engines comply with European EURO 4 emissions standard The newly developed 1 3 liter gasoline engine is equipped with a KP39 turbocharger while the 2 liter gasoline engine uses a K03 turbocharger From 2010 onwards BorgWarner will manufacture the turbochargers in the eastern Chinese city of Ningbo where the supplier has been operating a production facility since 2004 The EGR valve will also be produced in Ningbo Our application and production capacities directly on location allow us to optimally serve the Chinese market and react very fl exibly to FAW s requirements said Roger Wood president of BorgWarner Turbo and Emissions Systems CPT unveils eco friendly unit Engineers at Controlled Power Technologies CPT have developed the world s fi rst bespoke belt driven Integrated Starter Generator B ISG that makes use of a conventional 12 volt electrical system and is capable of starting a 2 liter diesel engine CPT s technical breakthrough has resulted in a unique 12 volt B ISG with the high torque and power necessary to restart quickly smoothly and more frequently most modern diesel and petrol engines According to CPT this means it can offer a more advanced solution to existing stop start systems which are all based on modifi cations to a conventional starter motor or conventional alternator As a result of such a setup the technology can be put into production without resorting to the high cost of developing a higher voltage system CPT says that the production ready SpeedStart technology addresses three of the major challenges of existing stop start systems the technology is twice as fast as a conventional starter motor or alternator the restart is quiet and offers excellent refi nement and the unit is powerful enough to cope with a driver having a sudden change of mind when the stop start system is already stopping the engine Sales for ZF have fallen by one third from January to August 2009 over the same period in 2008 The supplier has estimated corporate sales will fall further by one quarter to around US 13 55 billion with sharp net losses as well ZF is feeling the effects of the economic crisis very deeply There is still uncertainty in the marketplace which is obscuring a clear view of the coming months said ZF CEO Hans Georg H rter It remains to be seen if government stimulus programs such as Germany s cash for clunkers scheme can sustain an elevated demand for cars We cannot exclude a W shaped trend in which ZF CEO DEFIANT OVER SALES Jatco the world s largest manufacturer of CVTs with 43 of the CVT market has taken the covers off its next generation CVT which it claims is one of the most compact and lightweight units on the market Co developed with Nissan Jatco s latest product will be seen as a huge boost to CVTs a technology that many leading experts predict will all but be eradicated by the end of the next decade Due to be launched in a number of Nissan vehicles by the end of this year the new Jatco transmission features an innovative structure that combines a conventional CVT belt operation with an auxiliary gearbox that has helped to reduce the length of the unit by 10 while weight has been cut by 13 The combination of a belt operated CVT with an auxiliary transmission has also enabled Jatco engineers to realize a greatly increased gear ratio range that jumps from the current 6 0 1 to a 7 3 1 arrangement Jatco says this not only represents a 20 leap over other CVTs but is among the world s highest ratios for all types of transmissions in production for vehicle use DCTs aside Other features of the unit include adaptive shift control which improves performance by automatically selecting the best ratio for startup acceleration and uphill downhill driving We believe the CVT has very good potential as a leading technology for raising the fuel effi ciency of IC engine systems said Nissan s VP of powertrain engineering Shuichi Nishimura when discussing the latest CVT development Nissan fi rst began applying CVT technology in 1991 and has been continuously evolving CVTs engine cooperative management and other such systems The need to improve fuel economy with the resulting reductions in CO2 emissions motivated us to step up our efforts in the joint development with Jatco of this next generation CVT Jatco VP Yo Usuba added We believe this CVT is an excellent choice for car makers seeking to raise the fuel effi ciency of their smaller cars JATCO AND NISSAN BOOST CVT FUTURE case we are now riding an artifi cially generated peak before entering a second valley The fact that ZF has always operated according to sound business principles and has paid particular attention to liquidity since the beginning of the crisis is now paying off added H rter giving grounds for his cautious optimism OEMs are becoming increasingly determined to work with suppliers that are stable dependable partners committed to a long term business relationship Our liquidity serves as an insurance policy in this regard We must now safeguard this position with our austerity plan Transmission Technology International January 2010 Jatco s all new CVT which will be launched in numerous Nissan models is 13 lighter than the outgoing unit New base for Romax Romax Technology is scheduled to open a center of excellence for CAD and CAE in late 2009 in Pune India With India s automotive and transmission markets growing Romax plans to expand its existing highly skilled team to over 50 employees within the next few years Allison Transmission has been awarded a US 62 8 million grant from the US Department of Energy to continue with its efforts to develop and manufacture a cost effective commercial hybrid truck system In a separate announcement the former GM company has also confi rmed plans to open a new 18 868m2 production plant early next year to better serve OEMs in Chennai India where the US supplier has been based for more than 40 years Chairman and CEO Lawrence E Dewey said the investment in the plant was proof that the company is targeting growth in developing countries It is important to strengthen our local presence in India to support our growing in country operations said Dewey It is one of the world s largest economies and a global supplier of commercial vehicles and our investment comes at a time when global demand for our fully automatic transmissions continues to increase I am extremely proud of the milestone this represents and thankful to the Tamil Nadu government for its enthusiastic support ALLISON TARGETS GLOBAL EXPANSION Mercedes is considering establishing a plant in India that will be responsible for the production of bus engines gearboxes and other parts A massive investment of US 600 million would be necessary but the German manufacturer says the lower cost of manufacturing in India has made it give serious thought to the prospect In a separate announcement Toyota Kirloskar Motors TKM the Indian subsidiary of Japan s Toyota Motor Corporation plans to set up an state of the art engine manufacturing facility most likely within the existing TKM premises at Bidadi near Bangalore Currently Toyota imports petrol and diesel version engines for its locally made multipurpose Innova and its luxury Corolla sedan from its engine factories in Thailand and Japan However with a second vehicle assembly plant on its way at the Bidadi site the company believes it is now time to produce engines in India January 2010 Transmission Technology International 03TRANSMISSIONS NEWS Editor Dean Slavnich Editorial assistant Bunny Richards Production manager Ian Donovan Production team Joanna Coles Lewis Hopkins Carole Doran Emma Uwins Art director Craig Marshall Art editor Ben White Design contributors Louise Adams Andy Bass Anna Davie James Sutcliffe Nicola Turner Julie Welby Chief sub editor Alex Bradley Sub editor William Baker Proofreaders Christine Velarde Frank Millard Contributors John Challen Brian Cowan Matt Davis Jonathan Lawson Adam Gavine Max Glaskin Maurice Glover Graham Heeps Greg Offer Mike Magda Jim McCraw Keith Read John Simister Saul Wordsworth CEO Tony Robinson Managing director Graham Johnson Sales and marketing director Simon Willard Circulation manager Suzie Matthews Contact us Transmissions Technology International Abinger House Church Street Dorking Surrey RH4 1DF UK tel 44 1306 743744 fax 44 1306 742525 editorial fax 44 1306 887546 email enginetech web The views expressed in the articles and technical papers are those of the authors and are not endorsed by the publisher While every care has been taken during production the publisher does not accept any liability for errors that may have occurred This publication is protected by copyright 2008 ISSN 1460 9509 Transmissions Technology International Printed by William Gibbons a design that s based on existing transmission designs low battery power demands and longer battery life high fl ywheel power assist and fast engine start and high top speed towing and electric maneuvering Battery Generator Internal Combustion Engine Electric Motor Power Split Device Improve Fuel Consumption with Romax Hybrid Engineering Services Finding the right hybrid concept is definitely challenging With Romax hybrid engineering services it doesn t have to be We can help you to Compare and contrast different hybrid driveline structures with our advanced energy flow analysis Predict efficiencies of driveline sub systems Modify and optimise driveline layout and operation Analyse and improve fuel consumption across all operating conditions and vehicle life What makes us unique Break down of energy flow in the driveline to an unmatched level of detail Ability to compare functional efficiencies of different driveline architectures Guidance on design optimisation without being overwhelmed by data Enabling a unique understanding of energy flow behaviour in different states To find out how Romax hybrid engineering services can help you Visit Mail sales CONTACT DETAILS PAULSTRA OIL SEAL DIVISION Z I d Etriche Route d Avire 49504 Segre Cedex France 33 0 2 41 94 51 00 33 0 2 41 92 22 67 paulstra seal segre hutchinson fr Hyundai has unveiled a new six speed transmission that boasts more than 12 better fuel economy than the company s outgoing fi ve speed gearbox The development is the culmination of a project that began in 2004 The new transmission means that Hyundai becomes only the third OEM in the world to develop its own six speed transaxle with the South Korean car maker sticking to its strict policy of developing gearboxes in house and not relying on suppliers Until now only Toyota and a Ford GM JV could claim to have developed their own in house six speed unit Most of the fuel economy savings are a result of the new transmission s reduced weight down 12kg length 41mm shorter and parts 62 fewer than the fi ve speed version The most distinguished thing about our transmission is the totally unique and advanced layout that makes it smaller more compact and lighter than any other six speed on the market today Hyundai s principle engineer for the transmission team Hong Min Kim tells TTi The hallmark of the gearbox which has three planetary gearsets is simplicity of design and a super fl at torque converter that shortens the unit s length Four pinion differentials Hyundai is only the third company in the world to have developed its own six speed transmission improve durability and further minimize size The addition of a sixth gear helped to realize the main fuel savings but closer ratio spacing also played a part as no exotic materials were used during the development However Kim s team created a new oil that has low viscous characteristics to reduce overall transmission oil resistance during operation We adopted slip lock up control into the torque converter explains Kim This 10 HYUNDAI AUTOMATIC technology improves fuel economy by reducing transmission oil slippage in the torque converter It performs as a clutch in a manual but is operated by transmission oil Designed for transverse engine applications in passenger cars and SUVs the six speed is so advanced that Hyundai had to apply for nearly 300 patents relating to the technology A good example of engineering ingenuity is to be found in the design of the hydraulic pressure control unit says Kim Because there are always slight manufacturing deviations from one solenoid valve to the next which cause fl uctuation in the hydraulic pressure and affect shift precision and quality we integrated adjustment screws into each of the valves that enable them to be individually calibrated at the factory This feature ensures stable hydraulic pressure at any shift point that facilitates a high degree of precision and control needed to deliver fast smooth and precise shifts throughout the rpm range The gearbox does not have a dipstick as it is fi lled for life with an automatic transmission fl uid that needs no topping up which also reduces costs The transaxle will fi rst feature in the new Grandeur equipped with a 3 3 liter V6 petrol engine It will then be available in a further 16 Hyundai models including the new Santa Fe and nine Kia products TTi The new automatic will be launched in all global markets Transmission Technology International January 2010 Magic number The six speed transmission will be made available to innumerable Hyundai and Kia vehicles including the new Coupe Hyundai s six speed transmission weighs 12kg less than the outgoing fi ve speed Mobile 27 82 331 4956 Fax 27 11 476 3285 Email jnaude Varibox CVT Technologies has developed a two stage ratcheting CVT called the Naudic RotorCVT This CVT features a robust and very simple design intended for small vehicles A 25 50 kW prototype has been built and testing so far indicates signifi cant advantages in terms of weight mechanical effi ciency and production cost This prototype includes a geared neutral and therefore eliminates the need for a launching device Varibox CVT Technologies has also developed a prototype proven mechanical positive drive CVT transmission called the Naudic iCVT The current model features 78 ratios that shift ratios under load without any clutch or torque convertor The main drive is via a custom purpose silent chain It also features a newly developed integrated mechanical ratio shifting device The RotorCVT prototype as well as a fully functional model of the 78 ratio iCVT will be displayed at our stand at the 8th International CTI Symposium Innovative Automotive Transmissions 30 November 2 December 2009 in Berlin Germany stand no 68 Famed for its manual and automatic transmissions Renault is now working hard on developing its own DCT systems as John Challen found out during a recent visit to France 12 OEM INTERVIEW RENAULT Transmission Technology International January 2010 Fuel economy and fuel effi ciency are two phrases commonly used by Fran ois Gougeon Renault s director of engineering for transmissions projects when he talks about the future direction of the company s vehicles This year has seen a shift in emphasis for Renault with the French manufacturer determined to bring clean motoring to