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ReMaTec 2011

Vortragender/Speaker

Günter HerthZF-Getriebe GmbHSaarbrückenGermany

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Drivelinde Technology | Automatic Transmission, Manual Transmission and Dual Clutch Transmission Strategic Business Areas

The new 8-speed transmission model line

KT/KT-A, Juni 2011 Seite 5 © Z

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ZF-Getriebe GmbH SaarbrückenFactory 1 Saarbrücken

KT/KT-A, Juni 2011 Seite 7 © Z

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Technological leap from 5- to 6-speedautomatic transmission

?

Generation 1

Generation 2

En

gin

e t

orq

ue

[N

m]

KT/KT-A, Juni 2011 Seite 9 © Z

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Results of brainstorming and product conception

More gears are able to create an added value to the costumer.

8-speed-systems have an optimized cost-value ratio.

During the product conception the Lepelletier wheel set has also been taken into consideration. Result: this system has not really benefits compared to the second generation of 6-speed-transmissions. The degree of efficiency is even smaller compared to the 6-speed.

Ambitious aim of ZF: Introduction of a 8-speed transmission generation with a great added value to the costumer, in particular concerning fuel consumption.

KT/KT-A, Juni 2011 Seite 11 © Z

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A B C DE

F

ZF 8 HP design based on Lepelletier principle (Prototype)

KT/KT-A, Juni 2011 Seite 13 © Z

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Objectives 8HP…

fuel consumptionemissions

control of variability

cost

- 6 %

modulardesign

- 20 %

KT/KT-A, Juni 2011 Seite 15 © Z

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6 HP TÜ

Pump

Operating point

Lock-up clutch

Engine torque

8 HP..

- 6 %

- Spread- No. of gears

- Open clutches- Gearset efficiency- Optimized lubrication

oil

- Vane cell pump

- Better torsion damping

Reduction of fuel consumption and technical solutions

KT/KT-A, Juni 2011 Seite 17 © Z

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- 6 %

4-speed

- 5 %

6-speedFirst gen.

3-speed

- 2 %

5-speed 6-speedSecond gen.

8-speed

- 3 %

- 6 %

Fuel consumptions savings

KT/KT-A, Juni 2011 Seite 19 © Z

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8 HPprduct family

8 HP 90

8 HP 45

8 HP 70

8 HP 30

8 HP 55

8 HP 55 A

8 HP 90 A

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Transmission section 8HP70

Gearset 1

Gearset 4

Gearset 3

Gearset 2

Clutch D

Clutch C

Clutch E

Brake A

Brake B

Drive

Vane pump

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ten8-Gang

Gang A B E C D FL F

1

2

3

4

5

6

7

8

R1

F

Gang A B C D E

1

2

3

4

5

6

7

8

R

BA

C

E

D

A

C DB

E

GWK

Drag losses from 4 open shift elements and one free wheel

8 HP

= open shift element

Tranmission schema 8 gear ZF / AW

KT/KT-A, Juni 2011 Seite 25 © Z

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gearbrake clutch ratio gear

stepA B C D E

1

2

3

4

5

6

7

8

4,70

3,13

2,10

1,67

1,29

1,00

1,50

1,49

1,26

1,30

1,29

1,19

7,05Overall

R

0,841,25

-3,30

0,67

BA

C

E

D

RS3RS2RS1 RS4

82 3 4 5 6 71

Transmission schema 8HP

KT/KT-A, Juni 2011 Seite 27 © Z

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Disk brakes ( A and B )

Piston chamber B2Piston chamber B1

Return spring(Cup spring) Brake

KT/KT-A, Juni 2011 Seite 29 © Z

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Multiple disk clutch ( E, C und D )

Baffle plate Cub spring Pistons Clutch pressure

Dynamic pressure balance via the lubricating oil passage

KT/KT-A, Juni 2011 Seite 31 © Z

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Automatic transmission 8HP70

Break Clutch Planetary gearset

Output flangeMechatronicsOil screenVane pump (DFZ)

Converter design:Turbine torsion damper with

Two dampersOne damper

Planetary gearset

KT/KT-A, Juni 2011 Seite 33 © Z

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modular design (kits) starting elements

Hybridcompatible

Options 8HP.. starting elements

KT/KT-A, Juni 2011 Seite 35 © Z

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Hydrodynamic Cooled Clutch

Hydrodynamic Cooled Clutch

Integrated starting clutch

Integrated starting clutch

Basis 3-line converter

Basis 3-line converter

HybridHCC integrated

HybridHCC integrated

Crankshaft-starter generator

Crankshaft-starter generator

Options starting elements

OptionsOptions

KT/KT-A, Juni 2011 Seite 37 © Z

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4-wheel torsen

integrated

4-wheel hang-on

4-wheel ToD integrated

Options 8HP… 4W-drive

KT/KT-A, Juni 2011 Seite 39 © Z

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Pump

KT/KT-A, Juni 2011 Seite 41 © Z

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Double hub vane cell pump

Drive via a rolling toothed chain that is easy to rotate into overdrive directly from the converter neck.

Supply volume at 14.7 cm3/revolution

Pressure and suction canals are linked directly to hydraulic control with tubing travelling an unimpeded route for the best possible flow.

Suction flow charging from the main pressure valve improves the efficiency factor even more.

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Installation space comparison IZP / FZP

b = 14 mm b = 23.5 mm

d = 9

6 m

m

d = 4

7 m

m

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Overall efficiency factor oil pump

Engine rotation speed [rpm]

Ove

rall

eff

icie

ncy

[%

]

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Torque converter

KT/KT-A, Juni 2011 Seite 49 © Z

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Challengecurrent development trends in the drive train

On the engine side, a reduction in displacement, weight, installation space... (Downsizing) is causing greater irregularity (e.g. 4 instead of 6 cylinders)

Downshifting (driving under high load at low rotational speed)

With the newest converter generation, which is used in the 8HP, ZF is already well equipped for the future.

In the same applications, we have a better decoupling factor than with the preceding generation by up to a factor of 5

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3-line converter

For ZF it is the first time to use a three-line converter in passenger cars

The third control line, together with the separately sealed piston chamber, makes it possible to better adjust the converter bridging clutch (WK) than with a 2-line system.

KT/KT-A, Juni 2011 Seite 53 © Z

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Converter construction kit

NW:=neue Wandlergeneration

Converter Transmission

ZDW = two damper converterTTD = turbine torsion

NW = new converter generation

KT/KT-A, Juni 2011 Seite 55 © Z

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Torque converterTyp NW 235 RH - 4GWK / TTD

1 housing / outer disk carrier WK(n_mot)2 Chamber for WK(converter bridging clutch) 3 WK piston4 Torsion damper5 Clutch pack for WK Lined disk and outer disks

6 Converter housing7 Turbine8 Pump 9 Guide wheel10 Free wheel from the guide wheel11 Line 1 and 2 (pumps and turbine chamber)12 Line 3 (Chamber for pressure charging the WK)13 Inner disk carrier WK

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Special ZF hybrid solutions

KT/KT-A, Juni 2011 Seite 59 © Z

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Parallel hybrid – output classesZF Transmission

HIS

8 HP

EM

IAB

8P

K0

E-pumpHIS

8 HPEM

Installed electrical output 3-5 kW 4-20 kW 30-120 kW

Voltage 14-42 V More than 42 V 144-600 V

Fuel consumption reduction 3-5% About 15% 15-30%

1 start-stop (all)-/generator function (mild + full hybrid)

2 Recuperation

3 Boosting

4 Electrical starting

5 Purely electrical drive

Mild hybridMicro hybrid Full hybrid

KT/KT-A, Juni 2011 Seite 61 © Z

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Savings potential for the hybrid performance classes

Full hybrid systems offer the greatest savings potential.

Measured against their lower purchase costs, this savings from micro and mild hybrids can also pay off for drivers or fleet operators.

KT/KT-A, Juni 2011 Seite 63 © Z

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Why parallel hybrid?

ZF is conceptually oriented to the parallel hybrid in the passenger car sector.

Most affordable solution with the greatest customer benefits

The parallel hybrid drive is comparably cost effective to produce, since it gets along with just one electric motor

Only moderate electrical output in driveline necessary

High installation space efficiency compared to power-split hybrid transmissions because only one electrical motor is required

Higher efficiency

Modularity advantage

Various versions can be built upon available automatic transmissions as an “add-on module”

KT/KT-A, Juni 2011 Seite 65 © Z

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Definition of name for converter hybrid transmission (mild hybrid)

Converter – hybrid transmission:

x HP xx HNumber of gears

SizeHydrodynamic starting element

Hybrid

Planetary design

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ZF mild hybrid

Example: mild hybridBMW Gen. 1.5: 8HP70H = Standard transmission with e-motor

KT/KT-A, Juni 2011 Seite 69 © Z

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Definition of name for (full) hybrid transmission

Hybrid transmission (without converter):

x P xx HNumber of gears

Size

Hybrid

Planetary design

KT/KT-A, Juni 2011 Seite 71 © Z

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ZF full hybrid

BMW Gen. 2.0: 8P70H Standard transmission with e-motor; brake B is the starting element

Audi MLB : 8P55AF H = Front longitudinal transmission including all-wheel drive and front axle differential between engine and e-motor ; brake B is the starting element

KT/KT-A, Juni 2011 Seite 73 © Z

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ZF full hybrid concept

EM

IABK0

E-pumpK0

combustion engine

E-motor

IAE

KT/KT-A, Juni 2011 Seite 75 © Z

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8P70H BMW Gen. 2 (full hybrid)Transmission schematic

Gear

Brake Clutch Ratioi

Gearratiostep

A B C D E

1

2

3

4

5

67

8

4.696

3.1302.104

1.667

1.285

1.000

1.50

1.49

1.26

1.30

1.29

1.19

7.05 Total

R

0.8391.25

-3.275

0.667

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Summary

ZF focuses on hybrid drive

ZF focuses on parallel hybrid solutions

ZF is pursuing economical solutions with rather small e-motors

ZF is stronger due to a partnership with CAS*

ZF is active with all its important customers on the hybrid issue

ZF already develops generation 3.0 as a plug-in Hybrid. „In 2014 every vehicle manufacturer must have a hybrid plug-in car in his portfolio who wants to sell cars in China.

*Continental Automotive Systems

KT/KT-A, Juni 2011 Seite 79 © Z

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Thank you very much for your attention

KT/KT-A, Juni 2011 Seite 81 © Z

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The End