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© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSION FLUIDS
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
BASICS OF TRANSMISSION What does a Transmission do?
• Automotive engines typically operate at a high rotational speed which is inappropriate for starting, stopping and slow travel
• Therefore, a transmission serves to:
– Transmit power from engine to wheels
– Adapt this power by varying torque, speed and direction
– Allow the engine to operate at its optimum efficiency
• Automatic transmission fluids (ATF) generally relates specifically to fluids for stepped automatic transmissions
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INFINEUM CONFIDENTIAL INFORMATION
BASICS OF TRANSMISSION What are Gear Ratios?
• A transmission has multiple gear ratios, with the ability to switch between them as automotive speed varies
• Gear ratio is the ratio of the angular velocity of the input gear to that of the output gear
Gear Input gear
rpm Output gear
rpm
1st gear 2.97 1
2nd gear 2.07 1
3rd gear 1.43 1
4th gear 1.00 1
5th gear 0.84 1
6th gear 0.56 1
Reverse -3.38 1 Source: 2004 Chevrolet Corvette C5Z06 with a six-speed manual transmission
Increasing automotive
speed, decreasing
torque
Input gear
Output gear
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INFINEUM CONFIDENTIAL INFORMATION
BASICS OF TRANSMISSION Types of Transmissions
• Stepped Automatic Transmission (AT) – Most common automatic transmission that uses a planetary
gear set and a torque converter
• Continuously Variable Transmission (CVT) – Automatic transmissions that use variator pulleys with an
unlimited number gear ratios
• Dual Clutch Transmission (DCT) – Automatic transmissions that use manual gearbox
architecture with dual clutches
• Electrical Variable Transmission (EVT) – Combines stepped automatic transmission with electric motor
(e.g. Toyota’s Hybrid Synergy Drive)
• Reduction Transmission (Electric) – Transmissions used by purely electric vehicles to reduce
torque output from electric motors (Nissan Leaf)
• Automated Manual Transmission (AMT) – Manual transmissions that use servos to engage clutch and
change gears automatically
• Manual Transmission (MT)
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Hardware Overview
Clutches Torque Convertor Valve Body Planetary Gear
Ph
oto
sou
rce: BM
WB
LOG
.CO
M
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INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Hydraulics
• Components
• Valve body
• Pump
• Filter
• Cooler
• ATF
• Used to pressurize piston plate for plate clutches
• Used to move band-activation pistons up and down for band clutches
Act as a Hydraulic Fluid
Antifoam properties
Large operating range
(-40C to 175C)
Resist oxidation
Remove Heat Efficiently
Ensure seal performance
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INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
In summary, different components can assigned to be the input, output or locked, giving rise to different gear ratios
Gear Input Output Locked Input gear
rpm Output
gear rpm
1st gear Small sun
gear Ring gear Planet carrier 3.18 1
2nd gear Small sun
gear Ring gear
Large sun gear
1.84 1
3rd gear Ring gear Ring gear Planetary gear set
1.00 1
4th gear Planet carrier
Ring gear Large sun
gear 0.61 1
Reverse Large sun
gear Ring gear Planet carrier -1.59 1
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INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
Source: https://www.youtube.com/watch?v=Y1zbE21Pzl0
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
Source: https://www.youtube.com/watch?v=Y1zbE21Pzl0
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INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
Source: https://www.youtube.com/watch?v=Y1zbE21Pzl0
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
Source: https://www.youtube.com/watch?v=Y1zbE21Pzl0
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
Source: https://www.youtube.com/watch?v=Y1zbE21Pzl0
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
ATF requirements
AUTOMATIC TRANSMISSIONS – STEPPED AT Planetary Gearsets
Planetary Gear
• Three Main Components
• Sun Gear
• Planet gears (and carrier)
• Ring Gear
• Any one of these components can be locked in place; more importantly, any one can be an input or output drive
• Different gear ratios possible from one planetary gear set
Provide anti-wear performance
Shear Stability
Corrosion protection
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INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Clutches
• Plate Clutches
• Band Clutches
Shifting
• Torque Converter Clutches
Fuel Economy
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INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – STEPPED AT Plate and Band Clutches
Plate Clutch Band Clutch
ATF requirements
Remove heat efficiently
Resist oxidation Deliver specialized
friction requirements
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AUTOMATIC TRANSMISSIONS – STEPPED AT Torque Converter
Torque Converter Lock-Up Clutch
ATF requirements
• Large energy loss without clutch
• Clutches added in 1970s to improve fuel economy
• Full lock-up at highway speeds
• Lock-up clutch evolved for improved comfort and additional fuel economy benefits
• Slipping clutch at low speeds
Act as a Hydraulic Fluid
Large operating range (-40C to 175C)
Deliver specialized friction requirements
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INFINEUM CONFIDENTIAL INFORMATION
Intermittent Shudder Continuous Shudder No Shudder
100 150 200 250 300 350
100 150 200 250 300 350
0 2 4 6 8
Torq
ue
Mea
sure
d a
t W
hee
l of
Car
(in
lbs)
Time (sec)
100 150 200 250 300 350
AUTOMATIC TRANSMISSIONS – STEPPED AT Torque Convertor Clutch, Friction Deterioration Shudder
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AUTOMATIC TRANSMISSIONS – STEPPED AT Torque Convertor Clutch, Friction Deterioration Shudder
Deliver specialized friction requirements ATF must:
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
ATF PERFORMANCE REQUIREMENTS
Act as a Hydraulic Fluid
Provide Anti-wear performance
Remove heat efficiently
Ensure transmission seal performance
Shear Stability
Corrosion protection
Antifoam properties
Large operating range (-40°C to 175°C)
Resist oxidation
Deliver specialized friction requirements
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
VISCOMETRICS PERFORMANCE Key Performance Tests
Viscometrics
Kinematic viscosity @ 100⁰C (KV100)
Brookfield viscosity @ -40⁰C
(BF-40)
Shear stability 20hrs KRL (KV100 and apparent viscosity),
Sonic Shear
Performance
Lubrication of transmission parts at high temperature
Transmission operability at cold temperatures - cold morning start
Ensures aged ATF adequately lubricates transmission parts
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VISCOMETRICS PERFORMANCE Trends
DEXRON®-III
/ MERCON®7.00 cSt
MERCON®-V
7.50 cSt
DEXRON®-VI
6.00 cSt
MERCON® LV
6.00 cSt
VOITH / ZF
7.30 cSt
Allison TES-295
7.30 cSt
0%
10%
20%
30%
- 5,000 10,000 15,000 20,000 25,000
KR
L S
hear
Sta
bilit
y (%
KV
100 L
oss)
Brookfield -40C (cP)
ATF Shear Stability vs. Low Temperature Viscosity
Group I
Group II
Group III
Group IV
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INFINEUM CONFIDENTIAL INFORMATION
•Reduces fluid resistance and friction losses
•Coupled with improved shear stability to control thinning
Latest 6+speed transmissions use lower viscosity ATF
•Others maintain two specs – notably Ford, Hyundai and Toyota
Some OEMs replacing high-vis ATF with low-vis ATF
Toyota T4
Toyota WS
Nissan Matic-J
Nissan Matic-S Honda Z-1
Honda DW-1
Hyundai SPIII
MERCON® LV
DEXRON® IIIH Chrysler ATF+4
DEXRON® VI
MB 236.14
Mercon® V
15.0
20.0
25.0
30.0
35.0
4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00
KV
@ 4
0°C
(cS
t)
KV @ 100°C (cSt)
KV @ 100°C vs KV @ 40°C
VISCOMETRICS PERFORMANCE New Generation ATFs - Lower Viscosity for Fuel Economy
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
OXIDATION PERFORMANCE Key Performance Tests
Oxidation
Aluminum Beaker Oxidation Test (ABOT) - Ford
Turbo Hydra-Matic Oxidation Test* (THOT) - GM
Indiana Stirring Oxidation Test (ISOT) - Asia Pacific OEMs
CEC L-48-A-00 (A), DKA Oxidation Test – European OEMs
Performance
Chain scission Loss of lubrication
Viscosity increase Sluggish operation
Sludge formation Clogged valve body
Acid formation Corrosion
Friction Modifier attack Poor shifting
*GM THOT has been made obsolete
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INFINEUM CONFIDENTIAL INFORMATION
OXIDATION PERFORMANCE Trends
ABOT Test Delta TAN
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
0 100 200 300 400 500 600 700
Test Duration (Hrs)
Del
ta T
AN
DEXRON®-IIIG DEXRON®-IIIH / MERCON® DEXRON®-VI Allison TES-295®
Decrease Spec. Limit
Increased Test Duration
Dec
reas
ed
Lim
it
DEXRON® IIIG
DEXRON® IIIH / MERCON®
DEXRON® VI
Allison TES-295®
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CLUTCH FRICTION PERFORMANCE Key Performance Tests
Clutch Friction
Shifting Clutch
•SAE#2 Friction and Anti-Shudder Durability (ASD) rig – US and Asia Pacific OEMs
•Band Friction test – GM
•Plate Friction test – GM and Ford
•Cycling test – GM
Torque Converter Clutch
• Low Velocity Friction Apparatus (LVFA) for ASD – Asia Pacific OEMs
Performance
Shifting Clutch
• Allows diagnosis of abrupt, harsh shifts
• Allows diagnosis of elongated shifts and potential slippage
• Allows development of fluids that give clutches good holding power and high transmission capacity
Torque Converter Clutch
• Allows assessment of anti-shudder durability
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INFINEUM CONFIDENTIAL INFORMATION
CLUTCH FRICTION PERFORMANCE SAE No. 2 Friction Test Machine
Apply Piston
Load Cell
Static Drive
Inertia Flywheel
Worm Gear (Static Measurement)
Test Fluid Reservoir Dynamic Speed
Measurement
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CLUTCH FRICTION PERFORMANCE SAE No. 2 Friction Test Machine – Clutch Head
Clutch Head
Pressure Plate
Load Cell
Input Shaft
Steel Plate
Friction Plate
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INFINEUM CONFIDENTIAL INFORMATION
CLUTCH FRICTION PERFORMANCE SAE No. 2 Friction Test Machine – Output
Sliding
Speed (high RPM)
Dynamic cycle
µs
Static Cycle
0
Torq
ue
or
Fric
tio
n C
oef
fici
ent
Time
µT
Torque Capacity µ0
Shift Performance
(µ0/µD)
Apply Force
Start Static Drive (low RPM)
µD
Dynamic Friction
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INFINEUM CONFIDENTIAL INFORMATION
CLUTCH FRICTION PERFORMANCE SAE No. 2 Friction Test Machine – Output
0
Torq
ue
or
Fric
tio
n C
oef
fici
ent
Time Start Static Drive (low RPM)
Hard Fluid
Soft Fluid
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CLUTCH FRICTION PERFORMANCE Desirable Clutch Friction Performance
• Short shift minimizes energy transfer to fluid
Dynamic friction (µD) high, flat
• High value - abrupt, harsh shift
• Low value - elongated shift and potential slippage
Low speed friction (µ0) slight decrease
• Gives clutches good holding power, high transmission capacity
Static friction (µT) high
• Increase friction durability
Trend
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CLUTCH FRICTION PERFORMANCE Low Velocity Friction Apparatus (LFVA)
Reasonable µ level with positive slope required
Used
New
Speed
Anti-shudder Performance Slipping Clutch
Load Compression Force
Steel Plate Rotates with Driver
Friction Plate Fixed to Cup
Test
Cu
p
Co
nta
ins
Flu
id
Driver
Rota
tes
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INFINEUM CONFIDENTIAL INFORMATION
CLUTCH FRICTION PERFORMANCE What Affects Friction?
Impacts on Friction
Hardware Demands
Temperature Sliding Surface Composition
Load Sliding Speed
Fluid Technology
Friction Modifier Type
Friction Modifier
Concentration
Increased interest in friction durability
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
ATF PERFORMANCE SUMMARY
ATF must meet exacting requirements for a variety of metrics
• Viscometrics
• Oxidation resistance
• Friction stability and durability
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
SERVICE FILL SPECIFICATIONS Passenger Car ATF
OEM High Viscosity Low Viscosity Ultra Low Viscosity
No
rth
Am
eric
an
OEM
s
MERCON®
MERCON® V MERCON® LV -
ATF +3® ATF +4®
948TE -
DEXRON® II DEXRON® III
DEXRON® VI -
Euro
pea
n
OEM
s
MB 236.10 MB 236.12 MB 236.14
Lifeguard 5 Lifeguard 8 -
Asi
a Pa
cifi
c O
EMs
Toyota T-IV Toyota WS -
Matic J/K Matic S -
Honda Z-1 Honda DW-1 -
Hyundai SP-III Hyundai SP-IV -
*Bolded specifications are open to licensing
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SERVICE FILL SPECIFICATIONS Key JAMA Requirements
Used
New
Speed
Slipping Clutch
Anti-shudder Performance • Method: JASO M349-95 Sonic
• Requirements: KV100 after shear 5.7 minimum
• ~20% max vis. loss when fresh fluid KV100 is 7.1
Shear Stability
• Method: JASO M348-2002 SAE#2 (NW-461E)
• Requirements: Torque capacity, Dynamic friction stability, and shift performance
Friction Characteristics (Shifting Clutch)
• Method: JASO M349-2001 LVFA (D-0512)
• Requirements: Durability of positive m-V slope
Anti-Shudder Performance (Torque Convertor Clutch)
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SERVICE FILL SPECIFICATIONS Heavy Duty ATF Specifications
OEM Region / Type Standard
Drain Interval Intermediate Drain Interval
Long / Extended Drain Interval
1000/2000, 3000, and 4000 Series
Allison TES-389™ - Allison TES-295® Allison TES-468™
H 40 EP™ H 50 EP™
- - Allison TES-468™
5000, 6000, 8000, and 9000 Series
Allison TES-439™ - Allison TES-353™
North America Service Bulletin 13 & 118 Standard Drain (36K mi)
- Service Bulletin 13 & 118
Long Drain (72K mi)
Europe G607 – H55.6335xx
Standard - 60,000 km -
G1363 – H55.6336xx Long - 120,000 km
EcoMat ZF TE-ML 14A
30,000 km
ZF TE-ML 14B 60,000 km
ZF TE-ML 14C 120,000 km
EcoLife ZF TE-ML 20B
60,000 km -
ZF TE-ML 20C 120,000 km
All 339 Type V1/Z1 339 Type Z2/Z11 339 Type V2/Z3/Z12
All STD 1273,40 – Trucks
STD 1273,41 – VCE - STD 1273,42 – VCE
All MB 236.7 MB 236.9
- -
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
ATF FORMULATIONS Typical ATF Additives
• Sludge and varnish control
Dispersants
• Oxidation control
Antioxidants
• Planetary gear, bushing, thrust washer, sprag and pump wear control
Anti-wear Agents
• Control clutch plate and band friction
• Shift feel
• Control torque converter and clutch friction
• Prevent shudder
Friction Modifiers
• Prevent corrosion of bushing and thrust washers
Corrosion Inhibitors
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ATF FORMULATIONS Typical ATF Additives
• Control swelling, hardness, and tensile strength of elastomers
Seal Swell Additives
• Reduces temperature at which fluid starts to gel
Pour Point Depressant
• Reduce rate of change of viscosity with temperature; dispersant type also provides sludge and varnish control
Viscosity Modifiers
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ATF FORMULATIONS Typical ATF Additives Treat Levels
ATF
Performance package
Seal Swell agent
Pour Point Depressant
Viscosity Modifier
5-10%
0-3%
0-0.5%
3-10%
Vol %
Total Additive treat: 8-24%
Base Oil (Group II,III)
Red Dye
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
- Launch Feel compared to torque converters in stepped AT
+ Fuel Efficiency
+ Shift Feel
+ MT Manufacturing (EU) • Combines elements of both manual and
automatic transmissions
Hardware
• DCT currently attracting great interest
• Especially in Europe where market share projections approach 20% by 2020
Market
• First commercial transmission introduced by VW
• Driven by fuel efficiency and driver comfort
Manufacture
AUTOMATIC TRANSMISSIONS – DCT Technology Update
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INFINEUM CONFIDENTIAL INFORMATION
• 2 input shafts are connected to two different clutches
– 1,3,5 gears are connected to one
– 2,4,6 gears are connected to the other
Input Shaft 1
Input Shaft 2 Double-Clutch Module
Transmission
Output Shaft Input Shaft
AUTOMATIC TRANSMISSIONS – DCT How it works
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INFINEUM CONFIDENTIAL INFORMATION
• Consecutive gears can be ‘synchronized,’ but only one gear is connected to engine via active clutch
– e.g; While 2nd gear is synchronized and engaged, 3rd is ‘synchronized’ and disengaged.
• To change from 2nd gear to 3rd gear, the secondary clutch opens (disengages) while the primary clutch closes (engages)
– Shortest shift time of any production transmission type
Time
Torq
ue
2nd Gear 3rd Gear
AUTOMATIC TRANSMISSIONS – DCT How it works
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AUTOMATIC TRANSMISSIONS – DCT Technology Trends -Wet or Dry Clutch?
• Used in medium segment car market
• Torque limitation of 250Nm
Dry-DCT Applications
• Used in high torque demanding vehicles to improve heat dissipation and friction performance.
• Also finds application with very small engines, where heat dissipation is critical
Wet-DCT Applications
Simplicity
Use only MTF
Higher efficiency
Heat & Friction losses
Torque Limitation (250Nm)
Dry
DC
T P
RO
s
Dry D
CT C
ON
s
Higher Torque Capacity
Improved friction, controllability and heat dissipation
Require special DCT Fluid
Shorter oil drain interval (i.e. ~40K mi for VW)
Cost
Wet
DC
T P
RO
s
Wet D
CT C
ON
s MTF “Dry”
MTF “Wet” (DCTF)
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AUTOMATIC TRANSMISSIONS – DCT Fluid Requirements
• Gear Pitting protection
• Friction and wear control for synchronizers
• Corrosion resistance
• Material compatibility
• Oxidation control
Dry-DCT Fluid Requirements
• Same as for Dry DCT, but adding / balancing Clutch Friction control and Anti-Shudder Durability
Wet-DCT Fluid Requirements
MTF “Dry”
MTF “Wet” (DCTF)
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.
INFINEUM CONFIDENTIAL INFORMATION
AUTOMATIC TRANSMISSIONS – CVT Hardware Overview
Engine Efficiency
Effi
cien
cy
RPM
4-speed CVT 6-speed
• Key component allowing continuous step-less change in gear ratio by changing running radii
• Engine run at optimum efficiency
• Fuel economy and performance
• Driving performance – minimum power loss during ratio changes
Variator
• Steel belt – push or pull belt types
• Toroidal – traction drive
• Hydromechanical – combination of hydraulic and mechanical
Types
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AUTOMATIC TRANSMISSIONS – CVT CVT Variator
• Gear ratio = Ri / Ro
• Defined by radius of belt travel on pulley
• Ri = input pulley radius
• Ro = output pulley radius
• High clamping forces prevent belt from slipping
• Radius of belt travel controlled by width of pulley
Metal ‘V-belt’ and conical pulley system
Nissan CVT Video http://youtu.be/GLNqzn7WgDQ?t=31s http://www.nissanusa.com/content/dam/nissan/vehicles/2013/pathfinder/colors-photos/videos/cvt.mp4
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AUTOMATIC TRANSMISSIONS – CVT CVT LuK CHAIN – Pull Belt
• Chain links joined by rocker pins
– Pulley clamping force acts on rocker pin ends
• Force transmitted by tension on chain links
Driving Pulley
Driven Pulley
Subaru Chain CVT Transmission Video: http://www.subaru.com/engineering/transmission.html
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AUTOMATIC TRANSMISSIONS – CVT VDT – Push Belt
• Developed by Van Doorne Transmissie (VDT)
• Push belt consists of ~300 steel blocks connected by flexible steel rings
• Force transmitted from pulley to pulley via compressional forces between belt elements
Contact surface
Driving Pulley
Driven Pulley
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AUTOMATIC TRANSMISSIONS – CVT Fluid Requirements
• Wear control
• Fatigue and sliding wear control
Steel-on-steel friction
• High pressure pumps shear fluids aggressively
Shear stability
• CVTs run hot
• Fill for life application
Oxidation stability
• Starting clutch, torque converter clutch, forward-reverse clutch
Paper-on-steel friction
• Hydraulic performance, antifoaming, transmission coolant, seal compatibility, non-corrosive
All other conventional ATF properties
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AGENDA
• What does a transmission do?
• What are gear ratios?
• Types of transmission
Basics of Transmission
• Hardware components and their impact on ATF
• Testing for ATF
• Service Fill specifications
• ATF formulations
Automatic Transmissions – Stepped Planetary (AT)
• Hardware components and their impact on DCTF
• DCTF formulations
Automatic Transmissions – Dual Clutch (DCT)
• Hardware components and their impact on CVTF
• CVTF formulations
Automatic Transmissions – Continuously Variable (CVT)
• Hardware comparison
• Market overview and market drivers
• Summary
Transmission Comparison, Market Trends and Summary
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HARDWARE COMPARISON Stepped Planetary AT
- Torque Capacity
- Launch Feel
- Fuel Efficiency in 6-speed + applications
- Fuel Efficiency in applications with less than 5-speeds
- Packaging Size
STEP
PED
AT
PR
Os
STEPP
ED A
T CO
Ns
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HARDWARE COMPARISON Dual Clutch Transmission (DCT)
- Torque Capacity
- Acceleration
- Fuel Efficiency
- Shift Feel
- Can use existing MT manufacturing sites
- Launch feel not as smooth as stepped AT
DC
T P
ros
DC
T Co
ns
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HARDWARE COMPARISON Continuously Variable Transmission (CVT)
- Comfort due to no shifting
- Acceleration
- Fuel Efficiency
- Torque Capacity
- Cannot utilize existing stepped AT manufacturing sites
CV
T P
ros
CV
T Co
ns
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: Major : Minor : Not Required
OEM Requirements CVTF DCTF ATF
Steel on Steel Friction Wear Protection / Paper on Steel Friction / Shear Stability Oxidation Air-release Gear Protection
HARDWARE COMPARISON Fluid Requirements
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Driving Performance
Compact size Reduced weight
Fuel Economy
Low Emissions
TRANSMISSION TRENDS Drivers for Transmission Development
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Fuel Economy And Emissions
Compact Size And Reduced Weight
• Increased torque density
• Reduced fluid required
Driving Performance and Comfort
• Shift quality / response time / comfort
• Shift sequence control / driving strategy to suit individual driving style
2012 SAE Transmission Symposium - FE Driver – WW legislation - Projected International Fuel Economy Targets (Gott - IHS)
TRANSMISSION TRENDS Drivers for Transmission Development
• Development of CVT, DCT and stepped AT with higher gear ratio spreads
• Improvement of friction clutch, pump, seal efficiencies
• Low viscosity fluids
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Global Transmission Production is forecasted to growth to 100+ Millions in 2020 from 74 Millions in 2010
Source: IHS Dec. 2013 Transmission Production Forecast
Manual transmission (MT) production share will decrease by 9% from 2010 to 2015 and remain stable until 2020
Stepped Automatic Transmission (AT) production share will slowly decrease to 29% in 2020 from 34% in 2010
Continuously Variable Transmission (CVT) production share will increase to 10% in 2015 and 11% in 2020 from 7% in 2010
Dual Clutch transmission (DCT) production share will increase to 6% in 2015 and 8% in 2020 from 2% in 2010
Electric Vehicle Transmission (Reduction) production share will remain very low, at 1% by 2020
Electrically Variable Transmission (EVT) production share will remain low, at 2% by 2020
TRANSMISSION TRENDS Global Transmission Production and Share
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‘Automatic’ transmission production in Europe will increase by 80% by 2020
• DCT production will increase and replace CVT
• DCT captures market share from MT and AT
China is forecasted to become one of the production centers
• AT, DCT and CVT will grow significantly at the expense of MT
Japan and Korea production will stay current with diversification
• OEMs increase their production presence abroad instead of exporting
North America production will significantly increase
• Recovery from financial crisis
• CVT production share increases to 21% in 2020
0.0
10.0
20.0
2010 2020
Mil Units
0.0
10.0
20.0
2010 2020
Mil Units
0.0
10.0
20.0
2010 2020
Mil Units
0.0
5.0
10.0
15.0
20.0
2010 2020
Mil Units
Automatic CVT DCT EVT
TRANSMISSION TRENDS Regional Transmission Production and Share
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TRANSMISSION TRENDS Stepped AT Global Production - Leading OEMs
ZF, Ford, Aisin, Hyundai, and GM represent the most AT growth as they refine their designs with added forward speeds
Other currently top manufacturers i.e. Jatco, Honda and Toyota shifting focus to other types of Automatics e.g. CVT
Source: IHS Dec. 2013 Transmission Production Forecast
North America and Japan remain the AT production leader, but China and Europe will grow
+25%
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TRANSMISSION TRENDS Stepped AT Global Production – Leading Technologies
• Rapid increase in AT forward speeds
– 8+ Speeds ATs will represent more than 50% of AT produced in 2020
– higher transmission-ratio spreads and more gears with smaller gear steps
• Increasing efficiency, with power-to-weight advantage over CVTs and DCTs
http://www.zf.com/media/media/en/document/corporate_2/products_3/innovation_1/9hp_1/brochure_9hp.pdf
More Forward Speeds
Source: IHS Dec. 2013 Transmission Production Forecast
Increasing power-to-weight performance
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AUTOMATIC TRANSMISSION FLUIDS Summary
• Stepped ATs remain predominant
• Increase in gear ratios to improve fuel economy
• Reduced size and weight
• Nonconventional transmissions gain market share
• CVT growth in Asia and North America
• DCT growth in Europe
Transmission Trends
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AUTOMATIC TRANSMISSION FLUIDS Summary
• OEMs specify ATF with
• Specific viscosity and shear stability requirements
• Exact friction requirements (friction durability and anti-shudder durability)
• Better oxidation performance for longer drain intervals
• Low Viscosity ATF becoming more predominant • Improved fuel economy
• Longer oil drain intervals
• Service-Fill market preference towards Multi-Vehicle ATF
• CVTs and DCTs initially require genuine OEM fluids
Fluid Trends
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