itcc active on-demand awd system -...

Active on-demand AWD systemIntelligent Torque-controlled Coupling

CAT.NO.D1002E-1

01 02

Stable, Smooth and Highly Efficient Transmission of Power Expanding the possibilities of AWDWeather conditions, vehicle use, driver's intentions… Calculating every element to ensure that all four tires are firmly hugging the road under ever-changing conditions.Expanding the ability of more and more vehicles to give the driver that true feeling of confidence and driving pleasure. Our goal is to deliver that experience to everyone! With this in mind, JTEKT has reduced size and weight while simultaneously improving reliability in the production of ITCC*: electronically controlled coupling for AWD vehicles.

Continuing the Evolution of JTEKT ITCCExcellent response and powerful torque drawing the maximum potential of all four wheels

From differential sensitive on-demand coupling (RBC) to the recently developed active on-demand AWD system (ITCC), automotive manufacturers around the world are using JTEKT AWD systems

ITCC…

ITCC History

Continuously evolving since beginning of mass-production, the third-generation system (Gen 3) introduces epoch-making improve-ments in performance and durability.

ITCC Evolution

Intelligent Torque Controlled Coupling

1985 1995 2000 2005 2010 2015 20201990

19901985

1980

1980 1995 20001998 2005 2010 2015 2020

AWD for daily use

Part-time Full-time

Developmentstarted Generation1

Generation 2

Performance

AWD mark

et tre

nds

ITCC ev

olutio

n

AWD market trends

The continuous evolution of active on-demand AWD is based on a quest with a single theme: consider-ation of every aspect to deliver optimum torque to each of the four wheels, front and back, left and right. At the core of this torque management is JTEKT's electronically controlled AWD coupling, ITCC.※1 Capable of responding instantaneously, safe and controllable, ITCC offers continuous control of the driving force delivered to the front and rear wheels, from 100:0 (front:rear) to 50:50 (front:rear). As a result of the unparalleled results achieved for both high fuel efficiency and traction performance, ITCC is now installed in many AWD vehicles, and holds No. 1 market share in the world.※2 Its superior installation ease, drive force transfer efficiency and wide-ranging load capacity are key factors supporting the development of AWD systems.

※1) ITCC:Intelligent Torque Controlled Coupling . ITCC is a registered trademark of JTEKT Corporation.※2) As of Jan. 2014, in-house study

Generation 3Reliability further enhanced through longer services life

Torque precision further improved

・DLC-coated control clutch introduced・Special high-performance ITCC fluid

introduced

・Newly developed control clutch introduced

Active on-demand

Improved fuel efficiency

Active on-demand (lightweight driveline)

Generation1

Generation 3

Improvements in AWD operation

Differential-speed sensitive on-demand

Generation 2

Safety Factors

03 04

Structure Operating principle

Transfer case

Transmisson

Rear differential

Propeller shaft

Front differential

・Electromagnetic clutch adopted, realizing reductions in size and weight.・Components broadly divided into five sections: Input case, main clutch, electromagnetic clutch, cam mechanism and output shaft.

ITCC structure

In vehicles with a FWD configuration, the ITCC is installed in front of the rear differential; the active on-demand (active torque split) AWD system providing optimum torque distribution to the front and rear wheels. This contributes to ensur-ing both high fuel efficiency and superior driving performance.

Rear differential

Main clutch section

Input case

Fluid

Main cam

Armature

Control clutch

Rear housing

Control cam

Output shaft

Electromagnetic coil

Cam mechanism

Electromagnetic clutch sectionITCC cross-section

Input case

Main clutch section

Electromagnetic clutch section

Cam mechanism

Output shaft

Based on signals from each sensor in the vehicle, such as wheel speed sensors, etc., the ECU analyzes driver operation and road surface conditions, and then ITCC transfers the appropriate torque to the output shaft according to the electrical current from the ECU.

ITCC Operating PrincipleITCC Installation Layout

●Electrical current to torque (I-T) characteristics

ECU

Control current＝OFF

Control current＝ON

1

2

3

4

Current applied to coil　Generate magnetic flux　Armature suction

Generate control torque

Cam actuated　Pressure on main clutch

5

6

Torque transmitted from input case to output shaft

●Torque transmission flow

Output torque acquired is approximately proportional to the electrical current.

When in 2WD (normal driving)

Sensors for four wheel speeds, throttle position, etc.

ECU automatically analyzes signals from wheel speeds and other sensors, and continuously adjusts the driving force (e.g., 100:0~50:50) to the front and rear wheels according to driver operation and road surface conditions.

ECU

ITCC

Main camControl cam

Ball

Main clutchArmature

Control clutch

ECU

ECU

4 Control torque(generation of frictional torque on control clutch)

6 Main clutch pressure

5 Cam sectionTorque

1 Control current

2 Magnetic flux3 Armature suction force

When in AWD (front wheels slip)

Example of on-demand AWD mounted in FWD configurationIn this mounting example, the ITCC is located in front of the rear differential and the vehicle normally runs with the front-wheel-drive. The ECU receives signals from each sensor, analyzes driving and road surface conditions, and controls the electrical current sent to the ITCC, which then transfers the optimal torque to the rear wheels based on various conditions.

Out

put t

orqu

eElectrical current

Engine

ITCC

ITCC

Transfer case

Transmisson

05 06

Features Driving Performance

Driving Performance with ITCC

Lightweight/Compact size contributes to higher fuel efficiency

Superior durability and quietness have been realized, contributing to a confident, comfortable drive.

ITCC can be used in large-sized vehicles where the clutch is subjected to large load, and the amorphous carbon film contributes to both reducing size and increasing service life.

Newly developed control clutch, further improved torque precision and lighter driveline contribute to higher fuel efficiency.

Aiming to improve durability, a special fluid has been introduced that makes it possible to reduce the number of clutch plates to lighten the weight. Additionally, compared to conventional automatic transmission fluid (ATF), AWD coupling performance has been improved, thereby contributing to quietness of eco-cars.

■Special high-performance ITCC fluid introduced

ITCC AWDDesired driving line Neutral steer

Rigid AWDOversteer

2WD( FF )Understeer

Standing-start full-throttle acceleration on ice floe

Vehicles equipped with ITCC exhibit a standing-start acceleration performance equivalent tothat of rigid AWD.

Vehicles equipped with ITCC exhibit brilliant handling stability even on a slippery surface.

Traction performance Handling performance/Stability

FWD base electronically controlled

AWD coupling world share

No.1※1

Superior traction and maneuverability

Lighter driveline and improved fuel efficiency

Excellent compatibility with ABS and stability control systems

● Optimum driving force distributed based on road surface and driving conditions ● Compact, lightweight system

ITCCAWD

Rigid AWD

2WD( FF )

※1)As of Jan. 2014, in-house study

Lon

gitu

dina

l ac

cele

ratio

n（m

/s2 ）

Yaw

rate

(rad

/s)

0

1

2

3

4

・ Ice surface・ Acceleration: Stop→WOT(wide open throttle)

・Ice surface・Accelerate from 30km/h

Time (s) Time (s)

2WD( FF )

2WD( FF )

Neutral steer

Rigid AWD

0 1 2 3 4 5 00

0.05

0.1

0.15

0.2

0.25

1 2 3 4 5

ITCC: Equivalent to rigid AWD

Direct-coupled AWD

ITCC: Ideal neutral steer

■Launch performance

ITCC Features

Introduction of an electromagnetic clutch enabled reductions in weight, size and electricity consumption, contributing to improved fuel efficiency.

Remarkable anti-shudder performance contributes further to quietness.

●Newly developed control clutch

■Control clutch coated with diamond-like carbon (DLC) introduced

■Newly developed control clutch introduced

ECU

■Cornering performance

●Durability results using special high-performance ITCC fluid

Gen1 Gen2Serv

ice lif

e du

rabi

lity (h

) Improved 1.4-fold

●DLC-coated control clutch

DLC coating

Oil groove shape optimized Oil groove shape optimized

Based on extensive experience, ITCC control contributes to reducing abnormal noises (e.g., driveline torsional vibration, driveline chattering, etc.) generated by the vehicle.

07 08

Control System Development Bases

　

Driveline component manufacturing

Steering manufacturing

Bearing manufacturing

Technical centers

Sales

Machine tool sales & service

Regional headquarters 1

4

2

9

3

3

1

Machine tool sales & service 1

NORTH AMERICA




Technical centers

Sales



7

1

6

4

8

2

EUROPE

Machine tool manufacturing


Technical centers

Sales

2

1

1

2

SOUTH AMERICA




Machine tool manufacturing

Technical centers

Sales

3

3

5

1

3

24

JAPAN

Nagoya Osaka

Head Office

名古屋大　阪

ITCC Control System Features

Optional control including driveline lightening and improving vehicle vibration/noise performance is available

AWD basic control

Coordinate with other electronicallycontrolled devices・ABS and stability

control systems

Driving mode judgment

Drivetrain systemInput torque control

Highly accurate control

Road surface condition judgment

DrivelineVibration/

noise reduction

The ITCC electromagnetic clutch is highly responsive, making it easy to coordinate control with various vehicle control systems (ABS and stability control systems), etc.

■Rear differential

ECU automatically analyzes sensor signals such as wheel speed, etc., and the driving force to the front and rear wheels can be varied continuously from 100:00 to 50:50 depending on driver operation and road surface conditions

■Intelligent Torque Controlled Coupling

■Wheel Speed Sensor


■Throttle Position Sensor

■AWD Mode Select Switch



■ECU for Controlling ITCC

ITCC system layout

In situations such as driving in the city and on snowy roads, the simple ITCC system improves vehicle controllability and contributes to safe, confident driving.

Torque vectoring unit installation example

In addition to the function that distributes optimum torque to the rear wheels depending on vehicle operation and driving conditions, the system can also freely distribute torque to the right and left rear wheels. When cornering, large torque can be distributed to the outer rear wheel to produce yaw moment that suppresses understeer, thereby enabling the vehicle to hold the desired cornering line. Quick response to steering operation realizes sporty handling performance.

Torque Vectoring Unit Adaptation

Extended Use Example Based on ITCC

Ensuring the delivery of safer, more secure electronically controlled AWD couplings to customers around the world

Using wheel speed signal, throttle position signal, etc. that come as standard equipment in the vehicle, ITCC basic control logic compatible with traction performance and tight corner binding avoidance is developed

ITCC basic control

logic

■Easily coordinate control with other control systems

Sales 1

OCEANIA




Technical centers

Sales



11

4

11

2

12

Machine tool manufacturing 1

9

ASIA

Ensuring the Delivery of Safer,

More Reliable

Power Steering Systems

JTEKT has been conducting activities to ensure compliance with functional safety standards in accordance with ISO26262 Road Vehicles – Functional Safety since 2005.

Japan

・Projectmanagement・Labor

management

・Requirementsmanagement・Specifications

management

Activities started(2005)

Global organizationestablished

(2009)

Developmentprocess

introduced(2011)

Activities streamlinedusing management tool

(2013)

America

Europe

・Processmanagement・Structure

management

Transfer case

Transmisson

Rear differential（Torque Vectoring Unit）

Front differential

Control current

ECUITCC

Engine Propeller shaft

B

C

D

E

FA

F Noise Evaluation CourseFording CourseD Administration / Maintenance BuildingE Dynamics Pad

Straight-line CourseA Winding CourseB

C

Fully utilizing our knowledge as a world-leading systems supplier, JTEKT conducts driving evaluations and analyses of products installed in vehicles. We exhaustively pursue the highest standards in product safety and operation on a test course capable of simulating various road and weather conditions around the world. As a total systems supplier, our highest value is to provide our customers with products that deliver outstanding performance and the best quality that help to make automobiles that are more than just fun to drive.

Advanced R&D producing next-generation electronically controlled AWD couplings

JTEKT R&D centers exchange information around the world, enabling the company to accurately understand market demand and provide the newest/best/optimal systems to meet the diversified needs of our customers.

ITCC performance tester (equipped with gradient function)

ITCC durability tester

ITCC performance tester

Low-friction grade

Driving simulator

OFFICES

■JTEKT CORPORATION NAGOYA HEAD OFFICENo.7-1, Meieki 4-chome, Nakamura-ku, Nagoya, Aichi 450-8515, JAPAN TEL:81-52-527-1900 FAX:81-52-527-1911

■JTEKT CORPORATION OSAKA HEAD OFFICENo.5-8, Minamisemba 3-chome, Chuo-ku, Osaka 542-8502, JAPAN TEL:81-6-6271-8451 FAX:81-6-6245-3712

■Sales & Marketing HeadquartersNo.5-8, Minamisemba 3-chome, Chuo-ku, Osaka 542-8502, JAPAN TEL:81-6-6245-6087 FAX:81-6-6244-9007

PUBLISHER

www.jtekt.co.jp

■JTEKT Iga Proving Ground・Site area: 500,000m2

・Course area: 170,000m2

・Combined circuit length: 2,200m・Dynamics Pad area: 54,000m2

■JTEKT NORTH AMERICA CORPORATION-Main Office-

47771 Halyard Drive, Plymouth, MI 48170, U.S.A.TEL : 1-734-454-1500FAX : 1-734-454-7059

■KOYO CANADA INC.5324 South Service Road, Burlington, Ontario L7L 5H5, CANADATEL : 1-905-681-1121FAX : 1-905-681-1392

■KOYO MEXICANA S.A. DE C.V. Av. Insurgentes Sur 2376-505, Col. Chimalistac, Del. Alvaro Obregon, C.P.01070, Mexico, D.F.TEL : 52-55-5207-3860FAX : 52-55-5207-3873

■JTEKT (THAILAND) CO., LTD.172/1 Moo 12 Tambol Bangwua, Amphur Bangpakong, Chachoengsao 24180, THAILANDTEL : 66-38-533-310~7FAX : 66-38-532-776

■JTEKT AUTOMOTIVE (THAILAND) CO., LTD.107 Moo 4 T.Pluakdaeng A.Pluakdaeng Rayong 21140, THAILANDTEL : 66-38-954320FAX : 66-38-954321

■PT. JTEKT INDONESIAJl. Surya Madya Plot l-27b, Kawasan Industri Surya Cipta,Kutanegara, Ciampel, Karawang Jawa Barat, 41363 INDONESIATEL : 62-267-8610-270FAX : 62-267-8610-271

■JTEKT MALAYSIA SDN. BHD.No.8, Jalan Palam 34/18A, Taman Perindustrian Pak Chun,Seksyen 34 40470 Shah Alam, Selangor, MALAYSIA

■JTEKT KOREA CO., LTD. Seong-do Bldg 13F, 207, Dosan-Dearo, Gangnam-Gu, Seoul, KOREATEL : 82-2-549-7922FAX : 82-2-549-7923

■TAIWAN JTEKT CO.,LTD.NO.23,Guangfu N.Road, Hukou Township,Hsinchu, Country 303,TAIWANTEL : 886-3-597-2453FAX : 886-3-597-4687

■JTEKT (CHINA) CO., LTD. Shanghai BranchRoom 25A2, V-CAPITAL Building, 333 Xianxia Road, Changning District, Shanghai 200336, CHINATEL : 86-21-5178-1000FAX : 86-21-5178-1008

■JTEKT (CHINA) CO., LTD. Beijing BranchRoom 1012, Fortune Building, No.5 Dong SanHuan North Road, Chaoyang-District, Beijing, CHINATEL : 86-10-6538-8070FAX : 86-10-6538-8077

■JTEKT EUROPE S.A.S. (FRANCE)ZI, Rue du Broteau, CS 70001, 69540 Irigny, FRANCETEL : 33-4-7239-4444FAX : 33-4-7851-2188

■JTEKT EUROPE BEARINGS B.V. Benelux Branch Office

Energieweg 10a, 2964 LE, Groot-Ammers, THE NETHERLANDSTEL : 31-184-606800FAX : 31-184-606857

■KOYO ROLAMENTOS DO BRASIL LTDA.Avendia Brigadeiro Faria Lima, 1744 - 1st Floor - CJ.11Sao Paulo - SP - Brazil CEP 01451-001TEL : 55-11-3372-7500FAX : 55-11-3887-3039

Electromagnetic Anechoic Chamber

Vehicle evaluation in cold regions

Iga Proving Ground Enables Testing / Evaluations Simulating Roads Worldwide

09 10

Research Facilities Contact

CAT.NO.D1002E-1Printed in Japan '15.08-12BCH(’14.04)

itcc active on-demand awd system -...

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