zf-grad-solutions for efficient cvt

ZF Friedrichshafen AG, 20131 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential

ZF Friedrichshafen AG

Division IKarl Grad

ZF Solutions for Efficient CVT and PowershiftTransmissions


Agenda

1.2.

3.

The Importance of Tractor Transmission Efficiency

Solutions for Efficient Tractor Transmissions

Introduction ZF Company and Product Portfolio

4.5. Conclusions and Outlook

Tractor Transmission Design for Reduced Fuel Consumption and Improved Performance


Agenda

1.2.

3.







The ZF Group Key Figures 2012

2012 2012/2011

Sales 17.366 million 12 %

Employees (end of year) 74.775 5 %

Capital expenditure 1.192 million 13 %

R&D expenditure 861 million 14 %

121 production companies in 26 countries

8 main development locations in 4 countries

32 service companies and more than 650 service partners

The ZF Group An Overview


ZF Corporate Structure

Corporate Materials Management

Electronic Systems

CEO, Corporate Market, Research and Development

Corporate Finance, Controlling, IT, Process Management

Corporate Human Resources, Governance

Corporate Production

ZF Services

Corporate Quality

ZF Friedrichshafen AG Shareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr.-Jrgen-Ulderup Foundation

Automatic Transmissions

Manual Transmissions/ Dual Clutch Transmissions

Axle Drives

Powertrain Modules

Die Casting Technology

Chassis Systems

Chassis Components

Rubber & Plastics

Suspension Technology

Truck & Van Driveline Technology

Bus Driveline Technology

CV Axle Systems

CV Chassis Modules

CV Damper Technology

CV Powertrain Modules

Off-Highway Systems

Test Systems

Special Driveline Technology

Marine Propulsion Systems

Aviation Technology

Wind Power Technology

Passenger Car Steering Systems

Commercial Vehicle Steering Systems

Passenger Car Steering Columns

Global Aftermarket

Steering Systems*

* ZF Lenksysteme GmbH is a joint venture in which ZF Friedrichshafen AG and Robert Bosch GmbH each hold 50 % of the shares.

Powertrain Technology

Chassis Technology

Commercial Vehicle Technology

Industrial Technology


Industrial Technology Division: Turnover by business units

* provisional, not consolidated

Construction Machinery Systems* 813,5 Mio. Electronic Systems* 628,3 Mio.

Aviation Technology* 72,3 Mio.

Marine Propulsion Technology*264,5 Mio.

Special Driveline Technology* 251,2 Mio. Test Systems* 67,3 Mio.

Components* 105,0 Mio.

Wind Power Technology* 409,6 Mio.

Agricultural Machinery Systems* 359,9 Mio.

Off-Highway Systems* 1.173,5 Mio.

Sales Division I 2012*: 2.971,7 million


Ag Machinery Systems: Product Portfolio for Standard Tractors

ZF TerraSteerAxle

ZF TerraMaticCVT

ZF TerraRearAxle

ZF TerraPowerPowershift

ZF Synchroshift

Engine Power400300 hp200100

9 11 14 16-18 20 25 32 45

9 11 14 16-18 20 25 32 45

9 11 14 16-18 20 25 32 45

T-500 T-600

9 11 14 16-18 20 25 32


ZF CVT Transmission Series

650400300200

Engine Power

1.5 2.92.42.01.8

hp

ZF ECCOM

5.0

4.5

low drop high drop

3.5

3214 4520 2516

ZF TERRAMATIC1109


ZF Powershift Transmission Series

300200

Engine Power

3214 20 2516

ZF TerraPower1109

100

7200 7300

ZF T-70007100


Agenda

1.2.

3.







1. Continuous tractor operation at max. engine power in many tractor applications verycommon

Why is it so important, to have high tractor transmissionefficiency?

Image Courtesy: Claas



2. Automatic transmission/engine control strategies available, that can hold theengine/transmission operating point permanently at max. power level


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Manual trans-mission acc.1)

CVT in max. power control mode

0

10

20

30

40

50

%Application: Primary Tillage

1) Renius, K.Th.: Last- und Fahrgeschwindigkeitskollektive als Dimensionierungsgrundlagen fr die Fahrgetriebe von Ackerschleppern. VDI-Fortschritt-Berichte,Reihe1 Nr. 49



2. Automatic transmission/engine control strategies available, that can hold theengine/transmission operating point permanently at max. power level

3. Costs performance and money

o Engine power is lost on the transmission output (drawbar, PTO)

o Power losses turn into heat of the oil

o Oil needs to be cooled by the fan powered by the engine



200

220

240

260

280

300

320

340

360

80 100 120 140 160 180Engine Power [kW]

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Results from Tier 3 and 3A Engines from 2007 until 2012

Tractor fuel consumption in DLG Powermix Test

PS

PS CVT

CVT

CVT

PS: Powershift transmission

CVT: Continuously variable transmission


0

20

40

60

80

100

120

Where does fuel energy go to?

crankshaft

fuel tank

4045 % 85 % 95 %Fuel Ancil-

lariesTrans-mission

EnergyConver-sion

%

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Various data sources, a.o. Reiter, H. and S. Pinter: Reducing CO2 mission in tractor applications. AVL ICPC 2013, p.39-50. AVL Graz.

33 % at PTO shaftin tractor standstill


Where does fuel energy go to?

0

20

40

60

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100

120

crankshaft

fuel tank

4045 % 85 % 88 % 95 % 70 %Fuel Ancil-

lariesTrans-mission

RearAxle

Tire/Soil

EnergyConver-sion

20 % at drawbar

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/

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wheel hub

Various data sources, a.o. Reiter, H. a. S. Pinter: Reducing CO2 mission in tractor applications. AVL ICPC 2013, p.39-50. AVL Graz.

%

= 84 %


1. Full-load and part-load operation

2. Tractor mission profiles and duty cycles

3. Drive line efficiency improvement for

transmission rear axle specific tractor operating conditions

Tractor drive line efficiency: What needs to be considered

Full load efficiency target for stepless transmissions > 100 kW.

Renius, K.Th. e.a.: Continuously variable tractor transmissions. ASAE Distinguished LectureSeries No.29, pp.1-37. AET Conference, 2005_02_14-16, Louisville USA.

4. Transmission design and controls facilitate

process and performance optimisation fuel consumption/CO2 emission reduction


Tractor Fuel Consumption and what can be influenced bytransmission

Potential Fuel Saving MeasuresSources:Schreiber , M.: Kraftstoffverbrauch beim Einsatz von Ackerschleppern Uni Hohenheim, 2006.Uppenkamp, N.: DLG Merkblatt 339. www.dlg.org

Upto%

Selection of Right Gear 26

Tractor-Implement Combination 20

Correct Tractor Ballasting 10

Correct Tire Pressure 8

Adaptation of Working Speed 8

FWD Engagement 8

Differential Lock Engagement 5

eco PTO speed 12

Overdrive ratio in transport 21

Directly influencedby

transmission efficiency

Influenced bytransmission design &

controls


Agenda

1.2.

3.







Components & Characteristics:1. Rear axle brake lube-oil cut-off

system dependent on travel speed forreduced power losses especially in transport operation

2. Valve with low pressure drop to tank and proper control strategy

ZF Efficiency Package: Brake lube oil cut-off system

0

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0 10 20 30 40

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Travel Speed [km/h]


Components & Characteristics: A bypass valve of the oil cooler shortens

the transaxle warm-up phase to givemaximum efficiency, especially at lowambient temperatures.

ZF Efficiency Package: Cold Start Management

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100

0 10 20 30 40 50

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Time [min]

Advantages and Benefits: Less power losses Better tractor dynamics Better controllability


ZF Multi Clutch Control

TerraPower 09 11 14 16 20 25 32 Components & Characteristics: Eliminating a dedicated main clutch for

tractor launching and reversing Share the required energy in small

powershift clutches by proper controlstrategies

Advantages and Benefits: Less power losses Less weight and space claim

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Time

Travel speed

Clutch A

Clutch B

Supporting Clutch


Agenda

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Design and Function:1. Power assisted range group shift

2. Electro hydraulic actuation of gear selectionand synchro gear shift

3. Spring force centred neutral position

Transmissions facilitating tractor performance increase:ZF Intelligent Range Shift IRS

Advantages and Benefits:1. Selecting proper gear more often and more

likely due to high operator comfort

2. Armrest controls also for manual shifttransmissions

3. Ready for fully automated operation andcontrol


Transmissions facilitating tractor performance increase:ZF TerraPower 6-speed powershift

Characteristics T-7000 TerraPower

Number of clutches 6 6

Number of powershift gears F/R 4/4 6/3

Number of synchro gears 6 5

Powershift gear step ratio 20% 18%

Engine speed @ 40 km/h [rpm] 1675 1185

@ 50 km/h [rpm] 2100 1480

@ 60 km/h [rpm] - 1776

TerraPower 09 11 14 16 20 25 32

5

6

7

8

9

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12

13

0500100015002000

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Engine speed @ 40 km/h

Source: N. UppenkampDLG Merkblatt 339. www.dlg.org

-14 %- 7 %


Transmissions facilitating tractor performance increase:Integrated Air Feedthrough for Tyre Pressure Regulation

Tractive Efficieny: = (1 i) /( + )

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Tire slip i

Rolling resistance dependingon soil conditions 0,05 0,30

For the sake of soil protectionslip rate shall not be above 20 %

Is very sensitive to overballasting

0 20 40 60 % 100

100

%

60

40

20

0

Tyre PressureRegulationTraction coefficient typically 0,3 0,4

Max. traction coefficient onlyat high slip rate


1. Design, Characteristic and Benefits:1. Tire pressure adjustment on-the-go for reduced tire wear and

tractor performance enhancement

2. Rotary feedthrough integrated into axle design with goodaccessibility

3. Ducts and hoses protected inside rim and final drive

4. Suitable for steer and rigid axles

5. Optional equipment for standard axle

6. Suitable for use with single- as well as dual-venting systems

7. Ample duct cross sections for fast tire inflation

8. Pressure applied seals only during tire pressure change forlong lifetime

Transmissions facilitating tractor performance increase:Integrated Air Feedthrough for Tyre Pressure Regulation


PTO Power Transfer

Efficiency

Controllability

Flexibility

Max. Power

Power Take-off: PTO Power Transfer Solutions & Evaluation

Mechanic Hydraulic Electric

o+++++

++-

- -++

++++

+(+)

+


Agenda

1.2.

3.







1. High tractor transmission efficiency is essential for low fuel consumption2. Tractor transmission and axle efficiency have reached a high level and can be further

optimized especially for particular driving and operating situations3. Tractor transmission and axle design is and will be even more a facilitator for improving

and enhancingo tractor/implement performance, o fuel consumption ando emission reduction

Conclusions and Outlook

4. Electric drives as an alternative for hydraulic drives and low power mechanical drivesturn out to promising for future drive line architectures

ZF Friedrichshafen AG, 201331 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF ConfidentialZF Friedrichshafen AG behlt sich smtliche Rechte an den gezeigten technischen Informationen einschlielich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor.ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.

Thank you for your attention!

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