zf as tronic description

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The automated transmission system for modern cranes GB

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Page 1: ZF as Tronic Description

The automated transmission systemfor modern cranes

GB

Page 2: ZF as Tronic Description

MKS-KD3333

21086 e

In recent years vehicle manufacturers have been directing a substantial share of their activities at relieving drivers of some of their workload so that they can fully concentrate on safe and economical goods transport.

To this end, mechanical transmissions were used, automated with add-on technology such as shift cylinders, valves, sensors and so on.

ZF has abandoned this approach and developed a new transmission concept which is setting standards. ZF´s tried-and-tested transmission technology wedded with state-of-the-art electronics have brought forth the promising ZF-AS Tronic system – and, sure enough, at reasonable cost.

All transmission functions have been integrated in one single unit. The driver can choose in favor of the automatic mode or opt for manual shifting of gears. In any case, he has been relieved of any clutch work and can fully concentrate on steering his truck.

Introduction

The ZF-AS Tronic stands for:

➽ Economic efficiency➽ Reliabilitiy➽ Environmental acceptability

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New technological solutions open up a whole world of novel opportunities of design for the entire driveline:

➽ EDC-engines have gone into production

➽ Standard dry clutches have become fully automatable

➽ EDC and other electronics systems can communicate(CAN-communication)

Increased reliability and raised economic efficiency of vehicles have been and still are core issues in development work. ZF fully supports these objectives and has made a major contribution with the ZF-AS Tronic.

➽ The entire driveline is relieved of substantial load by the fact that gearchanges are automatic and shift processes automated.

➽ Reduction of the number of sources for malfunction by integral construction.

➽ The new automatic ZF-shift strategy permits operation of the engine inthe most economical range (automatic mode).

➽ Simple operation (also facilitates change of drivers).

➽ If needed, the driver can intervene in any traffic situation and initiate gear changes at his own discretion (easy correction by means of a tip lever).

ZF-AS Tronic – A means to what end?

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It is the optimum drive system for trucks with electronically controlled diesel engines (EDC) and modern CAN-technology.

➽ Automatically shifting transmission system on the basis of a robust, mechanical transmission.

➽ If needed, semiautomatic operation (manual gear selection).

➽ Alternative operating concepts (e.g. console selector, steering column/steering wheel selector).

➽ Electronic/pneumatic clutch control; no clutch pedal.

➽ Electric/pneumatic shifting

➽ Speed adjustment of the gears (synchronization) in the main gear during gear shifts performed via EDC-engine and transmission brake.

009399

ZF-AS Tronic – By all means!

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A perfectly communicating driveline.

The ZF-AS Tronic offers:

➽ CAN-system network

➽ continuous monitoring of vehicle condition

➽ info readout for driver via display

➽ Selection of drive program and correction option via tip lever (joystick)

➽ Diagnosis possible direct on vehicle

integratedTransmission

ControlEDC ABS/ASR

Engine

010463

0005

65

ZF-AS Tronic – By all means!

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➽ No "add-on" operating elements.

➽ Only few central connections for compressed air and electric system.

➽ Electronic control system integrated in shifting module.

➽ Space and weight-saving construction:Two countershafts and 2-speed planetary gear.

➽ The basic gear is dog clutch-operated (non-synchronized);Splitter and range-change group are synchronized.

➽ Simpler, shorter, lighter and more versatile than anything elsethe market can offer today.

clutch

clutch actuator

shifting module withintegrated electronics

The first completely integrated transmission system.

This is ZF-AS Tronic

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Optimum installation space, weight and costs.

➽ 12 AS 2301

12-speed transmission

for vehicles up to 2 300 Nm (ca. 450 HP)

➽ 16 AS 2601

16-speed transmission

for vehicles up to 2 600 Nm (ca. 550 HP)

Specifically for this price-conscious vehicle class!

Ideal for demanding transport tasksin international transportation!

ZF-AS Tronic – Two Performance Classes

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Transmission Design

009931

Double-countershaft transmission with

• integrated splitter group and• planetary-designed range-change group

12 AS 2301 = 2 x 3 x 2

Splittergroup

Maintransmission

Range-changegroup

Page 9: ZF as Tronic Description

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011524

Legend:

Input

Output

Shifting module

Clutch actuator

Breather

Connection site for clutch-dependent PTO

Compressed-air connection

Oil fill opening and oil level check

Oil drain opening

Speedo sensor

Dimensions in parentheses for 12 AS 2301( )

1

2

3

4

5

7

8

9

10

622.5 (579.5)953 (910)

3955221

5 3 7

84167 9 210

278

301

32116.5(109)

Ø25

Ø51

1

Ø18

0

9

Installation Dimensions

6

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Technical Data

15.8612.339.577.445.874.573.472.702.101.631.291.00

8.88

12.339.597.445.784.573.552.702.101.631.271.000.78

12 AS 2301

Gear 123456789

101112

R 1 14.68 11.41 R 2 11.41

Nm

kg

L

OverdriveDirect Drive

1 900

250

11

2 300

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Internal Structure and Function16 AS 2601

➽ Housing: Light alloy, three parts; integrated clutch bell.

➽ Power distribution: Constant K1 or K2 on both countershafts.

➽ The 12-speed transmission 12 AS 2301 has no gear set Therefore, the transmission is about 43 mm shorter.

➽ Return of power distribution in 4-speed section onto main shaft incorresponding gear (or reverse gear).

➽ Drive via range-change group. In slow driving range speed 1 to 8 (12 AS 2301: 1-6) with range group ratio.

➽ In fast driving range speed 9 to 16 (7 to 12) direct to universal shaft.

Splitter groupK1K2

16 AS 2601: four-speed section

(12 AS 2301: three-speed section)

R-gearreversing

gear

R-gear reversing geartransmission

brakeRange-change

group

Output flange

34

1

1

2

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Gear Shifting

➽ Gearshifts are perfomed by the shifting module (pneumatically)

➽ For splitter and range groups one shift cylinder each

➽ One shift cylinder for actuation of main transmission section

➽ One shift cylinder for gear selector of main transmission section

➽ Valves, cylinders, sensors and external connections integrated in transmissionshifting module

➽ Shifting commands from the electronic system or, if needed, from the driver

Shift Cylinder forrange group section

Shift cylinder formain transmission

section

Selector cylinder for main transmission

Shift cylinder forsplitter group

2/3

GP

1/RGV12-speed

Shifting module

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Clutch Actuation

Clutch

clutchactuator

TransmissionControl Unit

airsupply

010842

actuatorpiston

travelsensor

valvesclutch open

valvesclutch closed

010833

controlelectronics

➽ No clutch pedal or hydraulic system

➽ Electro-pneumatic control of clutch processes

• when starting-off and when stopping• when shifting gears• when maneuvering

➽ Standard dry clutch actuated by clutch actuator

➽ Automatic clutch re-adjustment

➽ Driver automatically warned (display) if clutch is overloaded

➽ Display readout if clutch needs to be replaced

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Shifting Module

Shifting module withintegrated Transmission electronics

010291

Vehicle plug(CAN)

Transmissionplug

IntegratedTransmissionControl Unit

010833

The shifting module is installed on the top of the transmission, and easily accessible

It contains:

➽ the integrated transmission electronics➽ the valves for "shifting", "selecting", "transmission brake"➽ the shift cylinders➽ sensors for speed, pressure, etc.➽ pressure relief valve➽ the electric and pneumatic connections for vehicle and transmission

Page 15: ZF as Tronic Description

010832

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Transmission Control Unit

Clutch control

Transmission control,gear changes

Automatic system(Driving strategy)

CAN-communikation with EDC, ABS, ASR

The transmission electronic system controls all processes in the trans-mission and continuously communicates with linked-up vehicle systems.

Electronic Diesel Control (EDC)

Shifting module with integrated

Transmission Control Unit

EDC-engine

Dry clutch

Clutch actuator

Intarder electronics

Display

Range selector

ABS / ASR

Electrics

Pneumatics

CAN-communication

3

7

9

1

2

3

4

5

6

7

8

9

6

5

4

2

8

air supply

1

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0005

65

010464

D ... Drive (forward, automatic or manual)N ... NeutralR ... ReverseA ... AutomaticM ... Manual

switch over(only whilst driving)

reverseshifting(1 gear)

A/M

Severalupshifts

(several taps)

severaldownshifts

(several taps)

010463

The display keeps the driver informed:

➽ Operational mode (Drive mode, actual gear, etc.)➽ Warnings➽ Info on system malfunctions

upshifting(1 gear)

Operating ConceptConsole Range Selector

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Display Readouts

Foot off pedal

Clutch overloadedSelect lower gear

Communication errorto display

System error. Journey can be continoued with restrictions

System error.Stop!

Example error code: 153(Lines = "1")

Auxiliary gear shift system:L1 = forward speed engagedL2 = higher forwardLN = NeutralLR = Reverse gear

System self-check(when ignition on)

Transmission inNeutral position

Reverse gear "Low"engaged

Reverse gear "High"engaged

Air pressure insufficient(airless)

PTO 1 ist activated (P). Transmission Neutral (N).

PTO 1 und 2 are activated (P). Starting-off gear 3 engaged (3) speed

Gear selected, downshift options

Operating mode

Warning

System malfunction

Clutch wear indicator

Engaged starting-off or driving gear (here: 5th gear).Versions : 12-speed

Automatic mode

Start. speed: 1st - 6thDrive speed: 1st - 12th

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Operating modes

Automatic Mode

➽ Transmission shifts automatically

➽ Both hands always on steering wheel

➽ Optimum gearshifts in any situation"Dynamic" or "economical" drive style: the electronic systemrecognizes the style and responds

➽ If needed, correction of gear selected via tip lever

➽ The electronic system preselects a starting gear; the driver may adjust it to the situation given

➽ Maneuvering and PTO-operation only in manual mode

Manual Mode

➽ Gearshifts at driver´s discretion (via tip lever)

➽ Automatic clutch operation of transmission

➽ Shifting of transmission byrepeated tapping: 1x = 1 gear; 2x = 2 gears

➽ The electronic system preselects a starting gear; the driver may adjust it to the situation given

➽ Wrong gearshifts are precluded

010463

010832

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FeaturesTechnology and Function

➽ High-performance helical gears - new technology

➽ Central hydraulic oil supply

➽ Customary dry clutch

➽ Central cable harness; few external connections

➽ Robust housing with integrated clutch bell

➽ Full integration of all components

➽ Low temperature level for long service life of components

➽ Automated transmission functions for swift gearshifts

➽ Shifting in a manner that relieves the driveline of peak loads

➽ Jolt-free gear changes due to controlled clutch

➽ Display warning in case of clutch overload or if clutch needs to be replaced

➽ Diagnostic mode recognizes and indicates malfunctions on display, activates alternative functions and allows journey to be continued

➽ Simple trouble-shooting on vehicle by means of system-immanent error memory and ZF-diagnosis unit

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Benefits for the Driver

➽ Optimum relief for the driver:

• No clutch pedal• Swift, automatic gear changes• No operating errors

(electronic overspeed protection etc.)• Continuously updated info via display• All concentration focused on traffic• Suitable starting gear always available• Economical driving supported by most modern drive

strategies provided by transmission electronics• Low noise level

➽ Smooth clutch control for maneuvering and reversing

➽ At any time – depending on the traffic situation – the driver can change from the automatic mode to manual gear selection. The driver remains "in command" of his vehicle.

➽ Easy vehicle operation, promptly understood by rotating drivers; vehicle and driver are ready to go within a short time.

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Benefits for theVehicle Manufacturer

➽ No shift lever with shift block and shifting linkage.

➽ No connections and lines for clutch pedal (hydraulics, kinematics).

➽ Spatial flexibility regarding installation of display and range selector.

➽ Flexible driver cabin arrangement.

➽ Noise encapsulation not necessary (simple, robust basic transmission with helical gears).

➽ Long service life and high functional safety of the transmission through integration of all components.

➽ Complete system with final inspection from a single supplier (only one supplier).

➽ Improved economic efficiency of the transmission due to automatic program (more favorable operating costs).

➽ No operating errors

➽ Simple check of electronic components and interfaces on the assembly line by means of electronic diagnosis.

➽ Error memory integrated.

Benefits for vehicle manufacturer:

• Less installation costs• Parts and systems omitted• Less diagnosis and repair costs• Less training costs

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Benefits for theFleet Owner

➽ More payload(ca. 60 kg more as opposed to Ecosplit transmissions)

➽ The driveline is relieved of peak loads; therefore less clutch wear

➽ Economic efficiency improved by automatic program (Rental vehicle, etc.)

➽ Simple operation, no operating errors

➽ No clutch pedal, driver stays fit and motivated

➽ Ideal for unskilled drivers (driver rotation)

➽ High brake efficiency due to ZF-Intarder

➽ Only one contact partner for queries regarding entire transmission / Intarder system

➽ Easy procurement of spare parts

Benefits for fleet owner:

• Less training costs• Less maintenance and repair costs• Less operating costs (fuel, clutch, brake linings, brake drums)

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Benefitsfor the Environment

➽ Promotes fuel-saving drive style = less exhaust / particulate emission

➽ Optimum efficiency = low power loss

➽ 95% of all system components can be recyled = raw material savings

➽ No environment-critical material such as asbestos, cadmium = eco-friendly

➽ No hydraulic oil for clutch actuation = eco-friendly

➽ Prolonged oil change intervals = less waste oil

➽ Reduced transmission weight = increased transport efficiency

➽ Varnishing with water varnish = Savings in solvents = eco-friendly

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Self-Diagnosis

The AS Tronic system continuously performs self-diagnosis. It recognizes malfunctions, activates alternative functions and ensures continuance of journey.

010463011707

For the driver this means:

➽ In case of malfunction: • info by means of a symbol shown in display • in addition: buzzing signal

• the driver can react accordingly

➽ The driver is informed whether he has to stop immediately or whether the malfunction permits to continue the journey to a suitable checking point.

➽ There he can activate the check mode to define the malfunction (error code). Any measures to be taken will be found in the operating manual.

➽ There are several options:

• Journey can be continued without any restrictions

• Journey can be continued with restrictions

• Journey can be continued with severe restrictions (auxiliary control system)

• Journey cannot be continued. ZF comes to the driver´s aid: in the operating manual he will find

hot lines, addresses and actions to take.