zf-grad-solutions for efficient cvt
TRANSCRIPT
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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
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ZF Friedrichshafen AG, 20132 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20133 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20134 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20135 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20136 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20137 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20138 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 20139 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
ZF Powershift Transmission Series
300200
Engine Power
3214 20 2516
ZF TerraPower1109
100
7200 7300
ZF T-70007100
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ZF Friedrichshafen AG, 201310 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201311 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201312 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
1. Continuous tractor operation at max. engine power in many tractor applications verycommon
2. Automatic transmission/engine control strategies available, that can hold theengine/transmission operating point permanently at max. power level
Why is it so important, to have high tractor transmissionefficiency?
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Manual trans-mission acc.1)
CVT in max. power control mode
0
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%Application: Primary Tillage
1) Renius, K.Th.: Last- und Fahrgeschwindigkeitskollektive als Dimensionierungsgrundlagen fr die Fahrgetriebe von Ackerschleppern. VDI-Fortschritt-Berichte,Reihe1 Nr. 49
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ZF Friedrichshafen AG, 201313 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
1. Continuous tractor operation at max. engine power in many tractor applications verycommon
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
Why is it so important, to have high tractor transmissionefficiency?
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ZF Friedrichshafen AG, 201314 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
200
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280
300
320
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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
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ZF Friedrichshafen AG, 201315 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
0
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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
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ZF Friedrichshafen AG, 201316 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
Where does fuel energy go to?
0
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40
60
80
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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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 %
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ZF Friedrichshafen AG, 201317 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201318 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201319 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201320 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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Travel Speed [km/h]
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ZF Friedrichshafen AG, 201321 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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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Advantages and Benefits: Less power losses Better tractor dynamics Better controllability
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ZF Friedrichshafen AG, 201322 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201323 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201324 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201325 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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7
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9
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13
0500100015002000
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Engine speed @ 40 km/h
Source: N. UppenkampDLG Merkblatt 339. www.dlg.org
-14 %- 7 %
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ZF Friedrichshafen AG, 201326 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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20
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Tyre PressureRegulationTraction coefficient typically 0,3 0,4
Max. traction coefficient onlyat high slip rate
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ZF Friedrichshafen AG, 201327 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201328 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
PTO Power Transfer
Efficiency
Controllability
Flexibility
Max. Power
Power Take-off: PTO Power Transfer Solutions & Evaluation
Mechanic Hydraulic Electric
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ZF Friedrichshafen AG, 201329 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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ZF Friedrichshafen AG, 201330 12.11.2013 Karl Grad: ZF Solutions for Efficient CVT and Powershift Transmissions - ZF Confidential
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
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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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