ReMaTec 2011

Vortragender/Speaker

Gnter Herth
ZF-Getriebe GmbH
Saarbrcken
Germany

ZF Getriebe GmbH
 The new 8-speed
transmission model line

Drivelinde Technology | Automatic Transmission, Manual Transmission and Dual Clutch Transmission Strategic Business Areas

ZF Getriebe GmbH
 ZF-Getriebe GmbH Saarbrcken
Factory 1 Saarbrcken

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 5
 Technological leap from 5- to 6-speed
automatic transmission

?
Engine torque [Nm]

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Generation 2

Generation 1

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 7
 Results of brainstorming and product
conception
More gears are able to create an added value to the costumer.
8-speed-systems have an optimized cost-value ratio.
During the product conception the Lepelletier wheel set has also been taken into
consideration.
Result: this system has not really benefits compared to the second generation of 6-
speed-transmissions. The degree of efficiency is even smaller compared to the 6-
speed.
Ambitious aim of ZF:
Introduction of a 8-speed transmission generation with a great added value to the
costumer, in particular concerning fuel consumption.

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 9
 ZF 8 HP design based on Lepelletier
principle (Prototype)
F A B C D
E

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 11
 Objectives 8HP

fuel consumption
emissions
-6%

control of modular
variability design

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cost - 20 %

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 13
 Reduction of fuel consumption and
technical solutions

6 HP T
- Spread
Operating point - No. of gears
- Open clutches
- Gearset efficiency
-6% Engine torque - Optimized lubrication

oil
Lock-up clutch - Better torsion
damping

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Pump - Vane cell pump

8 HP..

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 15
 Fuel consumptions savings

3-speed 4-speed 5-speed 6-speed 6-speed 8-speed

First gen. Second gen.

-6%
-2%

-5%

-3%

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-6%

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 17
 8 HP
prduct family

8 HP 90 A
8 HP 90

8 HP 70

8 HP 55 A
8 HP 55

8 HP 45

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8 HP 30

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 19
 Transmission section 8HP70

Gearset 1 Brake B
Gearset 2
Gearset 3 Brake A
Gearset 4

Clutch D

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Clutch C Drive

Clutch E Vane pump

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 21
 Tranmission schema 8 gear ZF / AW
Gang A B C D E

A B
= open shift element 1
GWK
2

D 3
8 HP 4
E 5
6
C 7
8
R

Gang A B E C D FL F
C D 1
B
2
A
8-Gang F E
3

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4

Drag losses from 4 open shift

ZF Getriebe GmbH
8

elements and one free wheel R1

KT/KT-A, Juni 2011 Seite 23

 Transmission schema 8HP
A B

RS1 RS2 RS3 RS4

brake clutch ratio

gear gear
A B C D E
step
1 4,70
1,50

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2 3,13
1,49
3 2,10
1,26
4 1,67
1,30 1 2 3 4 5 6 7 8
5 1,29
1,29
6 1,00
1,19
7 0,84
1,25

ZF Getriebe GmbH
8 0,67
Overall
R -3,30 7,05

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 Disk brakes ( A and B )

Piston chamber B2
Piston chamber B1

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ZF Getriebe GmbH
Return spring
(Cup spring) Brake

KT/KT-A, Juni 2011 Seite 27

 Multiple disk clutch ( E, C und D )

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Baffle plate Cub spring Pistons Clutch pressure

Dynamic pressure balance via the

ZF Getriebe GmbH
lubricating oil passage

KT/KT-A, Juni 2011 Seite 29

 Automatic transmission 8HP70

Break Planetary gearset Clutch Planetary gearset

Converter design:
Turbine torsion
damper with

Two dampers
One damper

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ZF Getriebe GmbH
Vane pump (DFZ) Oil screen Mechatronics Output flange

KT/KT-A, Juni 2011 Seite 31

 Options 8HP.. starting elements

modular design (kits)

starting elements

Hybrid

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compatible

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 33
 Options starting elements
Options
Options

Basis
Basis
3-line
3-lineconverter
converter
Hydrodynamic
HydrodynamicCooled
Cooled
Clutch
Clutch

Integrated
Integratedstarting
starting
clutch
clutch

Crankshaft-starter
Crankshaft-starter
generator
generator

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Hybrid
Hybrid
HCC
HCCintegrated
integrated

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 35
 Options 8HP 4W-drive

4-wheel 4-wheel
torsen hang-on
integrated

4-wheel ToD
integrated

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 37
KT/KT-A, Juni 2011
Pump

Seite 39

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 Double hub vane cell pump

Drive via a rolling toothed chain that is easy to rotate into overdrive directly
from the converter neck.
Supply volume at 14.7 cm3/revolution
Pressure and suction canals are linked directly to hydraulic control with
tubing travelling an unimpeded route for the best possible flow.
Suction flow charging from the main pressure valve improves the efficiency
factor even more.

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 41
 Installation space
comparison IZP / FZP

m
m m
96 m
= 47
d =
d

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b = 14 mm b = 23.5 mm

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 43
 Overall efficiency factor oil pump
Overall efficiency [%]

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Engine rotation speed [rpm]

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 45
 Torque converter

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 47
 Challenge
current development trends in the drive train

On the engine side, a reduction in displacement, weight, installation space...

(Downsizing) is causing greater irregularity (e.g. 4 instead of 6 cylinders)
Downshifting (driving under high load at low rotational speed)
With the newest converter generation, which is used in the 8HP, ZF is already well
equipped for the future.
In the same applications, we have a better decoupling factor than with the
preceding generation by up to a factor of 5

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 49
 3-line converter

For ZF it is the first time to use a three-line converter in passenger cars

The third control line, together with the separately sealed piston chamber,
makes it possible to better adjust the converter bridging clutch (WK) than with
a 2-line system.

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 51
 Converter construction kit

Converter Transmission

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ZDW = two damper converter NW:=neue
NW = new converter generation
TTD = turbine torsion Wandlergeneration

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 53
 Torque converter
Typ NW 235 RH - 4GWK / TTD

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1 housing / outer disk carrier WK 6 Converter housing
(n_mot) 7 Turbine
2 Chamber for WK 8 Pump
(converter bridging clutch) 9 Guide wheel
3 WK piston 10 Free wheel from the guide wheel
4 Torsion damper 11 Line 1 and 2 (pumps and turbine chamber)

ZF Getriebe GmbH
5 Clutch pack for WK 12 Line 3 (Chamber for pressure charging the WK)
Lined disk and outer disks 13 Inner disk carrier WK

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 Special ZF hybrid solutions

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 57
 Parallel hybrid output classes
ZF Transmission

Micro hybrid Mild hybrid Full hybrid

EM
8 HP

HIS

Installed electrical output 3-5 kW 4-20 kW 30-120 kW

Voltage 14-42 V More than 42 V 144-600 V

Fuel consumption reduction 3-5% About 15% 15-30%

1 start-stop (all)-/generator
function (mild + full hybrid)

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2 Recuperation

3 Boosting

4 Electrical starting

ZF Getriebe GmbH
5 Purely electrical drive

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 Savings potential for the hybrid
performance classes

Full hybrid systems offer the greatest savings potential.

Measured against their lower purchase costs, this savings from micro and
mild hybrids can also pay off for drivers or fleet operators.

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 61
 Why parallel hybrid?

ZF is conceptually oriented to the parallel hybrid in the passenger car sector.

Most affordable solution with the greatest customer benefits
The parallel hybrid drive is comparably cost effective to produce, since it gets along
with just one electric motor
Only moderate electrical output in driveline necessary
High installation space efficiency compared to power-split hybrid transmissions
because only one electrical motor is required
Higher efficiency
Modularity advantage

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Various versions can be built upon available automatic transmissions as an add-on
module

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 63
 Definition of name for converter hybrid
transmission (mild hybrid)
Converter hybrid transmission:

x HP xx H
Number of gears Hybrid

Size
Hydrodynamic starting element
Planetary design

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 65
 ZF mild hybrid

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Example: mild hybrid

ZF Getriebe GmbH
BMW Gen. 1.5: 8HP70H = Standard transmission with e-
motor

KT/KT-A, Juni 2011 Seite 67

 Definition of name for (full) hybrid
transmission
Hybrid transmission (without converter):

x P xx H
Number of gears
Hybrid

Planetary design Size

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 69
 ZF full hybrid

BMW Gen. 2.0: 8P70H Standard transmission

with e-motor;
brake B is the starting element

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Audi MLB : 8P55AF H = Front longitudinal
transmission including all-wheel drive and
front axle differential between engine and e-
motor ; brake B is the starting element

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 71
 ZF full hybrid concept

E-motor

EM

K0 IAE
IAB

K0
E-pump

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combustion
engine

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 73
 8P70H BMW Gen. 2 (full hybrid)
Transmission schematic

Brake Clutch Ratio Gear

Ge ratio
A B C D E i
ar step

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1 4.696
1.50
2 3.130
1.49
3 2.104
1.26
4 1.667
1.30
5 1.285
1.29
6 1.000
1.19
7 0.839

ZF Getriebe GmbH
1.25
8 0.667
Total
R -3.275 7.05

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 Summary

ZF focuses on hybrid drive

ZF focuses on parallel hybrid solutions
ZF is pursuing economical solutions with rather small e-motors
ZF is stronger due to a partnership with CAS*
ZF is active with all its important customers on the hybrid issue
ZF already develops generation 3.0 as a plug-in Hybrid. In 2014 every
vehicle manufacturer must have a hybrid plug-in car in his portfolio who wants
to sell cars in China.

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*Continental Automotive Systems

ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 77
 Thank you very much
for your attention

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ZF Getriebe GmbH
KT/KT-A, Juni 2011 Seite 79
KT/KT-A, Juni 2011
The End

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