2p Gutzmer

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch
International VDI Congress "Drivetrain for Vehicles" - Friedrichshafen

June 18, 2013
How the Transmission Contributes to Reducing

CO2 Emissions A Supplier's View
Prof. Dr.-Ing. Peter Gutzmer
Member of the Executive Board, Chief Technology Officer
Schaeffler AG
All rights reserved to Schaeffler AG,
in particular in case of grant of an IP right.
Trends and Solutions
Powertrain revenues will grow

Global powertrain revenues
Global vehicle production

passenger car
in mn units
passenger car
based on scenario of 40 g CO2/km limit
in EUR billions
compound annual
growth rate
+ 3%
114
compound annual
growth rate
459
+ 5%
93
301
+ 272
65
187
2010
2020
2030
Source: Global Insight, McKinsey
Page 2
2010
2020
Source: Global Insight, McKinsey
International VDI Congress - Prof. Gutzmer

2030
Tomorrow's mobility combustion engine remains dominant
Powertrain concepts
CO2 legislation worldwide
Light vehicles
in mn units
270
250
100
230
80
210
60
190
40
170
20
2010
2015
2020
Combustion engine
w/o stop/start systems
Hybrids
Combustion engine
incl. stop/start systems
Electric
Source: IHS Automotive
Page 3
China: 117g
in 2020
150
USA: 107g
in 2025
130
Japan: 105g
in 2020
110
90
2000
EU: 95g
in 2020
2005
2010
2015
Source: icct, 8/2012

2020
2025
Transmission technologies needs and trends
needs
increasing
input
torques
increasing
torsional
excitation
reduced
engine
speeds
demanding
CO2
regulations
less space
less weight
less cost
more comfort
Automated
Manual
Transmission
trends
higher
ratio
spread
increasing
mechanical
efficiency
increasing
expectations
for
robustness
& lifetime
Manual
Transmission
Page 4
less damping
in the
transmission
increasing
number
of gears
start/stop &
hybrid
capability
increasing
number
of shafts
increasing
degree &
share of
automation
Double Clutch
Transmission
Continuous
Variable
Transmission
Automatic
Transmission
Others
(Hybrid Module,
eDifferential etc.)
Transmission Technologies
Trends in transmission production (light vehicle)

MT
AMT
DCT
AT
CVT
Others
0.7
0.5
3.9
11.3
25.9
28.6
6.0
11.6
2.3
0
2012 (81.2): 42.4

2020 (102.3): 50.3
2020
2012
9%
in mn units
2%
11%
5%
4%
China
5% 1%
2%
8%
20%
60%
9%
15% 4%
7%
81%
17%
30%
18%
2%
NAFTA
78%
67%
66%
Korea
11% 17%
Europe
79%
35%
64%
3% 2%
4%
2%
63%
1%
1% 4%
India
19%
6%
2%
1%
100%
South
America
99%
6%
20%
1%
42%
Japan
23%
98%
32%
95%
Page 5
Source: Schaeffler study

50%
MT-based Transmission Technologies
Parallel shaft spur gear components
MT
DCT
AMT
# gears
5, 6, (7);
parallel shaft design
5, 6;
6, 7, (10);
launch device
dry clutch
automated dry clutch
dry or wet dual clutch
hybridization
hardly feasible
enabled but with limited

comfort
feasible
start/stop
capability
full (standard)
few additional requirements
few additional requirements
Page 6

Shift systems: full gear detection for shift tower
Features and benefits
Detection positions: neutral,

every forward gear, rev. gear
New possible functions:

- Gear selective eng. mapping
- Torque limitation for 1/2 gear
- Gear shift advise
- Clutch protection function
Plug and play assembly

Elimination of several single
components, fixation materials
and assembly steps
Stop
Go
STOP
START
Product focus
Page 7
Compact Design
New function Efficiency

Challenges and requirements

Fewer cylinder
Down-speeding
Axial excitation
crankshaft
Increasing
sensitivities
300
2008
300
100
100
1000
1990
1000
4000
Speed
4000
Speed
Specific
engine torque
Effective
vehicle weight
200
150
100
100
2010
1980
Year
Time
Time
Time
Judder
Temperature
Launch
Time
Noises
Time
Pedal load
Pedal
Modulation vibrations
Load / Torque
Wear rate
Facing
wear
release systems
Frequency
Thermal
stress
Speed
Impacts
Temperature
Speed
Page 8
Mechanical
strength
Torque
Engine
start
Isolation
clutch systems
Speed
damper systems
Time
2010
Year
Time

MP EP DP
Pedal travel
Acceleration
1980
Speed
Full load curve
Time
Pedal load
Recommended clutch type meeting the requirements
Servo spring
clutch
120 N
Self adjusting
clutch
100 N
Conventional
clutch
Twin plate
clutch
Engine Torque
200 Nm
Page 9
400 Nm
Low Torque
Medium Torque
High Torque
High end Torque
Conventional clutch
Servo spring clutch

Self adjusting clutch
Self adjusting clutch
Twin plate clutch for

comfortable pedal feel

Centrifugal pendulum technology
Conventional damped clutch disc
Complexity, effort
DMF
DMF with CPA

Disc with wide
angle damper
"best in class"
1st SOP in 2008
ZmartDamp
Centrifugal pendulum absorber (CPA)
Disc with damper
and CPA
DMF technology
Performance
Disc with damper

A-segment
B-segment
C-segment
D-segment
Damper for small gasoline and

diesel engine
Damper for small turbo

charged engines
Damper for medium and high

torque applications
Damper for high torque

applications and highest
standard
Page 10

Centrifugal pendulum absorber for cylinder deactivation
Noise, vibration,
and harshness
Drawbacks
Cylinder deactivation,
downsizing, and downspeeding
Improvements
Fuel efficiency
and emissions
Dual Mass Flywheel (DMF)

Example: 8-cylinder engine with cylinder deactivation
Speed amplitude [min-1]
Current Trends
8-cyl. engine out
120
8-cyl. transmission in
100
4-cyl. engine out
80
4-cyl. transmission in
60
With pendulum absorber
40
20
Engine speed [min-1]
0
1,000
Page 11
1,500
2,000

Release system elementary parts
Valves and dampers
Master cylinders
Valves and dampers

Peak-torque
limiter
Position sensor
technology
Anti vibration unit
Membrane damper
HP pipe technology
PA12
Bearing competence
Concentric slave
cylinder (CSC)
Polymer
contact plate
Page 12
Steel-rubber
Slave cylinder
Finger run-out
compensation
Polymer improved
External cylinder

Release system sensor with linear and digital output
Master cylinder
Sensor signal required for

functions like auto-stop-start,
cruise control, electronic park
break or start-lock
Stop
Magnet
Piston
Go
Smart solution to measure

positions or travels
Contactless sensor system
Sealing of sensor housing

according IP6K9K
Space saving
START
Travel sensor
Technologies with magnet as target
Less cables, connectors and

space required
Linear output
Hall array
2d hall
Digital output
LVDT
New technology w/o

magnet as target
Page 13
STOP

Hall switch
Inductive
sensor
Options for automation: electromechanic clutch actuation
Applicable for wet and dry

clutches or double clutches
Self opening concept
High resolution:
2.25 mm / rev.
1 1.5 Nm / incr.
No sensors required
Good performance:
80 160 ms / smax
Key components
Support rollers:
7000 N max. load
Ball screw drive:

800 N max. load
efficiency > 75%
Page 14
Electromechanic clutch actuation

Lever actuator features and key components

Options for automation: dry and wet double clutches
Features of the new

modular design
Dry DC
Page 15
Integration of double CSC

into the double clutch
No support forces on
crankshaft, input shaft
or bell housing
Robust design against

NVH side effects
Compatible with hydraulic

powerpack and hydrostatic
clutch actuator due to nonrotating pressure pistons
without leakage
Wet DC

Options for automation: hydrostatic clutch actuation
Applicable for wet and dry

clutches or double clutches
Integrated local control

unit and power stages
Robust for mounting

at chassis, engine or
transmission
For safety critical

applications (ASIL C)
Compact actuator design
Key components
Page 16
Planetary roller spindle:

ratio = 0.75 mm/rev.
resolution < 0.5 Nm/incr.
axial load up to 3000 N
Hydrostatic Clutch Actuation

CVT and AT Transmission Technologies
Overview
CVT
AT
Hybrid Module
# gears
variable chain drive;

parallel axis
6-9, (10);
planetary gear design
dependent on
transmission
launch device
torque converter or
wet clutch
torque converter
electric engine;
no friction based launch
hybridization
feasible
feasible
inherent
start/stop
capability
additional requirements
additional requirements
full (standard)
Page 17

Continuous Variable Transmission Technologies
The next CVT chain generation: CL06

Type 08
Type 06
Conclusion
Optimization
of transmission
size / weight,
overall ratio and
NVH!
Significantly reduced minimum

running radius of chain type 06!
Height -10 %
Chain type 08
(Current mass
production)
Page 18
Chain type 07
(Current mass
production)
Height -10 %
New chain type 06

Automatic Transmission Technologies
Very low lock-up speed

due to CPA
High efficiency TC torus
Double damper
with CPA
Value enhancement
through reduction in
purchased components
Product focus
Stamped
components
CO2 potential (5% - 10%)
High efficiency
TC torus
volume amplitude
Next generation torque converter and damper systems
engine
transmission with turbine damper
NVH
transmission with CPA

1000
1500
2000
engine speed
Page 19
2500
[min-1]

3000
Automatic Transmission Technologies
Goal / Solution
Low friction rolling bearing with

dimensions of a sliding bearing
Thin drawn outer ring; special steel cage

design (bearing height of 1.5 mm)
old: Plain bearing
new: Slimeline HK
Energy saving due to min. 60% less

friction compared to plain bearing
(e.g. 10 W for load 150 N)
Only 1% of oil volume required vs. plain

bearing (0.01 vs. 1.0 l/min)
Cost reduction due to possible elimination

of oil bores and use of smaller oil pumps
Running change in mass production
Page 20
Frictional Torque [Nm]
Slimline drawn cup needle roller bearing
10 W = approx. 25l gas for whole vehicle lifecycle

Plain bearing
- 60 %
Slimline HK
Speed [rpm]
Hybrid Modul
Standard 40 kW variant
AT
DCT
Space-optimized design with

integrated coupling
High degree of controllability of

the clutch
Combination with existing transmission technologies (AT, DCT,

CVT, MT)
No change to existing damper

execution
Modular system for hybridization

of existing drive trains
No restriction of vehicle
functionality
Dry clutch system with low

losses in uncoupled state
MT
Page 21

Schaeffler Demo Cars
India Concept Car
Benefits
~10% Fuel Saving
Engine
Dual VCT (Variable Cam Timing)
Fuel efficiency
Coated Tappets
Emissions
Chain Guide / Arm
Friction
reduction
Overrunning Alternator Pulley

Smart Thermo Management
Increased
drivability &
comfort
Same
performance
Reduced total
cost
Transmission
Bearing Optimization
Start-Stop-System
Electronic Clutch Management
Shift Detection / Recommendation
Schaeffler System Competence
Page 22

Schaeffler Demo Cars
Efficient Future Mobility North America
~15% Fuel Saving

Benefits
Fuel efficiency
Emissions
Engine (2,0l I4 TGDI)

Coated Tappets
Smart Thermo Management
Balance Shaft needle bearings
Belt Drive Friction Optimization
Friction
reduction
Transmission (6-Speed ATX)

Wrap spring PES
Latching Valve
TC with centrifugal pendulum
absorber
Increased
drivability &
comfort
Drivetrain (AWD)
AWD disconnect
LRR tires / Ecotires
Schaeffler System Competence
Page 23


Page 24


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VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

International VDI Congress "Drivetrain for Vehicles" - Friedrichshafen

How the Transmission Contributes to Reducing

Trends and Solutions

Powertrain revenues will grow

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

Global vehicle production

Source: Global Insight, McKinsey

Source: Global Insight, McKinsey

International VDI Congress - Prof. Gutzmer

All rights reserved to Schaeffler AG,

Trends and Solutions

Tomorrow's mobility combustion engine remains dominant

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

CO2 legislation worldwide

Source: IHS Automotive

Source: icct, 8/2012

International VDI Congress - Prof. Gutzmer

All rights reserved to Schaeffler AG,

Trends and Solutions

Transmission technologies needs and trends

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

Trends in transmission production (light vehicle)

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

2012 (81.2): 42.4

Source: Schaeffler study

International VDI Congress - Prof. Gutzmer

All rights reserved to Schaeffler AG,

MT-based Transmission Technologies

Parallel shaft spur gear components

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

automated dry clutch

dry or wet dual clutch

enabled but with limited

few additional requirements

few additional requirements

International VDI Congress - Prof. Gutzmer

All rights reserved to Schaeffler AG,

MT-based Transmission Technologies

Shift systems: full gear detection for shift tower

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

Features and benefits

Detection positions: neutral,

New possible functions:

Plug and play assembly

All rights reserved to Schaeffler AG,

MT-based Transmission Technologies

Challenges and requirements

International VDI Congress - Prof. Gutzmer

All rights reserved to Schaeffler AG,

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

Full load curve

MT-based Transmission Technologies

VDI Wissensforum 2013 - Veranstaltungsunterlagen - nur zum persnlichen Gebrauch

Recommended clutch type meeting the requirements

High end Torque

Servo spring clutch

Self adjusting clutch

Twin plate clutch for

International VDI Congress - Prof. Gutzmer

All rights reserved to Schaeffler AG,

MT-based Transmission Technologies

Centrifugal pendulum technology