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25.02.2014 09 September, 2011
Future Powertrain Conference (20th February 2014)
Future transmission outlook and the implications for calibration
25.02.2014 25.02.2014 Clive Crewe (AVL UK)
AVL List, Transmission development. Internal Confidential
Contents
• Historical perspective Transmission Technology
• Key Market Drivers
• Global Industry Transmission Types and Volumes
• Transmission Technology Roadmap
• Calibration - The challenge
• Calibration Solutions
• Shift Quality
• Shift Scheduling
AVL List, Transmission development. Internal Confidential
Historical Perspective: Transmission Technology Introduction
Num
ber o
f Spe
eds
First Introduction Year
1
2
3
4
5
6
7
8
9
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010
'07
'04
‘13
‘15
'64
'89
'74
'02
Toroidal
2015
10
Average life cycle of new technologies getting shorter , # of technology options increasing rapidly.
AVL List, Transmission development. Internal Confidential
Key Market Drivers – Transmission Sector
• FE and CO2 Regulations • Market Competitiveness • Globalization of Powertrain
Portfolios • Expansion of Chinese
Applications • Emerging Markets Needs • Economic Recovery • Engine downsizing/boosting
Strategies • Diesel Projects • Family Approach • Electrification
• Integrated and Modular
Fleet CAFE increased by 34% over the past 7 years, It needs to increase by another 62% by 2025
Global CO2 Standards
NA CAFE Fleet
5
Recent Major Announcements & Activities
• VW is developing a 10-Speed FWD wet DCT
• GM and Ford jointly developing 9-speed FWD and 10-Speed RWD AT’s
• Chrysler will use ZF 9-speed FWD AT and 8-Speed RWD AT across the board • Chrysler to produce these units in NA in their facilities
• Hyundai is developing a 10-speed RWD AT
• Rumors of ZF developing a 10-speed RWD for BMW applications
• ZF is developing a 9-Speed wet DCT for Porsche application
• Daimler is developing a 9-speed RWD AT
• Honda is developing a 8-speed FWD wet DCT
• Jatco is working on introducing their CVT-8 in NA
AVL List, Transmission development. Internal Confidential
1%
37%
12% 4%
46%
AMT Automatic CVT DCT Manual
Current Global Transmissions Market
No one clear dominant type
Markets distinct
Manual
Automatic
DCT gaining ground
Euro / China
Source : PwC statistica 2013
Many options for vehicle/powertrain planners, transmission type highly application dependent
AVL List, Transmission development. Internal Confidential
2
64 12
10 12
AMT
Automatic
CVT
DCT
Manual
12 19 1 8
60
AMT
Automatic
CVT
DCT
Manual 5 10 2 2
81
AMT
Automatic
CVT
DCT
Manual
3 35
10 7
45 AMT
Automatic
CVT
DCT
Manual
0.5 40
41
0.5 18 AMT
Automatic
CVT
DCT
Manual
Current global market
North America
Europe
South America
China
Japan
Source : PwC statistica 2013
DCT, CVT & MT volumes are increasing in China, CVT penetration is increasing in NA
AVL List, Transmission development. Internal Confidential
Automatic transmissions
• Ratios increasing
• Volumes increasing
• China
• North America
• 9/10 Speeds
• Ford 10R / GM 9F / ZF 9HP
• Hyundai 10AT
8
0
5
10
15
20
25
30
35
Mill
ions
GLOBAL - AT Volume Forecast
Automatic 10
Automatic 9
Automatic 8
Automatic 7
Automatic 6
Automatic 5
Automatic 4
Automatic 3
Significant 9/10 Speed options by 2020
AVL List, Transmission development. Internal Confidential
DCT transmissions
• Ratios increasing
• Volumes increasing
• 10 Speeds
• ~50,000 units
• VAG
• 570 Nm
9
0
1
2
3
4
5
6
7
8
9
Mill
ions
GLOBAL - DCT Volume Forecast
DCT 10
DCT 8
DCT 7
DCT 6
DCT 5
Volkswagen Group dominates the market
10
DCT –Wet or Dry?
10
0 1 2 3 4 5 6 7 8 9
Mill
ions
DCT - GLOBAL
Wet Clutch
Dry Clutch
0 0.5
1 1.5
2 2.5
3 3.5
4
Mill
ions
DCT - CHINA
Wet Clutch
Dry Clutch
0 0.5
1 1.5
2 2.5
3 3.5
Mill
ions
DCT - Europe
Wet Clutch
Dry Clutch
Wet Clutch favoured over Dry
11
Source: IHS 04-2013
CVT
• Volumes increasing
• North America
• Asia
• Europe market declining
• Driveability
• Efficiency
• Saturating below 12M ~ 2020
CVT take up entirely market dependent
0
2
4
6
8
10
12
14
Mill
ions
GLOBAL CVT Volume Forecast
12
AT • Expanding rapidly from 6-speed to 8,9 & 10 speeds • Start/Stop capability with all new transmission • Emergence of new clutching systems for low losses • Integrated ETRS (Electronic Transmission Range Select) for all new designs • Electrification & Modular powertrain approach (Hybridization)
DCT • Moving from 6-speed to 7, 8, 9 & 10 speeds • Migration from dry-DCT to wet-DCT clutch system • Migration from electro-mechanical to electro-hydraulic Controls • ETRS and Modular Electrification • Emphasis on Cost Reduction
CVT • Emergence of Multi-mode CVT’s • Wider Ratio-Spreads and improved efficiency with significant FE/CO2 benefit • Steel-Belt dominance • Half-Toroidal CVT’s are being considered again
AMT • Migration from electro-mechanical to electro-hydraulic Controls • No significant growth – Emerging Market Opportunity
MT • Migrating from 5 to 6-speed, 7speed for high-end Sports Cars, eClutch
Summary
OEMs and transmission suppliers cannot handle this rapid growth with their in-house resources and need to outsource some Design & Development, Integration and Calibration
13
Calibration – Technology trend implication
Then
• Small teams
• 4/5 speed AT limited torque converter control
• Limited engine control integration
Transmission calibration has significantly evolved over the last 18 years
Now
• Medium/large teams
• 8/9/10 speed AT with sophisticated torque converter control
• Significant engine control capability
• GSI
Next
• 10/11 speed AT with increased torque converter control
• Driving environment/legislation -> Markets
• Platforms
• Increasingly complex engine control (Pedal maps now trans calibration task)
• Variable torque curves • Cylinder de-activation / 2 + 4 stroke / HEV /SCR
14
Transmission Calibration
Shift Quality
Shift Scheduling
Upshift
Downshift
A B
C
15
Calibration Tool Solutions
16
AVL DRICON:
• Enables fully automated test runs
AVL Transmission Calibration ACT for Chassis Dyno
AVL DRIVE: Objective drivability
assessment AVL CAMEO TRANSMISSION:
• Test plans using DoE methods • Perform controlled automated
test runs • Data evaluation and
optimization according the specified drivability target
Ground fixing device & load cell:
• Calculation of longitudinal vehicle acceleration
17
4. Driveability Evaluation Single Driving Mode Rating Overall Vehicle Assessment
1. Measurement of Driver Input & Vehicle Reaction Data Logging
2. Automated Driving Mode Detection
Nr. Time Driving manoeuver 1 11.56-15.59 Drive Away – Launch 2 19.14-20.81 Upshift – During WOT 3 21.21-24.11 Acceleration – WOT 4 25.54-26.25 Tip Out – After Acceleration ….
1 2 3 4
3. Parameter Calculation – Single Event
AccelerationGradient
Disengage
18,9[m/s3]
AccelerationGradient
Disengage
18,9[m/s3]
EngagementShock
0,48[m/s2]
EngagementShock
0,48[m/s2]
AccelerationGradientEngage
25,5[m/s3]8,19
AccelerationGradientEngage
25,5[m/s3]8,19
ZeroAcceleration
Time
0,47[s]
ZeroAcceleration
Time
0,47[s]
Traction Interruption
Time
0,81[s]
Traction Interruption
Time
0,81[s]
AVL Transmission AVL – DRIVE Objective Shift Quality Tool
18
In Vehicle Crankshaft Torque Measurement From Pressure to Torque
http://konstrukteur4u.de/Motoren/
ICE Working Cycle: (4-stroke)
Abstraction: (geometric relationships)
actual crankshaft torque
Pressure measurement: (gasoline, diesel)
19
CAN-Node
ECU TCU
CAN-Manipulation
Drive by-wire
Measurement System
AVL DRIVE SQ Ratings
Engine Acc. Sensor
Indication System AVL DriCon Driver Controller System
In Vehicle Crankshaft Torque Measurement Measurement Setup
20
Shift Scheduling
21
Shift scheduling = When does the transmission change gear?
Gear Decision
Decide suitable torque converter state
Road dependent
Driver dependent
System dependent
Market dependent
Situation dependent
CO2 Reduction – Fuel economy
22
Shift Scheduling
23
Base Shift Maps & Pedal Map Influences Trade off - Fuel Economy and Drivability
Gradient / Payload
Driver Defined Modes (Drive, Sport,
Eco,..)
Driver Sportiness
Best Operation Point
Eng
ine
Torq
ue (N
m)
Engine Speed (rpm)
24
The race for gears
25
AVL Shift Point Optimisation Tool
Shift map automatically generated based on user preferences
26
Transmission Technology Roadmap Pass Cars and LD Trucks
2010 2015 2020
eClutch for MT
8/9/10 Speed w-DCT’s6/7Spd Dual Clutch Transmissions wet, dry, moist applications
Multi-Mode and High-Efficiency CVTs Continuously Variable Transmissions - CVTs
Development of ‘add-in’ and ‘add-on’ Modules Alternative NVH solutions
Automated Process
NVH Optimization SW & Math-tool Development
ACT DRIVE INDICOM
‘Low-Cost’ DCT’s
‘Modular Hybridization of Transmissions’ Integration of DCTs/CVTs with electric final-drive units
New Low-Loss Clutching Mechanisms
Hydraulic Support Elements [Hydraulic Impulse Storage for Stop/Start]
6, 8, 9, and 10 speed AT’s 6, 7, 8 speed AT’s
Torq
ue-
Inte
rrup
t Tr
ansm
issi
ons
Pow
ersh
ift T
rans
mis
sion
s 5 and 6 speed MT 7 speed Manual for High-Performance Cars
Engine Start / Stop Capability
AMT & Electrified AMT Torque Fill / Fast Shifting AMT
Speed Matching for Smooth Shifting
27
America Argentinia Brasil Mexico Michigan Ohio
Europe Germany France Great Britain Italy Austria (HQ) Poland Romania Russia Sweden Slovenia Spain Czech Republic Turkey Hungary
Asia China India Indonesia Japan Korea Thailand Australia
AVL – A GLOBAL PARTNER Thank you for your Attention!
AVL List, Transmission development. Internal Confidential
Source: IHS 11-2011
Global Industry Transmission Types and Volumes
Full Hybrid and EV penetration is less than 3% , FE/CO2 regulations must be met by Conven. PTs
MT
29
Estimated time schedule
fast optimization loops
1st Calibration
Further calibrations (variants)
Test Plan Test Run Modeling Optimization Verify Resources
Calibration Phases
Engineer
Chassis Dyno
Vehicle
Generate Maps
Resources
Engineer
Chassis Dyno
Vehicle
Test Plan Test Run Modeling Optimization Verify
Calibration Phases
Generate Maps
Duration ~ 4 weeks
Data check
Data check
Repeat process
30
1st Gear,Upshifting
1st Gear,Downshifting
2nd Gear,Upshifting
2nd Gear,Downshifting
3rd Gear,Upshifting
3rd Gear,Downshifting
4th Gear,Upshifting
4th Gear,Downshifting
5th Gear,Upshifting
5th Gear,Downshifting
21 3 4 5 6
Adaptation
1st Gear,Upshifting
1st Gear,Downshifting
2nd Gear,Upshifting
2nd Gear,Downshifting
3rd Gear,Upshifting
3rd Gear,Downshifting
4th Gear,Upshifting
4th Gear,Downshifting
5th Gear,Upshifting
5th Gear,Downshifting
21 3 4 5 6
Adaptation
1st Gear,Upshifting
1st Gear,Downshifting
2nd Gear,Upshifting
2nd Gear,Downshifting
3rd Gear,Upshifting
3rd Gear,Downshifting
4th Gear,Upshifting
4th Gear,Downshifting
5th Gear,Upshifting
5th Gear,Downshifting
21 3 4 5 6
1st Gear,Upshifting
1st Gear,Downshifting
2nd Gear,Upshifting
2nd Gear,Downshifting
3rd Gear,Upshifting
3rd Gear,Downshifting
4th Gear,Upshifting
4th Gear,Downshifting
5th Gear,Upshifting
5th Gear,Downshifting
21 3 4 5 6
Modifications of reference GSP according to the optimal gears map
Original Shifting Programs Optimized Shifting Program (with CRUISE GSP)
Optimum Specific Fuel Consumption Zone
Fuel consumption optimization on NEDC cycle – Gasoline application
Shift scheduling = From bad to good