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The automated transmission systemfor modern cranes
GB
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
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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
MKS-KD3333
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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
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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21117 e
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.