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© 2013 The Lubrizol Corporation, all rights reserved. © 2013 The Lubrizol Corporation, all rights reserved.
OPTIMISING THE WET DCT WITH FLUID
TECHNOLOGY -FROM TRIBOLOGY TO IN-VEHICLE PERFORMANCE
MICHAEL GAHAGAN-LUBRIZOL LTD, DERBY, UK
JAMES ZHANG-LUBRIZOL, BEIJING,P.R.CHINA
© 2013 The Lubrizol Corporation, all rights reserved. 2
Contents
• Tribometer testing
• Formulation
• Clutch plate friction testing
• Vehicle dynamometer testing
– Driving cycle
– Sensor set-up
– Test outputs/results
– Fluid results
– Transmission rating/inspection
• Conclusions
© 2013 The Lubrizol Corporation, all rights reserved. 3
Steel rotor with annulus
Plain disk - friction material on steel backing
Force
Test DCT Fluid
Tribometer testing
Tribometer VSFT disk/rotor configuration
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Torque cell
Spindle
Test oil reservoir
Pneumatic cylinder Heater
Coolant
Tribometer testing
VSFT test rig - detail of test head
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VSFT mu-v curves
(friction coefficient versus m/s curves)
Positive engagement characteristic Negative engagement characteristic DCTF Comparison
Tribometer testing
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• Additive Package
– Friction modifiers
– Anti-wear
– Copper corrosion inhibitor
– Dispersant
– Detergent
– Seal swell agent
– Antioxidant
• Viscosity modifier
• Base Oil
DCTF – formulation and viscometrics
Viscosity:- KV 100 °C= 6.9 cSt BV -40 °C = < 12,000 cP
Formulation
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High Energy Launch Testing
Clutch plate friction testing
© 2013 The Lubrizol Corporation, all rights reserved. 8
Midpoint mu (friction coefficient)
Clutch plate friction testing
© 2013 The Lubrizol Corporation, all rights reserved. 9
Clutch lock-up time
Clutch plate friction testing
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Clutch plate friction testing
© 2013 The Lubrizol Corporation, all rights reserved. 11
Phase Details
Warm-up Vehicle idled at 0 mph
Standing Starts
Accelerator Pedal Position [%]
20
40
60
80
100
Single-Gear
Downshifts
Start Speed
[mph]
Downshift
Sequence
30 4-3-2
35 5-4-3
40 6-5-4-3
48 7-6-5-4-3
70 7-6-5-4
85 7-6-5
Skip-Shift
Downshifts selected selected
Cool Down Cool down cycle
Period Total Miles
288 hours 16917
Downshifts Upshifts Launches
70 94 7
Vehicle dynamometer testing
Drive cycle highlights
© 2013 The Lubrizol Corporation, all rights reserved. 12
(1) Blower; (2) Drive Axle and Roller; (3) Fueling Station with Hand Dispenser; (4) Stationary Axle; (5) Instrumentation and Control Cables
Vehicle dynamometer testing
Set-up on dynamometer
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Vehicle dynamometer testing
Robot driver
© 2013 The Lubrizol Corporation, all rights reserved. 14
0
20
40
60
80
100
0 5 10 15 20 25
Veh
icle
Sp
eed
[m
ph
]
Time [minutes]
Vehicle dynamometer testing
Driving profile
© 2013 The Lubrizol Corporation, all rights reserved. 15
Transmission Sump
Heat exchanger Mechatronic(case) Clutch housing
Mechatronic module
Vehicle dynamometer testing
Sensor location
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Standing Starts
Vehicle dynamometer testing
© 2013 The Lubrizol Corporation, all rights reserved. 17
KPa
Vehicle dynamometer testing
Average pressures
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Vehicle dynamometer testing
Temperature profile
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Interval Bo
ron
Ca
lciu
m
Co
pp
er
Iro
n
Mo
lyb
de
nu
m
Ph
osp
ho
rus
Sili
co
n
So
diu
m
Zin
c
SOT
(Virgin) 39 226 <1 <1 <1 540 2 7 <1
SOT 41 223 <1 1 <1 532 2 7 1
T2-1 46 223 4 42 <1 532 14 10 4
T2-2 45 221 5 56 <1 529 16 10 6
T2-3 47 222 6 75 <1 530 18 11 9
T2-4 48 223 6 92 <1 528 19 12 10
T2-5 43 218 7 111 <1 530 21 12 11
T2-6
(EOT) 46 222 7 121 <1 532 20 11 13
Vehicle dynamometer testing
Elemental analysis (ASTM D5185)
© 2013 The Lubrizol Corporation, all rights reserved. 20
Interval Odometer
Actual
Test Miles
Viscosity
@100C,
cSt
Viscosity
@ 40C,
cSt
SOT
(Virgin) 23,015 0 6.75 31.96
SOT 23,015 0 6.67 32.10
T2-1 26,015 3000 6.66 31.66
T2-2 29,071 6056 6.64 31.54
T2-3 32,016 9001 6.58 31.34
T2-4 35,015 12000 6.56 31.27
T2-5 38,015 15000 6.52 31.09T2-6
(EOT) 39,932 16917 6.52 31.11
ASTM D445
KRL shear test rig, 60 hours = 6.50 cSt
Vehicle dynamometer testing
Viscosity change
© 2013 The Lubrizol Corporation, all rights reserved. 21
Vehicle dynamometer testing
Component inspection/rating
© 2013 The Lubrizol Corporation, all rights reserved. 22
Vehicle dynamometer testing
Component inspection/rating
© 2013 The Lubrizol Corporation, all rights reserved. 23
Vehicle dynamometer testing
© 2013 The Lubrizol Corporation, all rights reserved. 24
• Tribometer for fluid selection
• Improved friction durability
• Faster lock-up times
• Good shear stability (viscosity retention)
• Severe test
– 118,674 shifts, over loaded-high ambient
– trouble-free transmission performance
– acceptable wear
– trace levels of non-ferrous metals
– surfaces clean, corrosion protection
• Robust core additive technology for DCT application
Conclusions
© 2013 The Lubrizol Corporation, all rights reserved.
Working together, achieving great things
When your company and ours combine energies, great things can happen.
You bring ideas, challenges and opportunities. We’ll bring powerful additive and
market expertise, unmatched testing capabilities, integrated global supply and
an independent approach to help you differentiate and succeed.
Contact us
– Name: James Zhang or Michael Gahagan
– E-mail: [email protected]
– E-mail: [email protected]
Thanks for your attention
