Future Development Targets for manual … Development Targets for manual Transmissions ... Global...

International VDI-Congress 2013 - Friedrichshafen

Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG

Future Development Targets for manual TransmissionsInternational VDI-Congress 2013 – Friedrichshafen

Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie K



Agenda

▪ Global market trends for manual transmissions

▪ Market specific customer requirements

▪ Impact on transmission engineering process

▪ Requirements Engineering

▪ Design cost optimization

▪ Functional integration

▪ Optimization of transmission attributes

▪ Efficiency improvement by passive oil management

▪ Weight reduction by structural optimization

▪ Weight reduction by new materials

▪ Weight reduction by new manufacturing processes

▪ Additional Customer Functions – Clutch-by-Wire

▪ Summary



Global Market Trends for manual Transmissions

▪ Market share for manual transmission is expected to be stable

▪ Global volume of manual transmissions is growing within this decade

Source: IHS Automotive March 2013



Global Market Trends – Regional Development for Europe (excl. Russia)

Characteristics of European market:

▪ Slightly market growth expected

▪ Manual transmission share becoming lower

▪ Major volumes below 300 Nm engine torque

▪ Permanent refinement of vehicle attributes

2013

2020

Vehicle Production – Engine Torques MT

HVAN = VAN > 3.5t

16.9 mn

units

20.5 mn

units




Global Market Trends – Regional Development for China

Characteristics of Chinese market:

▪ Significant market growth expected

▪ Manual transmission share becoming smaller


▪ Focus on product costs

HVAN = VAN > 3.5t

2013

2020

20.4 mn

units

30.7 mn

units





Global Market Trends – Regional Development for BRI (BRIC excl. China)

Characteristics of BRI market:

▪ Significant market growth expected

▪ Manual transmission share remains stable


▪ Focus on product costs9.5 mn

units

15.0 mn

units

2013

2020

HVAN = VAN > 3.5t





Book Ends of Manual Transmission Engineering based on Global Market Requirements

Characteristics:

▪ Low engine torque

▪ Base technical attributes required

▪ Minimized design costs

▪ Consider market specific duty cycles and driving conditions

▪ Platform product for several customer

▪ Local supply base

Mature MarketsEmerging Markets

Characteristics:

▪ Full range of engine torque

▪ Sophisticated technical attributes required due to further refinement of vehicles

- Weight

- Efficiency

▪ Optimized design costs

▪ Well known duty cycles and driving conditions

▪ Customer specific product

▪ Global supply base



Agenda













▪ Summary



Road Load Data – Basic Input for Transmission Design Requirements

Vehicle Measurements

Dynamic Vehicle Simulations

Market specific customer profiles

To

rqu

e

Time

TorqueTorque level

counting (RAL)

Revolutions

Market specific load profiles



Simultaneous Engineeringthrough complete supply chain

Key Success Factor Simultaneous Engineering

Target Costing

Modularity Functional integration

Functional optimization

Avoid overengineering

Standardization

Robust manufacturing

processes

Optimized Assembly

TransmissionRequirements, functions,

components, modules



Functional Integration leads to

▪ Significantly reduced number of parts

▪ Simplified assembly process

▪ Supply chain complexity reduced

but

▪ Complex design with addedfunctionality

▪ Need for cross functionalapproach

▪ Close communication withmanufacturing engineeringand suppliers

Parts with

modified

function

Example:

23 parts removed from bill of material of

successor transmission

Cost Optimization by functional Integration



Agenda













▪ Summary



Efficiency Improvement by passive Oil Management (1/2)

Initial situation:Churning losses are major contributor to transmission losses

Challenges:

� Reduce immersion depth of gear set

� Secure lubrication in each driving condition

� Limitation of power consumptionunder high-speed conditions

� Control complexity andon-cost of oil management system

Gears 0,88 %

Bearings 0,88 %

Seals 0,29 %

Synchros 0,15 %

Trans-mission3,24 %��

0,22

l/100km

Vehicle

96,76 %

Churning losses

1,03 %



Efficiency Improvement by passive Oil Management (2/2)

Hardware TestsSimulation / CFD

▪ Design solution

▪ Results of drag torque rig test

▪ CFD Analysis of base MT

▪ Optimization with oil shield

oil shield

2.000 1/min

Legend:

red: with oil

blue: with oil and oil shield

green: dry

50

%

10

0 %Operating conditions:

- 6th gear engaged- Input speed 2.000 1/min



Weight Reduction – Structural Optimization of Output Flange

Weight reduction potenzial [%]

Initial situation:

▪ Running mass production and stable processes

Challenges:

▪ Weight reduction by optimizing raw part geometry

▪ Cross functional collaboration with supplier under consideration of forging process capability

▪ Functional development of geometry to optimize stiffness and eigenfrequencyof powertrain



Current status @ GETRAG for a typical FWD MT:

▪ Aluminum die cast shift forks withsteel inserts

Under development:

1. Magnesium shift forks with steel inserts

2. Glass fibre reinforced plastic shift forks

− with steel inserts (plastic compound)

− without steel inserts (pure plastic)

Challenges:

▪ Limitation of peak loads

▪ Temperature profile of MT

▪ Keep cost under control

Weight Reduction – new Material for Shift Forks




Initial situation:

Potential for weight reduction of layshaftlimited, due to

▪ Root diameter of direct cutted gears

▪ Stress at press fits

Challenges:

▪ Development of a combined extrusion and rotary swaging process

▪ Ensure process stability under all conditions (e.g. quench distortion)

▪ Keep cost under control

Weight Reduction – hollow Layshaft for inline MTs




Additional Customer Functions – Clutch-by-Wire



Agenda













▪ Summary



Summary

▪ Global market requirements are specific

▪ Emerging markets – cost driven

▪ Mature markets – attribute driven

� “One-size-fits-all” approach does not match to market needs

▪ State-of-the-art engineering processes are needed to develop required products

▪ Simultaneous engineering

▪ Requirements engineering

▪ Further optimization of components is the key for improving attributes

▪ Consequent usage of simulation

▪ Implementation of new materials into mass production

▪ Development of manufacturing processes

▪ MT has potential for additional customer functions, e.g. clutch-by-wire

Future Development Targets for manual … Development Targets for manual Transmissions ... Global...

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