Innovative Products from ZF - uCozgershon.ucoz.com/ZF/Charts_ZF_Workshop_Valencia_2012.pdf ·...
Transcript of Innovative Products from ZF - uCozgershon.ucoz.com/ZF/Charts_ZF_Workshop_Valencia_2012.pdf ·...
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2Dr. Hans-Jörg Domian
ZF Friedrichshafen AG
Innovative Products from ZFE-Mobility - Efficieny - Performance
ZF-Technik WorkshopValencia, 22.-24. Okt. 2012
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Topics
Efficiency
Econnect
E-Mobility
Electric DrivePerformance
Intelligent Wheel Dynamics
Product Strategy
Innovative Technik von ZF - Valencia 12-10-22
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Econnect
Electric Drive Intelligent Wheel Dynamics
Product Strategy
Topics
Innovative Technik von ZF - Valencia 12-10-22
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ZF – Technological LeadershipSystems Partner With Complete Vehicle Expertise
Components
Units
Modules /
Systems
Partial Functionality
Vehicle Network
StartingComponents
Transmissions
TransmissionSystem
ChassisComponents
Steering System
Axle System
Innovative Technik von ZF - Valencia 12-10-22
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Global Megatrends
Demographic
ChangeGlobalization
UrbanizationNew
EcologyMobility
Innovative Technik von ZF - Valencia 12-10-22
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Reduction of Energy Consumption and Emissions
Traffic / Transport / MobilityPower
Generation
OptimizationConventional
PowertrainHybrid Drive Electric Drive
Lightweight Design
Alternative Energy
Optimization of Conventional Powertrain
9 HP
cPower 8 HP
Innovative Technik von ZF - Valencia 12-10-22
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Reduction of Energy Consumption and Emissions
Traffic / Transport / MobilityPower
Generation
OptimizationConventional
PowertrainHybrid Drive Electric Drive
Lightweight Design
Alternative Energy
Hybrid Drives
8 P 70 H
3rd Generation
AVE130 EcoLife Hybrid
Innovative Technik von ZF - Valencia 12-10-22
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Reduction of Energy Consumption and Emissions
Traffic / Transport / MobilityPower
Generation
OptimizationConventional
PowertrainHybrid Drive Electric Drive
Lightweight Design
Alternative Energy
Electric Drives / Alternative Energy
eTB
RW1 EVD1
Innovative Technik von ZF - Valencia 12-10-22
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Reduction of Energy Consumption and Emissions
Traffic / Transport / MobilityPower
Generation
OptimizationConventional
PowertrainHybrid Drive Electric Drive
Lightweight Design
Alternative Energy
Lightweight Design
Rear axle concept with wheel guide
GRP transverse (leaf) spring
Brake Module Plastics suspension strut
Plastics damper top mount
Plastics pneumatic spring
Plastics wheel carrier
Innovative Technik von ZF - Valencia 12-10-22
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Topics
Econnect
Electric Drive Intelligent Wheel Dynamics
Product Strategy
Innovative Technik von ZF - Valencia 12-10-22
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The Disconnect Idea
Innovative Technik von ZF - Valencia 12-10-22
Improving fuel consumption by temporarily disconnection of 4WD components
Benefits by 4WD
• increased traction
• improved handling and safety
• improved drivetrain response
Disadvantages by 4WD
• package space and integration
• added weight
• increased fuel consumption
and CO2 emission
In-line 4WD-driveline
East-West 4WD-driveline
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ZF-Demonstrator for ECOnnect
CO2-reduction up to 3-5% at full AWD-performance
when AWD is not needed, its losses are switched off
RDU„twin clutch system“ (without differential)
Functionalities: • Torque distribution
on demand• Torque Vectoring
• Tractionimprovement
PTORing Gear disconnect
by dog clutch
Functionalities: • bring rear driveline
to stand still
Almost complete disconnect of rear driveline,
Proven drag torque reduction up to 93% (related to standard units)!
strategy-based, fast and imperceptible changeover between 2WD/AWD
Driver has full AWD-performance in all relevant driving situations
RDU and PTO as implemented in ZF demo vehicle(Land Rover Freelander)
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ZF ECOnnect
PTO• separated input shaft by dog clutch• elektromechanic actuation
RDU - Basic• AWD-clutch on one output shaft• used for active torque distribution and AWD-disconnect
RDU – Sport• twin clutch system (without differential)• Locking- and Torque Vector-Functionality• 2 elektromechanic actors
ECOnnect
Option for
basic version
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Connecting sequence of ZF ECOnnect
PTO
RDU
1.Synchronize
propshaft
50 ms
to
100 ms
2.Engagedog ring
40 ms
to
70 ms
3.Build up of
rear axle torque
100ms
E-Motor position controlled connection sequence
Fast, reliable and silent activation process under all driving conditions
190 – 270 ms
Innovative Technik von ZF - Valencia 12-10-22
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full locking capabilities in longitudinal and transversal direction
Improved traction and gradability even under severe slip conditions
Performance of traction Improvement by individual torque transfer
Hang-on AWD Twin clutch AWD
low muelow mue
• limited traction
• brake intervention required
• increased torque on µ-high
• smooth and relaxed operation
Innovative Technik von ZF - Valencia 12-10-22
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Simulation of CO2 saving
• NEDC cycle
• mid-sized SUV
• gasoline engine
CO
2e
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sio
n[g
/km
]
-4.2% -2.3% -3.9% drag related saving
Ptotal losses = Pdrag torque + Pgear efficiency
Simulation derives a pure drag torque related saving potential of -5.3% CO²
The ZF-Disconnect System achieves an overall reduction of -4.7% CO2
- 5.3% - 2.3%
-4.2% -2.3% -3.9%
total saving- 4.7%
Innovative Technik von ZF - Valencia 12-10-22
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Topics
Innovative Technik von ZF - Valencia 12-10-22
Econnect
Electric Drive Intelligent Wheel Dynamics
Product Strategy
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Motivation iWD
Innovative Technik von ZF - Valencia 12-10-22
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iWDImproved Safety and Driving Dynamics
Innovative Technik von ZF - Valencia 12-10-22
optimization of tire forces by active systems
Wheel position control
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Target Setting
Innovative Technik von ZF - Valencia 12-10-22
brake
intervention
yaw
torque
yaw
torque
improved tractiondefinition vehicle characteristic
stability intervention improved agility
driving stability
driving safety
comfort
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Target Setting
Innovative Technik von ZF - Valencia 12-10-22
yaw torque
improved tractiondefinition vehicle characteristic
stability intervention improved agility
agility
safety
fuelconsumption
critical
tire/road contact
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Target Setting
Innovative Technik von ZF - Valencia 12-10-22
improved traction regarding straight driving and cornering!
improved tractiondefinition vehicle characteristic
stability intervention improved agility
traction
driving safety
driving stability
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iWDImproved Safety and Driving Dynamics
Innovative Technik von ZF - Valencia 12-10-22
Wheel position control
optimization of tire forces by active systems
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iWDImproved Safety and Driving dynamics
Innovative Technik von ZF - Valencia 12-10-22
Wheel position control
optimization of tire forces by active systems
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AKC® (Active Kinematic Control)Control Arm with adjustable Length
technical data
320 W mechanical,approx. 500 W electrical
range: ±18 mm (±6°at wheel)
dynamics: 60 mm/s
max. force: 4 kN
holding force during misuse: 17 kN
weight under 3 kg
size: 212x85x120 mm
low unsprung mass by compact design
Innovative Technik von ZF - Valencia 12-10-22
design
electric motor
gear box
fail-safe lock
ball-type linear drive
1
2
3
4
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iWDImproved Safety and Driving Dynamics
Innovative Technik von ZF - Valencia 12-10-22
Wheel position control
optimization of tire forces by active systems
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Innovative Technik von ZF - Valencia 12-10-22
torq
ue v
ecto
r unit
torq
ue v
ecto
r unit
differential
“brake“
planetary
gear
input
Torque Vectoring Axle Drive“Vector Drive”
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Innovative Technik von ZF - Valencia 12-10-22
Concept Vehicle with interacting Systems
Vector Drive AS ERC AKCAWD
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Influence on Self-Steering Characteristics
Innovative Technik von ZF - Valencia 12-10-22
* Radius 100m, Versuchsstrecke Nardo (Februar 2007)
2004 im Kurzprofilsteady-state circular test *
influence Active Steering
• agility at low vveh
• comfort at high vveh
10
20
30
40
50
60
70
80
90
Lenkra
dw
inkel [
°]
0 1 2 3 4 5 6 7 8 9 10
lateral acceleration [m/s2]
conventional
Active Steering ASTorque Vectoring TV
interaction AS & TV
influence Torque Vectoring
• gets higher with rising vveh
• optimized tire force
distribution
influence interaction
self-steering char.
adjustable in all areas
adjustable range
0 51 72 88 102 114velocity vveh [km/h]
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Topics
Innovative Technik von ZF - Valencia 12-10-22
Econnect
Electric Drive Intelligent Wheel Dynamics
Product Strategy
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Driveline Electrification Terms, Classes, Functions, Steps
Innovative Technik von ZF - Valencia 12-10-22
(Micro Hybrid)
Mild Hybridparallel
Full Hybrid parallel (serial, power split)
Plug-In-Hybrid Electric Vehicle
Electric driving speeds
– small medium all
ICE driving speeds
all – / some
ICE Driving
Stop/Start
Regeneration/Boosting
Electric Launch
Electric Driving(regen energy)
Electric Driving(with external energy)
Pure Electric Driving
Step 1
Range Extension
Step 2Step 0
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Driveline integrated HybridOne package: Torque converter, Hybrid module
Innovative Technik von ZF - Valencia 12-10-22
8HP70 8P70H
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Electric Drive Designed by ZFBase vehicle and design data
Innovative Technik von ZF - Valencia 12-10-22
Design weight (incl. driver and partial load) 1.250 kg
Axle torque 1.400 Nm
Axle power (maximum during acceleration) 90 kW
Gradeability 35 %
Maximum speed (equivalent power: 30 kW) 150 km/h
Acceleration 0-100 km/h < 10 s
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Motor technology and speed considerations
Innovative Technik von ZF - Valencia 12-10-22
Equivalent motor speed at 150 km/h [rpm]:
8.000 13.000 21.000 26.000 40.000
ASM
PSM
0
10
20
30
40
50
60
6 10 16 20 30
Final eDrive ratio i (–)
Moto
r w
eig
ht
[kg]
Effect: light-weight and compact solution due to high speed approach
Design focus
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ZF’s EVD1 for Small Passenger Cars
Innovative Technik von ZF - Valencia 12-10-22
Specifications:
Performance: max. 90 kW / 30 kW cont.
Axle torque: approx. 1.400 Nm
Max. Speed: 21.000 rpm
Characteristics:
Single-speed two-step transmission: i = 16
Compact, light weight: 45 kg
Power density: 2,0 kW/kg
Optimized acoustics
Scaleable up to: 130 kW / 2.000 Nm axle torque
460 x 325 x 250 mm
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Testing Vehicle for EVD1
Innovative Technik von ZF - Valencia 12-10-22
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EVD1 Testing VehicleZF Stromos with EVD1
Innovative Technik von ZF - Valencia 12-10-22
E-Vehicle based on
Suzuki Splash / Opel Agila
Replacement of the existing E-drive by
E-drive EVD1 and ZF inverter
Concept proof – driving functions
Driveline test under real conditions
Evaluation of acoustic behavior
Vehicle testing started
Available for demonstration
purposes since August 2012
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EVD1 Acoustics
Innovative Technik von ZF - Valencia 12-10-22
Vehicle tests Bench tests
FE Model
MBS Model
Gear layout optimized towards
high speed concept
Latest methods and tools used to
understand and improve the acoustic
behavior
No driveline noise perceptible in or
outside the demo vehicle
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EVD1 – Outlook Integration levels for central electric drive
Innovative Technik von ZF - Valencia 12-10-22
Integration
Level 2
Integration
Level 1
Progress will be made by overall system optimization and integration
TransmissionCAN
Cooler
Battery
E-M
oto
r
Po
wer
ele
ctr
on
ics
Axle drive
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Summary
Innovative Technik von ZF - Valencia 12-10-22
Pure electric driving technologies will co-exist with conventional
and hybrid solutions for a long time
E-mobility solutions will have to fulfill various specifications within a
small range of design kit variants
The use of e-axle drives for both EV and Axle based HEVs
is reasonable
System optimization has to be applied to E-motor,
gears and inverter in a holistic approach
“Power out of speed” is a feasible
approach regarding the key factors
of an EV drive system
Integration is a key factor
for optimized solutions