MX65 – an all-new Small Modular Manual Transmission with best-in ...

MX65 – an all-new Small Modular Manual Transmission with best-in-class Torque Density Dr. Christof Schulte, Senior Engineering Manager Small MT GETRAG FORD Transmissions © GETRAG, 2015-08-12, 14th International CTI Symposium December 2015, Berlin

Agenda

1. Market drivers for a new Modular Manual Transmission Concept

2. Strategic Considerations during Design Concept Phase

3. MX65 Modularity Concept

4. Cost to Target Design Features

5. Market Attribute Sensitivity

6. Attribute Scalability Protection

7. Summary

14th International CTI Symposium Germany 2015, Berlin | Sen. Eng. Manager Small MT GETRAG FORD Transmissions | Dr. Christof Schulte 2

14th International CTI Symposium Germany 2015, Berlin | Sen. Eng. Manager Small MT GETRAG FORD Transmissions | Dr. Christof Schulte

Market Drivers – Manual to Automatic

Strong global sales volume growth with auto transmissions.

Slightly increased manual transmission sales volume expected.

AT catches up with MT sales volume, but MT keeps important share.

MTs remain significant in the product portfolio

3

million units (light vehicle)

Auto Manuals


Market Drivers – From West to East

Chinese market grows by factor 5 between 2005 and 2015

Chinese/EU customer demands are main technology drivers

New small MTs development need to consider a global scope

One new India MT plant to be launched dedicated to MX65

MX65 design supports global sourcing strategy

4

million units (light vehicle)


Market Drivers – From 5 to 6-Speed MTs

million units (light vehicle) Increasing use of 6-speed MTs

Trend expected to continue beyond 2020

Modular transmission designs required

New small MTs reflect global trends with 5 or 6 speeds and different torque capacities

Need for 6-speed MTs with modular technology

5


Market Drivers – From 4 to 3 Cylinders

million units (light vehicle) OEMs reduce no. of cylinders for downsizing/downspeeding

Engine compartment compression drives torque density and package

Global engine diversity requires flexibility

MX65 is prepared for a wide variety of engine designs and increasing customer expectations

6


MX65 Family: 5MTT152, 5MTT215, 6MTT215

Successor of the small MT family (iB5) produced >34 million times

Best-in-class torque density

Modular design for 5 or 6 gears

Improved efficiency, shiftability, NVH

MX65 provides a versatile solution for low-/mid-torque applications

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Strategic Considerations – Concept Phase

Target customers are B-Car and low entry C-Car applications

Improved quality performance over iB5 (synchronized reverse gear)

Standard technology and global specification to support localization in four markets

Modular architecture for nominal torque levels of 150Nm and 215Nm

MX65 targets iB5 level powertrain installation costs (All applications w/o DMF, match iB5 transmission cost level)

Protection of attribute scalability for future, local and application needs

Design protection for add-on AMT solution

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MX65 Modularity Concept (1)

Application Type - I Type - II Type - III

Speeds 5-speed 6-speed

Vehicle Class B - Car B & C - Car

Torque Capacity 150Nm 215Nm

GVM 1600kg 1900kg

Reverse Synchro Synchronized Reverse Gear Layout Type - I Type - II Type - III

Main Center Distance 65 mm

I/S – Diff. Distance 178mm 184mm

Trans Length 350 mm

No. of shafts 2 - shaft 2,5 - shaft

Synchronizer 1/2/3/4/5/6/R 2/2/1/1/1/1/1 2/2/1/1/1/1/2 2/2/1/1/1/1/2

Weight (dry) 27kg 29kg 30kg

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65mm

184mm

65mm

184mm

5MTT215 6MTT215

65mm

178mm

5MTT152

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65mm

178mm

5MTT152

65mm

184mm

6MTT215 Identical synchronizer design

for low/high torque architecture

Identical bearing design on I/S, O/S, differential

Identical differential assembly

Similar gear arrangement and internal controls set up (except Rev)

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6 to 5 speed high torque solution by omission of 6th gear pair

1st to 5th gear retain identical ratio

Revised synchro hub 5/6 and internal controls gate

65mm

184mm

5MTT215

65mm

184mm

6MTT215

184mm


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Cost to Target - Design for Manufacturing

Plain bearings for maximum re-use of available iB5 equipment

Avoidance of sensitive manufacturing processes (e.g. hard welding, shaping, shimming, etc.)

Design for Assembly All loose gears on O/S Floating bearing concept

on all shafts Simple transmission

assembly in clutch case

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Cost to Target - Design Features

High torque density drives low material usage (7kg less than outgoing 5spd IB5)

MX65 is consequently designed for minimum part count (32 parts less than outgoing 5 spd IB5)

Each part is designed for minimum no. of manufacturing process steps

Very simple internal controls layout

Split internal controls instead of shift turret

MX65 vs. IB5 (6 Spd) (5Spd)

Part Count 21% better Weight 23% better

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Cost to Target – Installation Features/Rattle Sensitivity Development

MX65 base architecture optimized by use of CAE tool for rattle sound pressure emission prediction

Simulation correlated on DoE base and applied for rattle level and sensitivity tuning

Main rattle robustness driver is: − ratio selection − inertia reduction on synchronizer system and gears − Axial and radial lash optimization

on synchronizer and gears − Gear set layout

Result: MX65 achieved vehicle NVH sign off without dual mass fly wheel for all transmission types Si

mul

atio

n

Rig Measurement

99,2 % Correlation

15


Market Attribute Sensitivity

Minor variation of attribute importance by market

Market specific compromises drive sales volume and customer satisfaction

A new global transmission architecture needs to protect attribute scalability

Whine

Rattle

Weight

DurabilityShiftability

Efficiency

Costs

Europe China India South America

low sensitivity

high sensitivity

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Attribute Scalability Protection

Synchronizer

Single cone synchronizer package provides protection for double cone deployment

Double cone synchronizer package provides protection for triple cone deployment

Typical protection for: Clutch friction disk inertia increase C-Car applications

(6MTT250/B6 comparator transmission) driving target improvements

Non-EU markets reducing shift quality target requirements

Single

Double / Triple

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Internal Controls

All internal control friction positions protected for three design levels: Plain aluminum/steel system Teflon bushing Low friction bearing (RLF)

Protection for external control shift cable routing effects (friction variation)

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Differential Sealing

Sealing scalability ranges from standard seal ring solutions to seal cassette type systems.

Transmission case and drive shaft interface designed to fit both solutions without design change

Typical application scenario: Standard seal ring: non-severe markets with low

dirt/salt exposure Cassette Seal: Severe markets or premium

customer requirements

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Ventilation

Ventilation scalability ranges from simple mushroom to membrane type breather system.

Remote breather system protected

Transmission case interface is identical for all ventilation design options.

Typical application scenario: Mushroom: Central EU markets up to 300mm water

wading depth Membrane: Severe markets up to 550mm water

wading depth

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Summary

Manual transmissions will continue to hold a significant market share, especially in lower-cost segments

High transmission torque density accommodates downsizing trends

Flexible transmission design considers 6-speed customer demand and engine diversity in B-Car segment

New modular transmission strategy increases market share in cost sensitive vehicle segments

Attribute scalability tailors transmission performance to global market requirements

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