Driveline and Chassis Technology

ZF Friedrichshafen AGBus Driveline Technology88038 FriedrichshafenGermanyPhone +49 7541 77-0Fax +49 7541 77-908000www.zf.com/bus-transmission

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New Mobility Requires New Ideas

Rapid and Mobile – BRT

The traffic solution for growing cities: BRT

In order to avoid a total gridlock in heavily populated cities, it is necessa-

ry to reduce individual traffic. This also means: Public passenger trans-

port must transport more and more people in ever shorter cycles – not

an easy task.

Modern transport authorities and city planners bank on the "Bus Rapid

Transit" (BRT) traffic concept to cope with all the passengers. BRT is pas-

senger transport at its best: It is possible to transport more passengers

more quickly and efficiently on separate, empty bus lanes.

BRT systems are flexible and individual: Local conditions and prefe-

rences decide about the specific design – from BRT lite and standard

BRT to full BRT.

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What is BRT?BRT means above all one thing: to transport as many passengers as possible to their destination quickly and comfortably. To this end, buses must offer a spa-cious passenger compartment with step-free access. This is the only way to enable quick, comfortable passenger changeover and transport and only then can the buses reach their highest average speed. Moreover, the BRT system must be economical and environmentally friendly. The best possible fuel economy is required to achieve both these targets. After all, urbanistic conditions and political prefer-ences are important factors. This leads to the most advantageous concept for the city: BRT lite, stan-dard, or full BRT.

BRT lite (extended bus service)*Bus priority but not entirely sepa-rate bus lanes, quicker schedules, improved bus stops, buses with good environmental standard, marketing identity

Standard BRT*Separate lanes, usually pre-paid ticke-ting, higher-quality bus stops, vehicles with good environmental standard, marketing identity

Full BRT*Metro service, integrated network of routes and corridors, enclosed, high-quality bus stops, pre-paid ticketing, quick journeys with scheduled cycles, buses have latest environmental standards, marketing identity, excellent customer service.

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*Specification according to: Bus Rapid Transit Planning Guide 2007 Institute for Transportation & Development Policy, New York

High requirements of the bus call for high requirements to be met by the driveline: characteristics which strike you as a passenger in the bus are the smooth ride and braking behavior as well as the high average speed. Apart from a powerful engine, particular importance is placed on the transmission and optimally fine-tuned drive axle of the bus. Bus operators focus on attractive operating costs (Life Cycle Costs), which are mainly influenced by fuel consumption. A wear-free brake which decelerates nearly to a standstill reduces both costs and brake dust. After all, vehicles with "clean" technology are important for the residents and politics. Exhaust gas, particulate matter, and noise emissions are to be kept as low as possible in order to make the "city" a better place to live.

EcoLife is the best automatic transmission for buses in BRT operation: After all, it combines strong ac-celeration, high top speeds, and powerful and com-fortable braking with economical consumption data. This means that it even tops the Ecomat, the classic BRT transmission which is proving well every day in thousands of BRT lines all over the world. EcoLife even exceeds the high expectations in terms of service life which are already met by the Ecomat; moreover, EcoLife above all improves fuel consumption and noise comfort for passengers and pedestrians.

On-site electronics

Transmission heat exchanger

Retarder heat exchanger

The BRT driveline

BRT speed profile

Buses in BRT systems are subject to considerably higher loads

than in traditional city traffic. Very short stops are followed by

phases of extreme acceleration so that the bus achieves high

average speeds. The focus is always placed on passenger safety

and comfort, so acceleration and braking must be jolt-free. The

cycle is more or less repeated again and again because the bus

stops are usually less than one kilometer apart.

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Fast decelerationStop

Distance (m)

Fast accelerationHigh final speed

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Distance (m)

References

Whether BRT passengers enter from sidewalk level or

from a raised platform – the focus is on quick change-

overs. Buses are adapting. And with them, the driveline

with the ZF automatic transmissions:

High-floor bus

for raised entry platform

Low-floor bus

for platform on sidewalk level

Johannesburg (South Africa)

Beijing (China)

Rhein-Neckar (Germany)

Istanbul (Turkey)

Curitiba (Brazil)

Santiago de Chile (Chile)

Orlando (USA)

City(country)

BRTlite

BRTstandard

FullBRT

25 km (15.5 miles) BRT · 1 route · approx. 140 buses · 100 % ZF

16 km (9.9 miles) BRT · 3 routes · approx. 320 buses · 100 % ZF

380 km (236.1 miles) BRT · 52 routes · approx. 110 buses · 82 % ZF

40 km (24.9 miles) BRT · 1 route · approx. 350 buses · 100 % ZF

72 km (44.7 miles) BRT · 10 routes · approx. 2200 buses · 60 % ZF

200 km (124.3 miles) BRT · 15 routes · approx. 4500 buses · 55 % ZF

5 km (3.1 miles) BRT · 1 route · 9 buses · 36 % ZF

ZF powershift transmissions – proven thousands of times worldwide in all BRT variants

Be it BRT lite, standard, or full, with or without platform, with low-floor or high-floor buses:The transmission and driveline expertise – gained from decades of experience with modern automatic transmissions for buses from all manufacturers and from analyzing tens of thousands of operating data – is reflected in the well-founded application and qualified driveline support.

Here are a few references

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Orlando

Curitiba

Santiago de ChileJohannesburg

Rhein-Neckar

Istanbul Beijing

As of 2010

High averagespeed

Why are buses with EcoLife faster on average? It starts with the converter already: The new torque converter with an innovative characteristic curve lets modern engines ac-celerate with high torques. The torque converter is bridged after a short time already so that the mechanical 6-speed transmission can fully play off its advantages: fine gear stepping and a high level of efficiency. The new single-side design of the multidisk clutches and brakes allows for very short shifting times.

All of the transmission's gearshift and control processes are controlled by the TopoDyn Life shifting software. It always selects the right gear with changing topography and also considers other driving resistance values. The integrat-ed primary retarder's brake force is continuously adapted to the downhill gradient. This means that the retarder can fully develop its high braking power in all gears and at all speeds, nearly down to standstill. The integrated oil accumulator guarantees extremely short retarder response times and the separate heat exchanger ensures optimal cooling, enabling the brake to be operated continuously.

n Best traction

n Fastest acceleration

n Highest top speed

n Strongest deceleratoin

Torque converter for starting with lockup clutch

and torsional vibration damper

6-speed planetary transmission

and shift elements

Primary retarder and dual cooling concept

with separate retarder heat exchanger

Control electronics with TopoDyn Life

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EconomyWhy are buses with EcoLife more profitable in service? Mainly because they consume less fuel. The fuel-intensive phase of hydraulic starting with a converter is very short. The new converter is bridged at a very early stage. The standard torsional vibration damper reduces shift speeds so that the engine can run at lower speeds. And finally, EcoLife has six purely mechanical gears, new shift elements, and many other technical innovations, resulting in the extremely good efficiency. The result: Up to 10% less fuel consumption with ZF-EcoLife!

EcoLife also reduces wear outside of the driveline because it is the only automatic bus trans-mission which features a primary retarder. This considerably reduces wear on the service brakes and they remain cool and ready for use – for the safety of all passengers! The cooler oil in turn increases the service life and reduces the maintenance costs for EcoLife transmis-sions. The result: Service life is increased by up to 40%.

n Lowest consumption

n Longest service life

n Lowest LCC/maintenance costs

n Very long service life of the brake linings

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Comfort

Why do passengers rate bus journeys with EcoLife as being so comfortable? This is also mainly due to the torque converter which lets the bus accelerate both smoothly and quickly. In the higher gears, its turbine torsional damper additionally allows for smooth running and gearshifts with lower engine speeds. The passengers immediately rate the trip as being more comfortable.

The planetary gearset with its six finely stepped gears and two overdrive gears lets the engine run at low speeds even when travel-ing fast. Also the helical gears contribute to smooth running, and the continuously controlled shift multidisks ensure smooth, jolt-free gear changes.

n Jolt-free driving

n Low noise level

n Smooth braking

n Highest safety level

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Environment

Why are buses with EcoLife good for the environment? Low fuel consumption at the same time also means fewer exhaust gas emissions. So anything that reduces fuel consumption is also good for the environment: the early bridging of the torque converter, the effective power transmission with the planetary gearset, the extremely high efficiency, and TopoDyn Life. Already before standstill, the electronic AIS (Automatic Idle Shift) function takes effect and decouples the transmission from the driveline – this saves considerable amounts of fuel.

Environmental friendliness is also expressed in noise quality: Thanks to the torsional vibra-tion damper, the high shifting quality plays a major part in this regard; it is just as important as the two overdrive gears and the helical-cut planetary gearset with which EcoLife keeps the engine speeds low. EcoLife reduces brake wear with the primary retarder which brakes ef-fectively in all speed ranges. The specially developed Ecofluid Life transmission fluid stands for a long service life and a good load capacity.

n Lower exhaust emission

n Less vehicle noise

n Minimal brake wear

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ZF –more than just atransmission

Driveline advice:

A bus provides for optimum economy when all driveline components – from the engine and transmission to the rear axle – work accurately and in perfect harmony. Every BRT system is unique in terms of route profile, distance be-tween stops, stopping times, average speed, top speed, acceleration values, and topography.

ZF's experts already support you beforehand and not only give you advice for the transmission design but also when determining and designing the drive axle as well as the later fine-tuning and adaptation of the control software to the specific characteristics of your city and lines.

ZF-Plus – long-term service:

n Extended Coverage Program Bus

(program covering repair-related risks)

Repair or replacement services on transmission systems by ZF Customer Service. ZF's contracting party pays a fixed price and the ZF service organi-zation renders the service for the fleet owner's ZF transmissions.

n Life Cycle Cost Coverage Program

(program covering life-cycle costs)

ZF - as the service provider - is in charge of preven-tive and corrective maintenance of the transmis-sions produced by ZF. This guarantees the best possible vehicle availability.

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ZF is a systems supplier!

Everything from a single source: transmissions, axles,

steering systems, chassis components

Beyond transmissions, ZF also develops and pro-duces axles, steering systems, and chassis compo-nents – worldwide. This means that ZF can supply the transmission and axle combinations from a single source – perfectly tailored to the respective BRT application! The right steering system also sup-ports accurate and comfortable driving on all BRT lines.

Remote diagnosis:

Modern BRT systems are even more efficient if the buses are monitored during travel and the statistical data can be evaluated. Of course, this also applies to the transmission data. The available interface enables the diagnosis memory to be read out in the vehicle itself but it is also possible to transfer the data via the telemetry system.

openmatics

The new telematics platform openmatics with an on-board unit on the bus, records the vehicle's and the transmission's operating data and continuously transmits it to a web portal. This is where different applications ("apps") evaluate the data. The results are made available worldwide to a registered user group which can use the data at the same time. Ecomat and EcoLife support openmatics – the latest telematics platform offered on the market!

ZF –more than just a transmission

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