The New ZF Nine Speed Automatic Transmission - The

©ZFGetriebeGmbH,2011Dr.HaraldMassmann,Dr.MichaelEbenhoch,Dr.JürgenGreiner,HeribertSchererZFFriedrichshafenAG,Friedrichshafen,GermanyTheNewZFNineSpeedAutomaticTransmission-TheBestChoiceforFutureFrontWheelDriveApplication-PRA2©ZFGetriebeGmbH,2012IntroductionTransmissionConceptDesignControlsDesign-KitFuelEconomy,Drivability,InstallationSpaceSummaryContentPRA3©ZFGetriebeGmbH,2012IntroductionTransmissionConceptDesignControlsDesign-KitFuelEconomy,Drivability,InstallationSpaceSummaryContentPRA4©ZFGetriebeGmbH,2012ProductPortfolioATMTDTMTATHybrid1002003004005006007008009001000TorqueCapacity[Nm]6HP32A6HP26AS6-53S6-377DT70HLAMildHybridFullHybrid7DT756Speed*)7Speed8SpeedATHybrid9Speed9P48HFull/Plug-inHybrid6HP326HP286HP216HP19AS6-457DT527DT75A7DT45HL/HLA/FL8HP908HP708HP90A8HP70H8P70H8HP55A8HP458P55AHPlug-inHybridRWDFWD/AWDFWDtransverseAT/HybridRWD/AWDFWD/AWDunderdevelopmentMTDT*)5-speed5HP19stillproducedinZFTS8P70PH9HP289HP487DT75HLnewprojects,nocustomeryetcontractedS7-45PRA5©ZFGetriebeGmbH,2012FuelSavingbyZFAutomaticTransmissions19952000200520102015Rearwheeldrive5-speed6-speed1stgeneration8-speed6-speed2ndgenerationFuelConsumption-10%19952000200520102015FrontwheeldriveCVT6-speed1stgenerationDCTwet4-speed9HPFuelConsumption-10%bis-16%PRA6©ZFGetriebeGmbH,2012IntroductionTransmissionConceptDesignControlsDesign-KitFuelEconomy,Drivability,InstallationSpaceSummaryContentPRA7©ZFGetriebeGmbH,2012TransmissionConceptConceptCompetitionBestinClassEast-WestATResultTodayCVTATDCTPRA8©ZFGetriebeGmbH,2012ATforEastWestInstallationComparisonwithDCTConcepts*9HPDCTdryDCTwetFuelEconomy+++++Dynamic+−−Torque+−oHybrid+−−−−Packagingo−−Weighto+oCostso−−−DesignKito−−−PRA9©ZFGetriebeGmbH,2012SearchMatrixforPlanetaryTransmissionSystemsInvestigatedsolution-findingfieldswithsuitablesystemsInvestigatedsolution-findingfieldswithoutsuitablesystemsSolution-findingfieldsnotinvestigated(buildingeffortstobeinvestedaretoohigh9andmorespeedsNumberofshiftingelements7566/7speeds8speeds6HP8HP9HP343434NumberofGearSetsPRA10©ZFGetriebeGmbH,2012ConceptSelectionResultDogclutchshiftslementsDoubleGearSetStartingbasis9speeds4gearsets6shiftelementsPRA11©ZFGetriebeGmbH,2012ConceptSelectionGearBrakeClutchDogClutchRatioRatioStepCDBEFA14.7022.8531.9041.3851.0060.8070.7080.5890.48R-3.801.651.491.381.381.241.161.211.21Total9.81ShiftPatternDogClutchesDoubleGearSetPRA12©ZFGetriebeGmbH,2012IntroductionTransmissionConceptDesignControlsDesign-KitFuelEconomy,Drivability,InstallationSpaceSummaryContentPRA13©ZFGetriebeGmbH,20129speedautomatictransmissionwithTCoptionalwetclutchlaunchdevice3planetarygearsetsectionCombinedgearset1/2Simpsongearset3/46shiftingelements4frictionclutches2dogclutchesmechanicaldrivenoilpumpparallel-axisvanepumpelectronic-mechanicalcontrol(E/M-Control)shift-by-wire,park-by-cablehydrauliccontrolunitsize-optimizedexternalTCUGeneralConcept9HPPRA14©ZFGetriebeGmbH,2012DogClutchDesignChallenges•Highcontactpressureresistanceatbeginningoftooth•Lowcontactclearancetoreducebacklash•LowfrictionforcestoavoidstickingclutchesunderloadConsequences•Specialmaterialconditionstofulfillallrequirementsabove•Specialtoothgeometry•AdditionalengagementteethPRA15©ZFGetriebeGmbH,2012Sun/RingGearDesignDetailsChallenges•Lowwallthickness•Teethtorootvariations•LowdeformationunderloadConsequences•Highdemandonrunoutvaluesinnertoouterteeth•AdditionalprocessstepstoensureproductionqualitywithlowvariancePRA16©ZFGetriebeGmbH,2012StartingElements–DampingSystemsofTorqueConverterDampercharacteristicAngle[°]Torque[Nm]PRA17©ZFGetriebeGmbH,2012OverallGoals:ReductionofFuelConsumptionIncreaseofPerformanceIncreasedtorsionalirregularitiesinthepowertrainDevelopmentofnewlaunchcomponentAvoidslip/CloseLUCearlySameorlesspackaging;TChydrauliccharacteristicbecomeslessimportantHigheffectivetorsionaldamperrequiredTasksoftheLaunchComponentChallengeinPowertrainDevelopmentPRA18©ZFGetriebeGmbH,2012OptionalStart-UpDevicesTCwithTWDTCwithTTD/TTD+TorqueConverterWetStartupClutchWetLaunchClutch-HCNPRA19©ZFGetriebeGmbH,2012IntroductionTransmissionConceptDesignControlsDesign-KitFuelEconomy,Drivability,InstallationSpaceSummaryContentPRA20©ZFGetriebeGmbH,2012HardwareandSoftwarefromZFSelectorleverTransmissionsoftwareTCUinstallationASISdrivingstrategyPRA21©ZFGetriebeGmbH,20129HPControlUnitTransmissionConnectorHydraulicControlUnitPlugBoardPositionSensorDualSpeedSensorTCUPRA22©ZFGetriebeGmbH,2012ComparisonofHCU9HPwith8HP•2-partAl-DGhousing•Totalweight3610g•Width170mm,height286mm,depth53mm•HCUwithplugboardandTCUinstallation•15Valves•Optimalassemblyandmanufacturingconcept•ConstructionkitEandE/Mshiftsystem•2lineconverter•Stop/startwithoutHISpossible•2-partAl-DGhousing•Totalweight6580g•Width326mm,height232mm,depth60mm•MechatronicssystemwithextensionmoduleandHCU•21Valves•3lineconverter•OptionalHISpossiblePRA23©ZFGetriebeGmbH,2012ROM-SizeDevelopment010002000300040005000119952000200520102015[kByte]Jahre5-Speed6-Speed8-Speed9-SpeedPRA24©ZFGetriebeGmbH,2012IntroductionTransmissionConceptDesignControlsDesign-KitFuelEconomy,Drivability,Installatio