MAG 2016 # December The AutomotiveCTI TM, HEV & EV Drives magazine by CTI A New Automatic Trans mission The Effect of Vehicle Approach – a Suitable MT Electrification on Replacement? Transmissions and the Transmission Market Interview with John Juriga Director Powertrain, What Chinese Customer Hyundai America Technical Center is Expecting Innovations in motion Experience the powertrain technology of tomorrow. Be inspired by modern designs that bring together dynamics, comfort and highest effi ciency to offer superior performance. Learn more about our perfect solutions for powertrain systems and discover a whole world of fascinating ideas for the mobility of the future. Visit us at the CTI Symposium in Berlin and meet our experts! www.magna.com CTIMAG Contents 6 The Effect of Vehicle Electrification on 45 Software-based Load and Lifetime Transmissions and the Transmission Monitoring for Automotive Components Market TU Darmstadt & compredict IHS Automotive 49 “Knowledge-Based Data is the Key” 10 What Chinese Customer is Expecting Interview with Prof. Dr-Ing. Stephan Rinderknecht, AVL TU Darmstadt 13 HEV P2 Module Concepts for Different 50 Efficient Development Process from Transmission Architectures Supplier Point of View BorgWarner VOIT Automotive 17 Modular P2–P3 Dedicated Hybrid 53 Synchronisers and Hydraulics Become Transmission for 48V and HV applications Redundant for Hybrid and EV with Oerlikon Graziano Innovative Actuation and Control Methods Vocis 20 eTWINSTER – the First New-Generation Electric Axle System 56 Moving Towards Higher Powers – GKN Driveline Electronic Control Units for the 48V Battery Network 23 “You Need a Software System that Reacts MELECS EWS to All Driving Situations” Interview with Jeffrey Carpenter, Eaton Corporation 59 Innovative Powder Metal Planetary Carrier Solution for World Class Automatic 25 High Speed Electric Drive with a Three- Transmission Recognized with 2016 EPMA Speed Gearbox PM Component Award Karlsruhe Institute of Technology (KIT) Stackpole 29 Modular and Scalable Layshaft 61 Advanced Insulation Systems for Cost Transmission Design Effective, High Power Density E-Motors GETRAG, Magna Powertrain Victrex 33 A New Automatic Transmission Approach – 64 Reduced Production Cost with Increased a Suitable MT Replacement? Performance Ricardo Deutschland Hirschvogel Automotive Group 37 “There is no Eigenvalue of a Single Solution” 67 World’s 1st Production Selectable One-Way Interview with John Juriga, Hyundai America Clutches for Automatic Transmissions Technical Center Means Industries 39 New Transmission Bearing Reduces 71 China Pushes Electrification Housing Wear Impressions of the CTI Symposium China, NSK Deutschland 21–23 September 2016 41 Evaluation of TIFF and TFF Load Carrying Capacities and Comparison Against Other Failure Modes Smart Manufacturing Technology 3 CTI MAG The Automotive TM, HEV and EV Drives magazine by CTI Publisher/ Business Address: Car Training Institute (CTI) A division of EUROFORUM Deutschland SE Prinzenallee 3, 40549 Dusseldorf, Germany Tel.: +49 (0)2 11.96 86–30 00 Fax: +49 (0)2 11.96 86–40 00 www.euroforum.de E-Mail: [email protected] Responsible for the publisher according to the German Press Law: Michael Follmann Print: ALBERSDRUCK GMBH & CO KG, Leichlinger Strasse 11, 40591 Düsseldorf Cover photo: Institut für Fahrzeugtechnik, Technische Universität Braunschweig Layout: Hanno Elbert, rheinsatz, Köln Print run: 2800 copies Copyright The articles in the CTI Mag are published by EUROFORUM Deutschland SE. Literary copyright to all articles, illustrations and drawings contained therein is held by the relevant authors. No part of the publication may be reproduced by any means, mechanical, electronic or otherwise, without the express prior permission of the publisher and authors of the articles and drawings. The authors accept sole responsibility for the content of the articles. 4 Dear readers, Welcome to the seventh issue of CTI Mag! With 22 contributions, it’s the biggest since our launch in 2013. Starting with an IHS market analysis, we’ve covered a wide range of current developments on your behalf in the field of transmissions and drives. In this issue well-known manufacturers and suppliers talk about their latest electrification concepts, but also about new developments in conventional transmissions and individual drive components in terms of efficiency, performance and costs. The latest insights in development methods and drive component production are another key topic, with contributions from AVL, Getrag, GKN, BorgWarner, Oerlikon and many more besides. To give you the bigger picture, we also interviewed high-calibre experts from the automobile industry. Read for yourself what Hyundai’s John Juriga has to say about full and plug-in HEVs for the medium segment, and how Eaton’s Jeff Carpenter answers the latest questions on DCT. And for everyone who was there (and those who couldn’t make it), we’ve included a follow-up report on our recent CTI Symposium China too. Our special thanks to everyone who helped to make this issue happen. Happy reading! Your CTI Mag Team PS: The eighth issue of CTI Mag will be published in May 2017. The submission deadline for articles and adverts is 1 March 2017. To get all the details, just send a brief email to [email protected]. Michael Follmann, Exhibition & Sponsoring Director CTI Transmission Symposia, CTI Prof. Dr Ferit Küçükay, Managing Director, Institute of Automotive Engineering, TU Braunschweig, Chairman CTI Symposium Sylvia Zenzinger, Conference Director CTI Transmission Symposia, CTI 5 The Effect of Vehicle Electrification on Transmissions and the Transmission Market It is clear that the electrification of on-highway vehicles is now very much a reality. But what are the implications for transmissions, and the transmission market, as governments, OEMs, suppliers and customers all strive for lower CO� emissions/fuel costs? Chris Guile, Principal Analyst, IHS Automotive Introduction From a technical perspective, there is a broad range of possible have much higher volumes to consider, but for these applications configurations for OEMs and suppliers to consider, when thinking conventional transmission technologies will be used, in most cases. about vehicle electrification. Whilst we cannot evaluate all of these possibilities in such a short article, what we can do is look at some of Usually, an additional sensor is all that is required to confirm when the the broader market trends which are emerging, during this ‘embryonic’ transmission is in neutral, for the stop-start operation. Most non- period. Let us start by looking at the implications for the different manuals also need some way to maintain oil pressure, usually in the types of electrified vehicle: form of an electric oil pump, or an oil storage system. Manual transmissions will also be offered on mild hybrids, particular in Europe, Electric Vehicles some of which will switch to e-clutches. For Electric Vehicles (EVs), there are many simple reduction transmissions/systems, which are available for the OEMs to use. With so much investment in the existing supply chain and production However, the volumes for EVs are not expected to represent a equipment, leading to high levels of inertia, this slow ‘evolution’ of an significant share of the global market (see graph below). In this respect existing technology is a story we have seen many times, in the they do not yet pose a threat to the existing transmission suppliers/ automotive industry. supply chain. Having said that, the high torques available from electric motors are making EVs increasingly attractive to customers, for Full Hybrids sporty/ performance applications. For the moment, most of these But the most interesting question arises when we consider the full vehicles use single-speed transmissions, but IHS Automotive does hybrids. Despite their current low share, this is an important part of the expect multi-speed transmissions to be used in the future. market, and involves much more complex powertrain systems which always require some kind of transmission. Stop-Start/Mild Hybrids At the other end of the electrification spectrum we have the stop-start For the full hybrids, OEMs have to ask themselves: ‘Should we retain vehicles, and the slightly more complicated mild hybrids. Here we conventional transmissions, or should we develop/use some kind of 6 Global Electrification Trends 100% 90% 80% 70% e (%) r 60% 50% et Sha k 40% Mar 30% 20% 10% 0% 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 Electric Fuel Cell ICE ICE: Stop/Start Mild Hybrid Full Hybrid Source: IHS AutoInsight Dedicated Hybrid Transmission (DHT)?’ For some, the costs involved available from an electric motor may appear to be attractive. But in in developing a DHT are prohibitive, at this stage, whilst for others the reality, the electric motors are not usually able to provide enough need to build up knowledge and experience is paramount. torque between the lower gears, where the torque interruption is most obvious to customers. Of those systems in use, the PSA MCPH4 is As the first OEM to bring full hybrids to the market, Toyota initially probably the best known example, but this will be phased out in favour offered products which featured a CVT or a DHT, but they quickly of an automatic transmission, as PSA launches its new PHEV dropped the P210 CVT in favour of the DHTs. And with the significant applications. Suzuki is also known to be working on an AMT-based full volumes which they have been able to achieve, have stuck with that hybrid system, although it may have been delayed, or possibly even technology ever since. dropped. Fast forward to 2016, and we now have many more full hybrids using Hybridised CVT Transmissions DHTs (or ‘EVTs’ in the IHS terminology), but we also have many using Another early adopter of full hybrid technology was Honda, with CVT- ‘standard’ transmission types, as well. These typically feature some based systems, although these have recently been replaced by DCT/ kind of add-on electric motor, to achieve a cost-effective modular DHT-based systems.