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Active Launch Systems Active launch systems For passenger cars up to 1,000 Nm 2 3 Powertrain compo- nents and systems for passenger cars and LCV Performance – comfort – environmental protection. Powertrain components and systems for passenger cars and light commercial vehicles, developed and delivered by ZF, meet the widespread challenges of the highly complex interface between engine and transmission. The demands placed on suppliers in the automotive sec- Dual wet clutch with a consequent reduction in fuel consumption. In the tor are changing dramatically. Increasingly, suppliers are chart on page 7, the central performance data of the being called upon to integrate components into complex The Dual Clutch Transmission System has two clutches new converter generation of turbine-torsional damper systems – a development task that can only succeed on at its disposal. The advantage here is that two gears (TTD) and twin-torsional damper (TwinTD) are presented. the basis of close partnerships with vehicle manufactur- can be engaged at the same time. One of the clutch- ers. The future will bring continued demands for reduced es serves the odd-numbered gears, and the other the fuel consumption, emissions, weight and installation even-numbered ones. The complete shift process takes Hydrodynamically space, along with enhanced comfort, safety, and driving a few hundredths of a second – without interruption of cooled clutch – HCC® dynamics. To meet these goals, innovative solutions and traction. In combination with a torsional damper a sig- new products are essential. nificantly reduced fuel consumption is reached as well The hydrodynamically cooled clutch (HCC®) is a newly as better characteristics in driving comfort. A dual clutch developed start-up element. This clutch is designed ZF has taken responsibility here, demonstrating exper- system can be used in all passenger cars, especially for use in strongly motorized vehicles with stepped tise in generating comprehensive solutions with its inte- high-performance vehicles. automatic transmissions or CVTs. The low mass iner- grated powertrain systems. In doing so, it consistently tia torque and the compact design make the HCC® an pursues a systems approach in developing and manufac- ideal startup element – not merely for sportive uses, but turing new products and technologies that represent real Torque converter also for vehicles with a distinct start-up deficiency (due advances. ZF provides overall solutions that meet the to i.e. turbo lag). The shifting of gears in an automatic demands of overall systems. The new generation of torque converters of ZF for transmission equipped with HCC® can be performed One example: As a powertrain specialist and manu- automatic transmissions in passenger cars features just as rapidly as in dual clutch transmissions. The HCC® facturer of electric drives, ZF can also provide superior numerous new developments that ensure superior converts a conventional stepped automatic transmission integration for the full spectrum of hybrid powertrain driving comfort, high driving dynamics, and a significant to a sportive transmission. designs and thus offer production-ready solutions that reduction in fuel consumption. One example: The tor- are already reducing fuel consumption and emissions sional damping system minimizes torsional vibrations for the vehicles of tomorrow. to such an extent that early shift points are possible, 4 5 Dual clutch system – Designs of the dual wet clutch Power range Diameter Mass Inertia Engine/Drive Powerful shifting [Nm] [mm] [kg] [kgm²] arrangement Front drive ND2015 250 11.7 0.0579 Rear drive Front drive The task The technology ND2216 270 13.0 0.0820 Rear drive Development work on the driveline aims to enhance The dual clutch system consists of two separate clutches, power transmission and to reduce energy loss as much which allow two gears to be engaged at the same time. 200 400 600 800 1000 as possible. Important criteria include lower fuel con- One of the gears is transferring torque, while the next is sumption combined with improved comfort and driving already pre-selected. The entire shift process takes only dynamics. The Dual Clutch Transmission System is an a few hundredths of a second, without any interruption excellent solution to accomplish all of the above. Two of torque and with minimal loss of power. A specially System design interlocking transmission shafts, each linked to a sepa- developed electronic control unit regulates the dual clutch rate clutch, allow for powershifting without torque system and the transmission actuation. It monitors all interruption. The central module in this transmission relevant parameters such as speed, rpm and transmission Outer clutch is the dual clutch from ZF. ratios, and adjusts shifting depending on the driving situ- The outer clutch is used as ation. Dual clutch systems from ZF combine the comfort a starting and shift clutch. of an automatic transmission with the sporty handling of Inner clutch Torque is transmitted to the a manual transmission. The result is a faster, smoother The inner clutch serves as inner input shaft. acceleration and superb shifting dynamics. A dual clutch a shift clutch and transmits system can be used in all passenger cars, especially torques onto the outer input high-performance vehicles. shaft (hollow shaft). Hollow shaft For even-numbered gears and reverse (optional). Inner input shaft For odd-numbered gears and reverse. Benefits • Torque ranges from 350 to 750 Nm, peak torque of up to 1,000 Nm • Very high thermal resistance • Smaller space claim • High speed stability • Low friction torque • Outstanding driving dynamics • Reduced fuel consumption Comparison of shift process 1st gear ation Ensure both: ultra-dynamic and economic eler cc driving! Dual clutches have shorter shift times Dual clutch than standard clutches. The shift strategy in hicle a Ve dual clutches is variable from extremely sporty 2nd gear to very comfortable within a range of 100 ms to 300 ms. In dual clutches, there are no 100...300 ms losses in driving performance during shifts as Conventional they occur in standard clutches. This makes clutch the entire powertrain more efficient. Dual wet clutch with dual mass flywheel (DMF) up to 2,000 ms Time 6 7 Torque converter – More comfort Designs of the torque converter Power range Diameter Mass Inertia Engine/Drive and less fuel consumption [Nm] [mm] [kg] [kgm²] arrangement 13.8 0.1186 Front drive NW235 TTD II 235 15.3 0.1310 All-wheel drive 16.2 0.1590 Front drive The task the new twin-torsional damper TwinTD can be applied NW250 TTD II 250 17.6 0.1689 All-wheel drive very early on, which improves driving comfort especially Hydrodynamic torque converters are used in modern at low engine speeds. This feature of the new twin- 17.4 0.1843 Front drive NW270 TTD II 270 passenger cars with automatic transmissions – both torsional damper also significantly reduces fuel con- 18.8 0.1938 All-wheel drive stepped and continuous. They eliminate wear when the sumption. vehicle starts up, and ensure superb driving comfort. NW235 ZDW II 235 15.5 0.1471 Front drive Together with a lock-up clutch and a torsional damper A further optimization of the system was achieved 18.0 0.2005 Front drive system adapted to the individual powertrain, they im- through an intelligent modular design of the lock-up NW250 ZDW II 250 prove both driving dynamics and fuel consumption. The clutches. It allows for 2, 4, or 6 friction surfaces with 19.3 0.2079 All-wheel drive new generation of torque converters from ZF represents hydraulic circuit diameters of 235, 250, or 270 mm, the ideal solution for modern automatic transmissions. which makes it easy to adapt the system to individual 200 400 600 800 1000 customer needs. In addition, more effective cooling of the lockup clutch, which ensures lower wear and higher The technology heat losses, is achieved by implementing a three-path system for these new generation torque converters. Torque converters from ZF feature superior performance Despite the considerably enhanced performance den- System design density for torsional dampers and hydrodynamic circuits sity, the system requires less installation space. Very as well as adaptable lock-up clutches and variable short high-performance axial solutions are available for damping systems. Compared to conventional converters, applications with extremely limited installation space. Torque converter the lock-up clutch of a torque converter equipped with The converter as a hydrody- Lock-up clutch namic start-up element with The controlled lock-up clutch pump, turbine, and stator. transitions the torque; it can The in size reduced round be adapted to fit individual torus reduces installation powertrain designs. space while displaying Benefits excellent efficiency. • Higher efficiency • High hydrodynamic performance density Torsional dampers • Lower inertia The integrated torsional • OEM-specific lock-up clutches dampers enable excellent • High efficiency for start-up and shift operations driving comfort, reduce • Torsional damper systems reduce fuel consumption fuel consumption, and last but not least, protect the transmission. Comparison of vibrational damping ²] 6 % /s Compared with conventional torque convert- tion [1 Conventional Superior comfort for high-end cars and good for the ra ers, the new twin-torsional torque converter le torsional damper environment as well. In fact, the newly developed torque ce significantly reduces engine irregularities, converter from ZF benefits the environment in two ways:
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