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Automotive Transmissions Innovation in high technology The Oerlikon group is one of the most innovative industrial groups in the world and is active in various markets around the world: machine and plant engineering, solar technology, thin film coating, vacuum systems, textile machines, drive systems as well as semiconductors and nano technology. With over 16,000 employees, more than 150 sites in 36 countries, Oerlikon develops solutions for leading industry applications and future-oriented markets, striving to be the most reliable business partner, worldwide. Oerlikon innovations help increase the productivity, efficiency and resource optimization of its customers, enabling them to achieve an effective differentiation in the marketplace. Automotive Transmissions - 3 Overview Global Drive Systems Provider Oerlikon Graziano and Oerlikon Fairfield, under the Oerlikon Drive Systems segment, are the leading worldwide provider of complete drive systems, gearing solutions and single components for transmissions, with a product portfolio providing transmissions for highperformance cars, complete solutions for all-wheel-drive vehicles and agricultural tractors as well as Torque-Hub® planetary drives and gear components. Our know-how and capabilities allow us to lead the full deployment of a development program from conceptual and simulation phases to mass production, for complete mechatronic driveline systems as well as for single gearing components. With more than 80 years in the market of power transmission, Oerlikon Drive Systems is focused on Automotive, Off-Highway and Industrial key markets. Excellent manufacturing, engineering and innovative expertise have made us the market leader for high-tech transmission systems. The European leader in High Performance Automotive Applications Oerlikon Drive Systems is market leader in high performing transmissions. This is the key to the company’s future growth. The objectives are to present new ideas and new developments to our OEM customers which will enhance the overall performance of these cars. Cars with high performance demand the best in all components. Advanced transmission systems such as DCTs, AMTs, active torque distribution systems and innovative electric drives, require sophisticated control systems. We offer to the customers a full “turn-key” service, with full capabilities developed in these advanced solutions, in particular in the electronic and control area. Worldwide leader in Gearing Solutions Oerlikon Drive Systems is the world’s largest and global manufacturer of custom gears and shafts, especially for agricultural, off-highway, industrial and power generation market and is the world leader in the design, development and production of synchronisers and hydraulic clutches used within the agricultural and off-highway vehicle industry. The technology and technical excellence, together with flexibility and services offered to customers, make us a unique supplier in these markets. The global player in Off-Highway Systems Oerlikon Drive Systems is the preferred partner in co-design tests and in the manufacture of drive systems for specialized applications of the off-highway market, mainly in construction and mining, agriculture, off-shore marine and specialty industrial applications. The experience of our engineering and technical team is called upon to provide innovative design solutions and meet all our customers needs of today as well as of tomorrow. Automotive Transmissions - 4 Automotive Transmissions Innovation, technology and manufacturing excellence have been the drivers of Oerlikon Graziano, allowing Oerlikon Group to reach the position of European market leader in high technology gearbox systems and to consolidate the role of preferred partner for the deve- lopment and supply of all wheel drive cars assemblies. Market Area & Core Competencies In the automotive market, the company is best known for its six speed transaxles, which are standard fitment in the ultimate high performance cars, and for the Four Wheel Drive/perfor- mance Rear Wheel Drive cars sub-assemblies such as Power Transfer Units and Rear Differential Modules. Only the absolute best in product design, development and manufacture is the requirement of our customers in this market segment. Oerlikon Graziano transaxles are standard fitment in the cars produced by Aston Martin, Ferrari, Lamborghini, Maserati, Alfa Romeo, Audi and the most recently announced new cars to feature our transmission systems are the Aston Martin One-77 and Vantage S, the McLaren MP4-12C and the Lamborghini Aventador. In addition, in the last 20 years, Oerlikon Graziano has acquired an excellent experience in the Electric Drivelines Assemblies Product Line, ranging from the very first golf/utility transaxle to the latest transfer case developed for the light commercial electric vehicle, and including the latest applications of the ever more popular and fancy “full electric”, “zero emissions” city cars, the market of the future. Automotive Transmissions - 5 Research & Development Oerlikon Graziano R&D department has the competence to develop a wide range of drivelines including: • Gearboxes for sport vehicles • AWD assemblies • Transmission fro electric/hybrid vehicles • Construction Equipment & Agricultural Axles • City Bus Axles • Material Handling Transmissions & Axles • Agricultural Transmissions • Synchronizers assemblies • Power-shift clutches Oerlikon Graziano has internal capabilities to fully develop complex system including the “base transmission”: • Mechanical Design - FMEA - CAD - FEM - Dynamic modelling - Modal analysis • Prototype manufacturing with dedicated machines • Prototype assembly in controlled environment • Testing - Functional tests - Lubrication analysis on programmable tilting rig - Structural tests - Under load contact pattern - Synchronizer tests - NVH measurement - Climatic test with temperature profile from -40°C to 130°C … but also (thanks to the partnership with VOCIS) hydraulic and controls/calibration competences: • HAZOP/FMEA • System Modelling • Algorithm development • SIL / HIL development Automotive Transmissions - 6 • Low level software • Production quality code generation • Software V & V • System Integration • Calibration • OBD Oerlikon Graziano has now the competence to be a Tier 1 full system supplier for complex driveline systems. As a result in 2010 two programs among others started the production: the drivelines for McLaren MP4-12C and Lamborghini Aventador drivelines. In the cases above Oerlikon Graziano acts as Tier 1 supplier, responsible for the entire driveline system. The company is actively working on EC funded programs (e.g. Green Car Initiatives, with the AUTOSUPERCAP project) and prepared several papers presented in the most renowned congress and symposia (SAE, CTI, AVEC, IEEE). Oerlikon Graziano is member of GearLab (Ohio University), hence it has access to the up to date SW for gear analysis as well as regular contacts with the community of gear manufacturers. Active cooperation with Surrey University (UK) and University of Naples (Italy) are in place, and a sponsorship is granted to Uninauto Master, a post-degree master in vehicle engineering from University of Naples. Automotive Transmissions - 7 Products and Solutions Transaxles – Oerlikon Graziano is the world’s leading designer and producer of manual/ automated manual and dual clutch transmission systems for high performance cars. These are six and seven speeds units, designed for either front engine rear transaxle configurations, or mid-engine configurations, and are specifically tailored to the particular requirements of the individual car. Sub-assemblies – these are PTUs (power transfer units), RDAs (rear drive axles), and RDMs (rear drive modules), for AWD (all wheel drive) and RWD (Rear Wheel Drive) performance applications. Customers include FIAT, VW and GM with PTU applications, Alfa Romeo with AWD applications, Aston Martin DB9 automatic with an RDM, and Maserati Quattroporte and the new GranTurismo automatic, with an RDA. A special angle drive application is the final drive unit for the Triumph Rocket III motor bike. Transmission for Audi R8 Transmission for Aston Martin V8 Vantage S Automated Manual Transmission for Lamborghini Aventador Dual Clutch Transmission for McLaren MP4-12C Differential unit for Aston Martin DB9 and DBS Differential unit for Maserati GranTurismo and Quattroporte Front PTU for GM Global Epsilon Platform Rear final drive for Triumph Rocket III Automotive Transmissions - 8 VOCIS In the five years since it was formed, VOCIS, a company formed by a nucleus of highly experienced engineers has rapidly grown from 5 to 29 employees. The combination of Oerlikon Graziano’s expertise in the design and manufacturing of high performance transmissions, with Vocis’ unique talent in controls techniques - looked perfect. Both sides could see the advantages of a close connection, and shortly after forming, Oerlikon Graziano took a controlling interest in VOCIS. VOCIS specialises in Control & Hydraulic System Engineering and Programme Management for the automotive industry. The founders together with the other Technical Specialist at Vocis are widely experienced in delivering challenging and high value automotive programmes for a variety of high profile OE customers, Tier One Suppliers and Design Consultancies. More than 150 man years’ experience is held in all aspects of mechanical and software control for DCT, AMT, CVT, AT transmissions, EV / Hybrid drive systems and active torque management systems.
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