International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Future Development Targets for manual TransmissionsInternational VDI-Congress 2013 – Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie K
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Agenda
▪ Global market trends for manual transmissions
▪ Market specific customer requirements
▪ Impact on transmission engineering process
▪ Requirements Engineering
▪ Design cost optimization
▪ Functional integration
▪ Optimization of transmission attributes
▪ Efficiency improvement by passive oil management
▪ Weight reduction by structural optimization
▪ Weight reduction by new materials
▪ Weight reduction by new manufacturing processes
▪ Additional Customer Functions – Clutch-by-Wire
▪ Summary
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Agenda
▪ Global market trends for manual transmissions
▪ Market specific customer requirements
▪ Impact on transmission engineering process
▪ Requirements Engineering
▪ Design cost optimization
▪ Functional integration
▪ Optimization of transmission attributes
▪ Efficiency improvement by passive oil management
▪ Weight reduction by structural optimization
▪ Weight reduction by new materials
▪ Weight reduction by new manufacturing processes
▪ Additional Customer Functions – Clutch-by-Wire
▪ Summary
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Global Market Trends for manual Transmissions
▪ Market share for manual transmission is expected to be stable
▪ Global volume of manual transmissions is growing within this decade
Source: IHS Automotive March 2013
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Global Market Trends – Regional Development for Europe (excl. Russia)
Characteristics of European market:
▪ Slightly market growth expected
▪ Manual transmission share becoming lower
▪ Major volumes below 300 Nm engine torque
▪ Permanent refinement of vehicle attributes
2013
2020
Vehicle Production – Engine Torques MT
HVAN = VAN > 3.5t
16.9 mn
units
20.5 mn
units
Source: IHS Automotive March 2013
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Global Market Trends – Regional Development for China
Characteristics of Chinese market:
▪ Significant market growth expected
▪ Manual transmission share becoming smaller
▪ Major volumes below 250 Nm engine torque
▪ Focus on product costs
HVAN = VAN > 3.5t
2013
2020
20.4 mn
units
30.7 mn
units
Source: IHS Automotive March 2013
Vehicle Production – Engine Torques MT
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Global Market Trends – Regional Development for BRI (BRIC excl. China)
Characteristics of BRI market:
▪ Significant market growth expected
▪ Manual transmission share remains stable
▪ Major volumes below 200 Nm engine torque
▪ Focus on product costs9.5 mn
units
15.0 mn
units
2013
2020
HVAN = VAN > 3.5t
Source: IHS Automotive March 2013
Vehicle Production – Engine Torques MT
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Book Ends of Manual Transmission Engineering based on Global Market Requirements
Characteristics:
▪ Low engine torque
▪ Base technical attributes required
▪ Minimized design costs
▪ Consider market specific duty cycles and driving conditions
▪ Platform product for several customer
▪ Local supply base
Mature MarketsEmerging Markets
Characteristics:
▪ Full range of engine torque
▪ Sophisticated technical attributes required due to further refinement of vehicles
- Weight
- Efficiency
▪ Optimized design costs
▪ Well known duty cycles and driving conditions
▪ Customer specific product
▪ Global supply base
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Agenda
▪ Global market trends for manual transmissions
▪ Market specific customer requirements
▪ Impact on transmission engineering process
▪ Requirements Engineering
▪ Design cost optimization
▪ Functional integration
▪ Optimization of transmission attributes
▪ Efficiency improvement by passive oil management
▪ Weight reduction by structural optimization
▪ Weight reduction by new materials
▪ Weight reduction by new manufacturing processes
▪ Additional Customer Functions – Clutch-by-Wire
▪ Summary
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Road Load Data – Basic Input for Transmission Design Requirements
Vehicle Measurements
Dynamic Vehicle Simulations
Market specific customer profiles
To
rqu
e
Time
TorqueTorque level
counting (RAL)
Revolutions
Market specific load profiles
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Simultaneous Engineeringthrough complete supply chain
Key Success Factor Simultaneous Engineering
Target Costing
Modularity Functional integration
Functional optimization
Avoid overengineering
Standardization
Robust manufacturing
processes
Optimized Assembly
TransmissionRequirements, functions,
components, modules
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Functional Integration leads to
▪ Significantly reduced number of parts
▪ Simplified assembly process
▪ Supply chain complexity reduced
but
▪ Complex design with addedfunctionality
▪ Need for cross functionalapproach
▪ Close communication withmanufacturing engineeringand suppliers
Parts with
modified
function
Example:
23 parts removed from bill of material of
successor transmission
Cost Optimization by functional Integration
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Agenda
▪ Global market trends for manual transmissions
▪ Market specific customer requirements
▪ Impact on transmission engineering process
▪ Requirements Engineering
▪ Design cost optimization
▪ Functional integration
▪ Optimization of transmission attributes
▪ Efficiency improvement by passive oil management
▪ Weight reduction by structural optimization
▪ Weight reduction by new materials
▪ Weight reduction by new manufacturing processes
▪ Additional Customer Functions – Clutch-by-Wire
▪ Summary
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Efficiency Improvement by passive Oil Management (1/2)
Initial situation:Churning losses are major contributor to transmission losses
Challenges:
� Reduce immersion depth of gear set
� Secure lubrication in each driving condition
� Limitation of power consumptionunder high-speed conditions
� Control complexity andon-cost of oil management system
Gears 0,88 %
Bearings 0,88 %
Seals 0,29 %
Synchros 0,15 %
Trans-mission3,24 %����
0,22
l/100km
Vehicle
96,76 %
Churning losses
1,03 %
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Efficiency Improvement by passive Oil Management (2/2)
Hardware TestsSimulation / CFD
▪ Design solution
▪ Results of drag torque rig test
▪ CFD Analysis of base MT
▪ Optimization with oil shield
oil shield
2.000 1/min
Legend:
red: with oil
blue: with oil and oil shield
green: dry
50
%
10
0 %Operating conditions:
- 6th gear engaged- Input speed 2.000 1/min
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Weight Reduction – Structural Optimization of Output Flange
Weight reduction potenzial [%]
Initial situation:
▪ Running mass production and stable processes
Challenges:
▪ Weight reduction by optimizing raw part geometry
▪ Cross functional collaboration with supplier under consideration of forging process capability
▪ Functional development of geometry to optimize stiffness and eigenfrequencyof powertrain
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Current status @ GETRAG for a typical FWD MT:
▪ Aluminum die cast shift forks withsteel inserts
Under development:
1. Magnesium shift forks with steel inserts
2. Glass fibre reinforced plastic shift forks
− with steel inserts (plastic compound)
− without steel inserts (pure plastic)
Challenges:
▪ Limitation of peak loads
▪ Temperature profile of MT
▪ Keep cost under control
Weight Reduction – new Material for Shift Forks
Weight reduction potenzial [%]
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Initial situation:
Potential for weight reduction of layshaftlimited, due to
▪ Root diameter of direct cutted gears
▪ Stress at press fits
Challenges:
▪ Development of a combined extrusion and rotary swaging process
▪ Ensure process stability under all conditions (e.g. quench distortion)
▪ Keep cost under control
Weight Reduction – hollow Layshaft for inline MTs
Weight reduction potenzial [%]
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Additional Customer Functions – Clutch-by-Wire
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Agenda
▪ Global market trends for manual transmissions
▪ Market specific customer requirements
▪ Impact on transmission engineering process
▪ Requirements Engineering
▪ Design cost optimization
▪ Functional integration
▪ Optimization of transmission attributes
▪ Efficiency improvement by passive oil management
▪ Weight reduction by structural optimization
▪ Weight reduction by new materials
▪ Weight reduction by new manufacturing processes
▪ Additional Customer Functions – Clutch-by-Wire
▪ Summary
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie KG
Summary
▪ Global market requirements are specific
▪ Emerging markets – cost driven
▪ Mature markets – attribute driven
� “One-size-fits-all” approach does not match to market needs
▪ State-of-the-art engineering processes are needed to develop required products
▪ Simultaneous engineering
▪ Requirements engineering
▪ Further optimization of components is the key for improving attributes
▪ Consequent usage of simulation
▪ Implementation of new materials into mass production
▪ Development of manufacturing processes
▪ MT has potential for additional customer functions, e.g. clutch-by-wire