Browse Topic: Transaxles

Items (124)
Leakage of oil through breathers can be a serious concern in electric vehicle (EV) gearbox or transaxle units, especially due to the complexities presented by the small housing space and rotational components, which are running at relatively high speeds compared to conventional transmission units. Predicting the oil leakage from the transmission unit is another concern. Traditional methods are mostly centered on developing individual breather compartments, resulting in excess material usage, additional weight, and increased cost of manufacturing. To eliminate oil leakage through the air breather, the oil channelization technique used involves integrated oil deflection baffles, low-friction return channels, an oil accumulation cavity with cover, and strategically optimized airflow paths/vents. This design provides a number of benefits, such as increased gearbox reliability, minimized risk of component failure, and reduced maintenance needs, with all of these and a compact, cost-effective housing structure maintained. This paper presents a novel and compact way of oil channelization that has been created for the Electric vehicle powertrain housing and seeks to counter oil leakage, along with optimizing space, supported by simulation- based tools. In addition, the fluid simulation analysis was carried out and tested to develop a correlation with the real-life events. Using computational fluid dynamics (CFD) simulations and experimental validation with a prototyped transaxle housing, we demonstrate zero oil leakage in different running conditions with various grades and different speeds with varying oil quantity.
Ekshinge, Mahesh ShivajiAgrawal, DeveshPandey, Ankit KumarBhandari, Kiran Kamlakar
Improving transaxle efficiency is vital for enhancing the overall performance and energy economy of electric vehicles. This study presents a systematic approach to minimizing power losses in a single-speed, two-stage reduction e-transaxle (standalone) by implementing a series of component-level design optimizations. The investigation begins with the replacement of conventional transmission oil with a next-generation low-viscosity transmission fluid. By adopting a lower-viscosity lubricant, the internal fluid resistance is reduced, leading to lower churning losses and improved efficiency across a wide range of operating conditions. Following this, attention is directed toward refining the gear macro-geometry to create a gear set with reduced power losses. This involves adjustments to parameters such as module, helix angle, pressure angle, and tooth count, along with the introduction of a positive profile shift. These modifications improve the contact pattern, lower sliding friction, and achieve a more uniform distribution of forces along the gear flanks. As a result, load-related gear losses are significantly diminished. In the final stage of optimization, high-performance, low-friction bearing designs are incorporated to further reduce mechanical drag and enhance overall drivetrain efficiency. For bearing loss optimization strategies, energy-efficient ball bearing designs is examined and engineered to lower internal friction and increase operational lifespan. Energy Efficient bearing prove significant improvement in efficiency and further reducing mechanical losses within the drivetrain. Taken together, the findings highlight that careful selection of lubricants, refinement of gear geometry, and adoption of advanced bearing solutions can deliver notable gains in transaxle efficiency. These outcomes reinforce the potential of such targeted interventions as practical means for boosting drivetrain performance in electric vehicle applications.
Agrawal, DeveshBhardwaj, AbhishekBhandari, Kiran Kamlakar
The automotive industry is a crucial sector that plays a significant role globally. Government policies have a profound impact on this automotive industry in defining the regulatory standards and emission controls. Such regulations incentivized automakers to invest in research and development complying those standards towards reduction of vehicle emission which intern result in higher torsional vibrations and excitations amplitudes. To address the rising NVH related concerns in driveline system. Drive shafts (CV shafts) is an important component in power-train system in vehicle. Drive shaft’s main purpose to transfer torque from engines to wheels at multiple speeds with different articulation angles. The roughness generated by the engine follows a transfer path from engine to transaxle and transaxle to half shafts in monocoque vehicles which generates discomfort to the drivers whenever the vehicle is driven. The roughness can also be addressed by proper design of CV Shaft stiffness and tuning mass dampers. In this paper we focus on parametric changes on drive shaft torsional stiffness and tuned mass damper to address Engine roughness and driveline induced noise. Test measurement is done to measure baseline CV Shaft bending frequency without dampers. AMESIM 1D simulation model is developed to reproduce Bending frequency and mode shapes. Optimization for the convergence on stiffness and damper frequency is done. With the new stiffness shaft and tuned damper vehicle has improved on the noise pattern, magnitude of oscillations and shift in natural frequency.
M A, Abdul AzarrudinJayachandran, Suresh kumarKumar, ShivaniBhardwaj, KinshukM, DevamanalanKanagaraj, PothirajAhire, Manoj
The rapid evolution of battery electric vehicle (BEV) development has highlighted the need to develop BEVs that meet customer demands for both high-performance and space-efficiency. This paper explores the optimization opportunities available within the landscape of BEV powertrains, focusing on the power-dense potential of single-axis powertrain systems. The need to adhere to power density requirements to accommodate performance aspirations while simultaneously yielding more cabin or storage space to the customer creates a challenging problem for designers. With this pursuit, these competing interests must strike a harmonious balance to create the best experience for the customer. The subject of this study is an investigation into a leading competitor's powertrain that explores the potential optimization opportunities available within its already compact single-axis electric transmission. The methodology entails a reverse-engineered model of the geartrain, enabling an outsider’s assessment of the gear durability responses experienced by the actual system. An in-house optimization workflow is then leveraged that can explore the feasibility of further size reduction while upholding the standards exhibited by the existing system. Insights into the workflow process and software employed are presented while analysis of the optimization outputs is examined. In conclusion, the findings provide a glimpse into the ability for the BEV transaxle design process to consider optimization at earlier stages in development. This study aims to highlight the need for continuous improvement in design by addressing the feasibility of attaining a more compact yet resilient powertrain. By leveraging an intelligent optimization workflow, the paper determines whether a compact production powertrain yields any additional room for improvement. With current technological advancements allowing for engineers to simultaneously pursue many competing objectives such as efficiency, NVH, durability, size, and cost into unique workflows, designs that bring the best driving experience for our customers can be delivered.
Villarreal, Jaret
Toyota Motor Corporation has developed a new battery electric vehicle (BEV) on the dedicated e-TNGA platform for BEVs, which was designed to lower the center of gravity of the vehicle and increase body stiffness. In addition to a full-time 4WD system, another feature of this new BEV is its pleasurable driving experience. A new inverter drive unit was developed for this system. Unlike the previous inverter, the advantage of the new inverter is that it is small enough to be mounted inside the transaxle housing, thereby contributing to the availability of interior and luggage space. The temperature rise of the power semiconductors in the inverter was reduced considerably by the development of a new power semiconductor for BEVs. This enables a parallel layout of two power semiconductors instead of three. The components of the inverter were also downsized. A coreless current sensor was adopted, and capacitors were developed with significantly lower capacitance. The rear inverter adopts silicon carbide (SiC) power semiconductors, which significantly reduce energy loss compared to Si power semiconductors. This paper describes the technology developed for this new inverter unit.
Yuichi, ShimoKanzaki, TakaoYanagi, TakashiGoto, YukioKurihara, TakashiKobayashi, Masayoshi
It is necessary for us to reduce CO2 emissions in order to hold down global warming which is advancing year by year. Toyota Motor Corporation believes that not only the introduction of BEVs but also the sale of the hybrid vehicles must spread in order to achieve the necessary CO2 reduction. Therefore, we planned to improve the attractiveness of future hybrid vehicles. Prius has always made full use of hybrid technologies and leading to significant CO2 reduction. Toyota Motor Corporation has developed a 2.0L hybrid system for the new Prius. We built the system which could achieve a comfortable drive along following the customer’s intention while improving the fuel economy more than a conventional system. The engine improves on both output and thermal efficiency. The transaxle decreases mechanical loss by downsizing the differential, and adoption of low viscosity oil. The Power Control Unit (PCU) is downsized by using high frequency for boost conversion and decreases loss by the adoption of Reverse Conducting Insulated Gate Bipolar Transistor (RC-IGBT). In addition, we’ve downsized the battery along with increasing the output power by adopting a new Li-ion battery. We also increased the output power of the E-Four system. This improves turning performance for dry road in addition to improving hill start performance. Moreover, we built in a drive force characteristic that adapts to the new acceleration pedal, therefore, following the customer’s intention.
Hirota, SatoshiKikuchi, TakajiKatanoda, Tomoya
To achieve carbon neutrality by reducing carbon dioxide (CO2) emissions, vehicles with an internal combustion engine have started to be replaced by electrification vehicles such as hybrid electric vehicles (HEVs), plug-in HEVs (PHEVs), and battery EVs (BEVs) worldwide, which have motors in their transaxles (T/As). Reducing transmission torque loss in the transaxles is effective to reduce CO2 emissions, and lowering the viscosity of lubrication fluids in T/As is a promising method for reducing churning and drag loss. However, lowering viscosity generally leads to thin oil films and makes the lubrication condition severe, resulting in worse anti-fatigue and anti-seizure performance. To deal with these issues, we made improvements on the additive formulation of fluid, such as the addition of an oil-film-forming polymer, chemical structure change of calcium detergents, and an increase of anti-wear additives including phosphorus and sulfur. As a result, we succeeded in developing a novel fluid with greater lubricity than a conventional automatic transmission fluid (ATF), despite the fact that the viscosity of the new fluid was lowered by around 50% compared with that of the ATF. In addition, the electrical insulating and anti-foaming performance of this fluid, which are required for T/A fluid in electrification vehicles, were equal to or greater than those of the ATF. The fuel economy in the Toyota Hybrid System (THS) was improved by 1.0% and more compared with the ATF because of the significant viscosity decrease in the developed fluid. This fluid will be widely used for HEVs, PHEVs, BEVs, and fuel cell electric vehicles (FCEVs) and can contribute to the realization of a carbon-neutral society.
Tada, AkiraAizawa, KoukiSusukida, YoheiTokozakura, DaisukeNakamura, TaikiSano, ToshinariShinyoshi, Takatoshi
Oil seal leakage is one of the major failure mode in gearbox / transaxle. Oil seal failures can be due to various reasons like high temperature, insufficient lubrication, failure due to external environment, incorrect fitment etc. Major reason for oil seal failure is insufficient oil flow inside gearbox when vehicle is running on gradient for long duration. When vehicle is running in hilly region, transmission will get incline leading to oil deficiency at one half of the transmission. Oil seal in this location will not get sufficient lubrication and will run dry. Also, there will be rise in local temperature at seal lip to shaft interface leading to failure of oil seal lip. Subsequently, oil leakage from transmission will start from this location when vehicle is running in different terrain. Due to continuous seepage, oil quantity in the transmission will get reduced and may lead to gear failure or seizure of bearing. Some OEM use transmission with transparent housing for lubrication study to get vital information on sufficiency of lubrication at critical parts at different inclinations of transmission (simulating driving of vehicle in different terrain). Such study does not provide clear idea about endurance life of oil seals and other parts under certain extreme / critical driving conditions. This paper discusses the test schedule & methodology developed to simulate oil flow inside gearbox as per real world driving scenarios on test bench and to evaluate endurance life of oil seal under such conditions. To develop the test procedure rigorous road load data need to be done at vehicle level. During this vehicle need to be driven in various road mix conditions like mines, rough road, hilly terrain in forward and reverse gear for few hundred kilometers and vehicle level and powertrain level data is recorded with help of commercially available sensors and data loggers. Test procedure need to be derived after data analysis to have test schedule for simulating real world condition on test bench. Process briefed in this paper will help to reduce development time & cost.
Uttamani, RahulTendulkar, VishveshvarNavale, PradeepKumar, Ravibhavikatti, Gururaj
Recently, electric-powered vehicle such as HV, PHV, EV and FCV has been highly demanded and getting attention due to the increase of environmental-consciousness. Also, environmental regulations are getting more and more strict in many countries and regions. Then, environmental friendly vehicle is needed to be spread more and more than ever. As it is found in “TOYOTA Environmental challenge 2050”, Toyota will rapidly increase the number of new car sales of electric-powered vehicle towards 2050. This paper covers the rear wheel drive Q710 electric drive transaxle for 2nd generation MIRAI FCV. Toyota developed the transaxle for FCV (rear mounted) and for EV (front mounted) simultaneously and achieved coexistence of vehicle mountability and commonization of majority of the parts. This paper describes the hardware feature and the detailed technology which was adopted to Q710. In the 2nd generation MIRAI, the transaxle is mounted under rear floor and contributed to the improvement of drivability by rear wheel drive. In addition, two air-cooled oil cooler are placed in parallel behind transaxle for motor cooling. Based on the adoption of world’s first “differential pressure wind guide oil cooler”, Toyota succeeded in motor cooling by the air-cooled oil cooler which is placed to rear.
NAKAMURA, KOICHI
Toyota has developed a new Hybrid (HV) transaxle P810 for Mid-Size SUVs to improve fuel efficiency and power performance. The transaxle was developed based on Toyota's new development strategy - Toyota New Global Architecture (TNGA). By adopting technologies to shorten overall length of the transaxle, installation into the same engine compartment of Mid-Size sedans have been realized while also improving the motor output. This paper will introduce technologies regarding the new mount structure for shortening overall length, and furthermore, noise reduction related to this mount structure.
Nobuyasu, SeitaroIwata, ShigetsuguNishigaya, MasabumiHagino, YoshiteruIto, MasatoshiAihara, Hiroshi
This paper presents about new concept developed on 7 speed DCT transaxle for transverse application and a torque capacity of 200 Nm to 360 Nm. How current 6 speed DCT can modified to 7 speed with packaging benefit is discussed. In this paper, discussions are focused about torque carrying parts of transaxle only. Here only single countershaft is used giving lot of packaging advantage and at first glance layout looks like four speed layout, but it is compact layout. Further in this paper effect of angular position of shaft in layout is discussed. Position of shafts in transaxle layout effects the stress, bending moment and displacement induced in shaft. Detailed study on effect of change in angle with respect to Bending moment, Stress in shaft, Cylindrical roller bearing (CRB) and Deep Groove Ball Bearing (DGBB) Bearing reaction force analysis, life calculations are computed.
Bhat, Muralidhar
To polish the 2020 mid-engine Corvette's driving prowess, GM and Tremec engineers joined forces to create a new and better automated transaxle. Explaining Corvette's move to one transmission for all buyers, global chief engineer Tadge Juechter notes, “Our customers began requesting a dual-clutch automatic transmission [DCT] several years ago. Following the introduction of the C7 Corvette in 2014, our take-rate for sticks [manual gearboxes] fell from 50 percent to less than 20 percent this year.” Searching the globe - read Europe - for a suitable DCT, Juechter's team found none with sufficient torque capacity to survive behind the lively LT2 6.2-L V8 planned for the all-new 2020 mid-engine edition of GM's reimagined sports car. To solve that dilemma, discussions began with Tremec, the Mexico City-based manufacturer which has supplied GM, Ford and FCA with manual transmissions for two decades. While Tremec had the expertise to make the mechanical components packed inside a dual-clutch box, the automated half of the equation - mechatronic actuators to engage the clutches and shift the gears - was beyond their ken. Tremec filled that need in 2012 by purchasing Hoerbiger Drivetrain Mechatronics, a Belgium-based supplier of electronic dual-clutch actuators with a customer list including AMG-Mercedes, Ferrari and McLaren.
Sherman, Don
The following schematic diagrams reflect various methods of illustrating automotive transmission arrangements. These have been developed to facilitate a clear understanding of the functional interrelations of the gearing, clutches, hydrodynamic drive unit, and other transmission components. Two variations of transmission diagrams are used: in neutral (clutches not applied), and in gear. For illustrative purposes, some typical transmissions are shown.
Automatic Transmission and Transaxle Committee
Derivation of Test Schedule for Jerk Test on Manual Gearbox Using Road Load Data2019-26-03471/9/2019
Shock loads/Jerk is a major cause of gearbox failure which occurs during abusive driving condition. In passenger car torque spikes are experienced by the transmission during launch/sudden clutch release events on flat road or off-road. Whereas, in case of commercial vehicle torque spikes are generated while operation in mines and off-road application especially in tipper vehicles. Torque spikes experienced by the gearbox can lead to gear failure, gear slippage and structural failure of housing. Research has been done till now to improve the design of gearbox to address such failures. However, with increased focus on transmission downsizing and improved vehicle performance (by weight reduction and more powerful engine) it is necessary to have optimum design to meet transmission life. This paper discuss the test setup and methodology used to simulate the torque spikes on test bench. To develop the test procedure huge data was collected on commercial vehicles. Road load data was collected in various road mix conditions like mines, rough road, vehicle launch in 1st gear & Reverse gear on straight and gradient road for few hundred kilometers. During data collection gearbox output torque and gear position were recorded against time scale. After analyzing the vehicle data test procedure was derived and existing production & prototype transmissions were validated on test bench and vehicle to establish co-relation. With increased competition vehicle development time has reduced drastically in recent past. Bench test procedure discussed in this paper will help to reduce development time and cost. Process briefed in this paper can also be used for similar test specification for passenger car transmission (gearbox/transaxle).
Uttamani, RahulNavale, PradeepTendulkar, VishveshvarPatel, Hiral
Electrified powertrains will play a growing role in meeting global fuel consumption and CO2 requirements. In support of this, FCA US has developed its first dedicated hybrid transmission (the eFlite® transmission), used in the Chrysler Pacifica Hybrid. The Chrysler Pacifica is the industry’s first electrified minivan. [2] The new eFlite hybrid transmission architecture optimizes performance, fuel economy, mass, packaging and NVH. The transmission is an electrically variable FWD transaxle with an input split configuration and incorporates two electric motors, both capable of driving in EV mode. The lubrication and cooling system makes use of two pumps, one electrically operated and one mechanically driven. The Chrysler Pacifica has a 16kWh lithium ion battery and a 3.6-liter Pentastar® engine which offers total system power of 260 hp with 84 MPGe, 33 miles of all electric range and 566 miles total driving range. [2] This paper’s focus is on the eFlite transmission.
Pittel, MikeMartin, Dale
The new P710 hybrid transaxle for a mid-size 2.5-liter class vehicle was developed based on the Toyota New Global Architecture (TNGA) design philosophy to achieve a range of desired performance objects. A smaller and lighter transaxle with low mechanical loss was realized by incorporating a new gear train structure and a downsized motor. The noise of the P710 transaxle was also reduced by adopting a new damper structure.
Matsumura, MitsutakaShiozaki, KazuyaMori, Nobuhito
BorgWarner's modular strategy provides OEMs optimal electrified-driveline flexibility. Five years ago, few predicted the high level of technology fragmentation in powertrains, drivelines and fuels that exists in 2017. Nearly everyone now agrees, however, that hybridization of all types is essential to meeting the latest European, North American and Asian emissions regulations-and to connect to the long-term full-electric future. Whenever that comes. “We see it as a ‘spectrum of electrification’ from stop-start systems all the way to pure EV-and everything's in play,” observed John Barlage, Director of Product Strategy, of BorgWarner PowerDrive Systems. Like other Tier 1 powertrain systems planners, he sees “very large volumes” of 48V hybrid applications coming in the next (2019-2021) production cycle.
Brooke, Lindsay
The following listed definitions are intended to establish terminology and criteria for describing the various kinds of automotive transmissions. A specific arrangement may be described by a combination of several of these definitions.
Automatic Transmission and Transaxle Committee
To help respond to growing customer demand for environmentally friendly vehicles, a new transaxle for plug-in hybrid vehicles (PHVs) has been developed that achieves excellent fuel economy and ensures high performance when the PHV operates in electric vehicle (EV) mode. Under the basic concept of sharing a large number of parts with the transaxle in the all new Prius, the newly designed PHV transaxle was developed with the aim of enhancing EV power and range. To achieve our goal, the new transaxle uses a Dual Motor Drive System that operates the generator as a motor to supplement the existing motor. It also features an electrical oil pump (EOP) that improves cooling performance in EV mode. The developed transaxle helps to advance the PHV as a key next-generation environmentally friendly vehicle by maximizing the performance of the Toyota Hybrid System (THS) and achieving even better dynamic EV mode performance than the new Prius HV.
Suzuki, YosukeNishimine, AkikoBaba, ShinichiMiyasaka, KenjiTsuchida, MichitakaEndo, HiroatsuYamamura, NorihiroMiyazaki, Tomoyuki
The scope and purpose of this SAE Recommended Practice is to provide a standard pattern or sequence for the manual control of automatic transmissions in passenger cars and light-duty trucks. This generally refers to left hand drive mechanical shift applications.
Automatic Transmission and Transaxle Committee
The reduction of CO2 emissions at vehicle level through the improvement of transmission efficiency represents the essential goal of transmission development engineers. New requirements, such as the recovery of the kinetic energy of the vehicle while coasting, the hybridization of drivetrains and autonomous driving, are challenges that can best be overcome with automatic transmissions. Dual clutch transmissions (DCT) with power-on-demand actuation systems offer a particularly efficient method of meeting the new requirements. However, many markets show vehicle applications with production volumes of less than 100.000 units per year. FEV’s new DCT family is conceived especially for customers in these markets. The re-use of proven subsystems which are already in series production results in a "business case" for applications with lower volumes also. This article introduces this transmission family.
Steinberg, IngoFreiholtz, DanHellenbroich, Gereon
To provide a Recommended Practice for validating the function and integrity of an automatic transmission park mechanism with its associated control system and environment.
Automatic Transmission and Transaxle Committee
GM has developed an all-new gasoline-electric hybrid powertrain for the model year 2016 Chevrolet Malibu Hybrid vehicle, which was designed to achieve excellent fuel economy, performance, and drive quality. The powertrain shares the transmission architecture with the 2016 Chevrolet Volt extended range electric vehicle, but includes changes to optimize the system for engine driven charge sustaining operation in the range of conditions represented by the US EPA 5 cycle fuel economy tests. In this paper, we describe the Malibu Hybrid propulsion system features and components, including the battery pack, transaxle, electric motors and power electronics, engine, and thermal system. The modifications between the Volt and Malibu Hybrid propulsion systems are discussed and explained as resulting from the differences between the primarily electric and gasoline powered applications. Additionally, operation of the propulsion system under nominal and cold fuel economy driving conditions is explained, and we present and discuss the efficiency and performance benefits and results of the new propulsion system.
Conlon, BrendanBarth, MindyHua, CharlesLyons, CliffordNguy, DanPalardy, Margaret
1 As the demand for so-called eco-cars has been increasing recently, new hybrid transaxle P610 has been developed to achieve outstanding fuel economy and an excellent driving performance. P610 was installed in the 4th generation Prius, the first car to implement TOYOTA's new development strategy, TNGA (Toyota New Global Architecture). In order to accomplish the goal, radical reduction of mechanical loss, size and weight, dual-axle motor structure are adopted to draw out the potential capability of the THS (Toyota Hybrid System) to the maximum extent possible. Furthermore, placing the compact power train low, which is realized by installed the PCU(Power Control Unit) on top of the transaxle, led to provide the low center of gravity of the vehicle and excellent driving performance.
Taniguchi, MakotoYashiro, TakahisaTakizawa, KeijiBaba, ShinichiTsuchida, MichitakaMizutani, TatsuhikoEndo, HiroatsuKimura, Hiromichi
Primary function of a drive half shaft is to transfer torque from transaxle to the wheels in East West configuration powertrain vehicles. Conventional practice is to consider either 1st gear max torque or the Wheel slip torque, whichever being the maximum as design torque. However vehicle dynamics and Powertrain characteristics have a major influence on the Driveshaft torque and the torques experienced can thus go beyond the design torque. This questions the design endurance limit for the driveshaft based on conventional design. One such situation is the torque experienced by the driveshaft during vehicle coasting condition with gear downshift. The torque experienced in such a scenario can go beyond the maximum design torque leading to failure as was observed in Vehicle level validation test. The paper mainly discusses about modelling such a scenario theoretically by a system approach to the vehicle test phenomenon and evaluating the torque pre-emptively to redefine the design torque strategy. Variables required for the calculation were identified and their values were determined using the engine and vehicle characteristics. Furthermore driveshaft torque measurement was done on the test vehicle with strained gauge shaft and telemetry to study the effect of variables and to refine the model based on measurement data. Finally a co-relation between the calculated torque values and measured torque was done to understand the level of accuracy.. Modifications were also done to the part and bench test was done to understand the level of improvement.
Darpkar, Kaushal KumarBidre, Anand
The extent of test conditions on the dynamometer must be sufficient to determine the efficiency characteristics corresponding to the following range of vehicle operations in all gear ratios with locked torque converters (open converter can also be done where appropriate and noted). a Efficiency versus output speed versus input torque b Torque ratio versus output speed c Input speed versus output speed d Output torque versus output speed e Parasitic loss versus input speed (spin losses) f Cooler flow g Output torque bias (front wheel drive transaxles)
Automatic Transmission and Transaxle Committee
The powersplit transaxle is a key subsystem of Ford Motor Company's hybrid electric vehicle line up. The powersplit transaxle consists of a planetary gear, four reduction gears and various types of bearings. During vehicle operation, the transaxle is continuously lubricated by a lube oil pump. All these components consume power to operate and they contribute to the total transaxle losses which ultimately influences energy usage and fuel economy. In order to enable further model-based development and optimization of the transaxle design relative to vehicle energy usage, it is essential to establish a physics-based transaxle model with losses distributed across components, including gears, bearings etc. In this work, such a model has been developed. The model accounts for individual bearing losses (speed, torque and temperature dependency), gear mesh losses, lube pump loss and oil churning loss. The losses are implemented as physics based equations as opposed to 2D or 3D table data, to enable smooth acausal simulation. Required bearing loss data are initially obtained from bearing suppliers. To aid the model development process, transaxle spin loss and torque loss tests were conducted. The test data was used to calculate unknown component loss information. The developed model was calibrated to match the transaxle test data. The model was also validated through comparison of dynamometer test data with vehicle level fuel economy simulations of the standard EPA City, Highway, US06 and FTP20 drive cycles and detailed energy analysis.
Samuel, KingslyBrigham, DavidJennings, Mark
The Chevrolet Volt is an electric vehicle (EV) with extended-range (ER) that is capable of operation on battery power alone, and on power generated by an on-board gasoline engine after depletion of the battery charge. For 2016, GM has developed the next generation of the Volt vehicle and “Voltec” propulsion system. Building on the experience of the first generation Volt, the second generation targeted improved all-electric range, improved charge sustaining fuel economy, and improved performance. All of this was to be accomplished while maintaining the EV character of the first generation Volt which customers clearly valued. This paper describes the next generation “Voltec” system and the realized improvements in efficiency and performance. The features of the propulsion system components, including energy storage, transaxle, electric motors and power electronics, on-board charging, and engine are described and compared with the previous generation. Next, the transaxle powerflow is discussed and operation under typical driving conditions is explained. Finally, system efficiency and performance data, based on component tests, is presented and compared with the previous generation. This system includes a battery pack with greater energy density, a new transaxle with integrated power electronics and motors, and an engine with optimized displacement, direct injection, and other advanced features. As a result of these improvements, the second generation Volt vehicle is projected to achieve a 30% increase in EV range, an 11% improvement in charge sustaining label fuel economy, and improved vehicle performance both as an electric vehicle, and in extended range mode.
Conlon, Brendan M.Blohm, TrevorHarpster, MichaelHolmes, AlanPalardy, MargaretTarnowsky, StevenZhou, Leon
This research developed a new measurement technology for thermal analysis of the heat radiation from a hybrid transaxle case surface to the air and improved the heat radiation performance. This heat flux measurement technology provides the method to measure heat flux without wiring of sensors. The method does not have effects of wiring on the temperature field and the flow field unlike the conventional methods. Therefore, multipoint measurement of heat flux on the case surface was enabled, and the distribution of heat flux was quantified. To measure heat flux, thermal resistances made of plastic plates were attached to the case surface and the infrared thermography was used for the temperature measurement. The preliminary examination was performed to confirm the accuracy of the thermal evaluation through heat flux measurement. The oil in the transaxle was heated and the amount of heat radiation from the case surface was measured. The input energy and heat radiation amount were compared. As a result, it was found that the measurement was accurate to be within about 13%. In addition, thermal analysis with conditions simulating an actual vehicle was performed. The surface temperature distribution and heat flux distribution were measured and results were obtained that reflected the effects of internal oil flow path layout and cooling air flow. Based on these results, locations with a large potential for improved heat radiation performance were identified and it became possible to effectively improve heat radiation performance by installing fins at those locations to enlarge the heat radiation surfaces.
Ozaki, YukikatsuSekiya, Keisuke
Finding space for an electric motor, battery, and all the controls that go with them while still providing sufficient 5-passenger cabin room and trunk/luggage capacity is a challenge. Space fiction has become part of some auto companies' description of hybrids. Finding space for an electric motor, battery, and all the controls that go with them while still providing sufficient 5-passenger cabin room and trunk/luggage capacity is not easy. And that means the hybrid versions of some sedans suffer in useful cargo space. But at Oerlikon Graziano, Claudio Torrelli, Head of Product Development, says far better packaging can be achieved. And to demonstrate it, the company recently fitted a Mercedes-Benz SLS AMG with its new OGeco transmission that integrates a 120-kW (161-hp) electric motor within the same space as a conventional transmission. The integration saw the electric motor installed deep in the gearbox and changing of the layout of the gearbox itself. The OGeco transmission is a 2-shaft configuration with one secondary shaft, whereas the dual-clutch (DCT) is a 3-shaft with two secondary shafts.
The General Motors (GM) 1ET35 drive unit is designed for an optimum combination of efficiency, performance, reliability, and cost as part of the propulsion system for the 2014 Chevrolet Spark Electric Vehicle (EV) [1]. The 1ET35 drive unit is a coaxial transaxle arrangement which includes a permanent-magnet (PM) electric motor and a low loss single-planetary transmission and is the sole source of propulsion for the battery-only electric vehicle (BEV) Spark. The 1ET35 is designed with experience gained from the first modern production BEV, the 1996 GM EV1. This paper describes the design optimization and development of the 1ET35 and its electric motor that will be made in the United States by GM. The high torque density electric motor design is based on high-energy permanent magnets that were originally developed by GM in connection with the EV1 and GM bar-wound stator technology introduced in the 2Mode Hybrid electric transmission, used in the Chevrolet Volt and in GM eAssist systems. The 1ET35 transaxle provides high power density and low system loss over a wide speed range, resulting in a class-leading combination of vehicle performance and vehicle range on a variety of global drive cycles.
Hawkins, ShawnHolmes, AlanAmes, DavidRahman, KhwajaMalone, Rodney
A new performance simulation capability has been developed for powersplit HEVs to enable analytical assessment of new engine technologies in the context of HEV system operation and to analyze/understand important system dynamics and control interactions affecting HEV performance. This new capability allows direct simulation with closed-loop controls and the driver, is compatible with Ford standard HEV system simulation capabilities and enables simulation with multiple levels of model fidelity and feature content across the vehicle system. The combined plant Vehicle Model Architecture (VMA) in Simulink was used for the infrastructure. The simulation capability includes a Dymola model of the powersplit transaxle, a Vehicle System Control (VSC) model implemented in Simulink, a high fidelity 2L Atkinson GT-Power engine model, and a simplified representation of the engine controls in Simulink. Also, the simulation capability interfaces to Ford standard vehicle data sets for HEVs through a Matlab interface. A GT-Power Fast Running Model (FRM) for the 2L Atkinson engine was also developed and used in the vehicle simulation in order to speed up the simulation time. The model results were validated with performance test data for the 2L Atkinson engine in a prototype Ford Fusion HEV.
Leach, SharonJennings, Mark
Interlock mechanism have found multiple uses in the shift system of a manual transmission. It can either be used to block every other rail from moving other then the active shifting rail or it can be used to bring all rails in neutral positions. As a designer the aim is to make systems more compact and efficient in its functionality. This desire to have a compact shift system results in the design of an interlock ball mechanism which allows the use of a single shift finger for two different rails. To validate this design a 5 speed manual transaxle was used, in which the 5th rail and the reverse rail are combined in a single shift finger. Between the rails a single 8mm interlock ball is used to transmit the shifting force to the rails from the shift finger. After a complete analysis of the profile for every degree of gradient the model was manufactured for testing on bench setup established for shifting tests. Various tests were performed and the system was tested and validated. Thus this system helps the designer to make the use of single shift finger for movement on two different rails without the use of a detent mechanism to centralize the rails. This system makes the shift mechanism cheaper, more compact and effective.
Singh, JaideepKunal, RohitVerma, AnkurDhane, Mangesh
The first commercially available Plug-In Hybrid Electric Vehicle (PHEV), the General Motors (GM) Volt, was introduced into the market in December 2010. The Volt's powertrain architecture provides four modes of operation, including two that are unique and maximize the Volt's efficiency and performance. The electric transaxle has been specially designed to enable patented operating modes both to improve the electric driving range when operating as a battery electric vehicle and to reduce fuel consumption when extending the range by operating with an internal combustion engine (ICE). However, details on the vehicle control strategy are not widely available because the supervisory control algorithm is proprietary. Since it is not possible to analyze the control without vehicle test data obtained from a well-designed Design-of-Experiment (DoE), a highly instrumented GM Volt, including thermal sensors, was tested at Argonne National Laboratory's Advanced Powertrain Research Facility (APRF). In this paper, we first describe the vehicle instrumentation and the test results. The vehicle control algorithm is analyzed from the test data and designed in Simulink. Finally, the Autonomie Volt component models and control strategy are validated, using APRF vehicle test data.
Kim, NamdooDuoba, MichaelKim, NamwookRousseau, Aymeric
Manual transmissions are characterized by gear ratios that are selectable by locking selected gear pairs to the output shaft inside the transmission. Top gear is selected to get a maximum speed and is limited by the engine power, speed and the fuel economy. Lower gears are selected to get maximum speed at maximum gradient. Lower gears are also expected to give creeping speed to avoid usage of clutch and brake in city traffic. Selection of intermediate gears is such that it provides a smoother gear shift. Gear spacing is done in geometric progression. Spacing between the higher gears is usually closer than in the lower gears because drivers shift more often between the lower gears. This is opposed to the conventional idea of progressive spacing where higher gears had more space between them. An objective method is provided for selecting gear ratios for use in vehicle transmission having multiple selectable gears. The method includes selecting gear ratios for a specific application followed by calculating a low gear ratio and a high gear ratio based upon vehicle parameters and performance requirements. The total ratio spread is determined by dividing the low gear ratio by the high gear ratio. Using the total ratio spread a geometric sequence is created with a plurality of terms, such that each of the terms respectively represents the ratio steps between the gears. Lastly, each gear ratio is divided by its respective ratio step plus one to find the gear ratio for the next gear. This method provides an objective method for selecting gear ratios, such that the steps between each of the ratios are uniformly progressive. Not only the procedure is generalized and validated but also a performance prediction tool is developed in house for quick validation and results. The theoretical gear ratio thus calculated was formulated and made using ROMAX as indicated in fig. 1. Thus, for a range of torques different gear boxes like 5 MT- 320Nm transmission, 6MT transmission, 6MT transaxle, 5MT-100Nm were tested. Performance prediction for vehicles with the designed gear ratios was rigorously done and required parameters were recorded and compared. An experience with the wide range of gear boxes with different number of gears and varying engine torques has proved that the above adopted method of gear selection is optimum and can be made a standard for gear selection. With this standard method of gear ratio selection the optimum gear ratio can be selected with ease and best results can be obtained.
Singh, JaideepSrinivasa, k.v.v. raoSingh, Jagmindar
This SAE Recommended Practice defines flywheel configuration to promote standardization of flywheels for engine flywheel mounted torque converters. Tables 1A and 1B and Figure 1 give dimensions for flywheels mounted-type torque converters. For torque converters using drive ring overcenter type disconnect clutch, see SAE J620.
Automatic Transmission and Transaxle Committee
Hybrid electric vehicle (HEV) systems offer significant improvements in vehicle fuel economy and reductions in vehicle generated greenhouse gas emissions. The widely accepted power-split HEV system configuration couples together an internal combustion engine with two electric machines (a motor and a generator) through a planetary gear set. This paper describes a methodology for analysis and optimization of alternative HEV power-split configurations defined by alternative connections between power sources and transaxle. The alternative configurations are identified by a matrix of kinematic equations for connected power sources. Based on the universal kinematic matrix, a generic method for automatically formulating dynamic models is developed. Screening and optimization of alternative configurations involves verification of a set of design requirements which reflect: vehicle continuous operation, e.g. grade test; and vehicle dynamic operation such as acceleration and drivability. Only the former are consider in this paper. The method automatically defines a design parameter space for each configuration which eventually would allow configuration evaluation and optimization, e.g. sizing of power sources or optimization of transaxle gear ratios.
Zaremba, Alexander T.Soto, CiroJennings, Mark
Recently, due to mounting concerns regarding the environment and energy conservation, demand for compact and hybrid vehicles with good fuel economy has been increasing. Toyota Motor Corporation has developed its first hybrid transaxle for installation in sub-compact class vehicles. This new hybrid transaxle is both smaller and lighter than the P410 hybrid transaxle for compact class vehicles, including the 2009 Prius. This was accomplished by creating new designs of the gear train, motor, and motor cooling system, and by adopting advanced technology. This paper describes the major features and performance of this transaxle in detail.
Furukawa, TomoakiIbaraki, RyujiKimura, HiroakiKondo, KoichiWatanabe, MasatoMizutani, TatsuhikoHattori, HiroyukiTakasaki, Akira
Newcomers to hybrid-vehicle development are bypassing the Prius-proven powersplit system for lower cost and moderately less capable single-motor solutions. What a difference a decade, give or take a couple years, has made in the size and breadth of the hybrid-electric vehicle segment. The original duel between the Toyota Prius and Honda's Insight has grown to include, in MY2012, nearly 40 models available in the U.S. and nearly 50 worldwide. And it's hard to find an OEM that doesn't have hybrids in its product portfolio. Not long ago, for example, HEVs were about as palatable as “lite” beer to many powertrain engineers at the German OEMs, whose belief in the diesel's superiority was unwavering. But new technologies are developed as mind-sets, regulations, and strategies change. Now, vehicle electrification is a product-development priority at BMW, Volkswagen Group, and Mercedes-Benz.
Brooke, Lindsay
AEI travels to Friedrichshafen for an exclusive look at the development and technology behind the 9HP-the industry's first nine-speed transaxle slated for MY2013 production. With its 9.84 ratio spread, clever controls, and compact packaging, ZF's new nine-speed automatic transaxle will offer OEMs capability to increase fuel economy in their front-wheel-drive vehicles by 10-16% at 75 mph (121 kph), based on the NEDC cycle, when the gearbox is launched for MY2013 production next year. Few new transmissions have caused as much buzz within the industry as the 9HP. ZF announced it at the 2011 Detroit auto show but provided almost no details of its inner workings. But this summer, ZF's top engineers gave a select group of media, including AEI, a look inside the 9HP and its development. The visit to the company's Friedrichshafen R&D center included a long test drive of three 9HP-equipped mules (see sidebar).
Brooke, Lindsay
It is anticipated that this SAE Recommended Practice will be only one step in a comprehensive evaluation of the vehicle/transmission application. This document alone is not adequate “due care” to insure against high-speed seizure or other high-speed problems. The notes printed in bold print throughout the practice convey important information about the test itself or the results and should be considered carefully. All references to transmissions also apply to transaxles, except for the unbalance evaluation which applies only to rear-wheel-drive transmissions with propeller shaft output.
SAE IC Powertrain Steering Committee
Because of the intense focus on CAFE and fuel emission standards, optimization of the automobile drivetrain is imperative. In light of this, component efficiencies have become an important factor in the drivetrain decision-making process. It has therefore become necessary to develop a universal standard to judge transmission efficiency. This SAE Recommended Practice specifies the dynamometer test procedure which maps a manual transmission’s efficiency. The document is separated into two parts. The first compares input and output torque throughout a specified input speed range in order to determine “in-gear” transmission efficiency. The second procedure measures parasitic losses experienced while in neutral at nominal idling speeds and also churning losses while in gear. The application of this document is intended for passenger car and light truck. All references to transmissions throughout this document include transaxles.
SAE IC Powertrain Steering Committee
The following system of symbols is recommended for use in technical papers and engineering reports dealing with hydrodynamic drives.
Automatic Transmission and Transaxle Committee
The Chevrolet Volt is an electric vehicle (EV) that operates exclusively on battery power as long as useful energy is available in the battery pack under normal conditions. After the battery is depleted of available energy, extended-range (ER) driving uses fuel energy in an internal combustion engine (ICE), an on-board generator, and a large electric driving motor. This extended-range electric vehicle (EREV) utilizes electric energy in an automobile more effectively than a plug-in hybrid electric vehicle (PHEV), which characteristically blends electric and engine power together during driving. A specialized EREV powertrain, called the "Voltec," drives the Volt through its entire range of speed and acceleration with battery power alone, within the limit of battery energy, thereby displacing more fuel with electricity, emitting less CO₂, and producing less cold-start emissions than a PHEV operating in real-world conditions. The Voltec powertrain architecture provides four modes of operation, including two that are unique and maximize the Volt's efficiency and performance. The specialized electric transaxle, known as the 4ET50, enables patented operating modes both to improve electric driving range when operating as a Battery Electric Vehicle (BEV) and to reduce fuel consumption when extending range by operating with the ICE. Historically, most EVs have used a single-speed electric transaxle with one motor and a fixed gear reduction. The single-speed gear reduction is a simple arrangement that takes advantage of the wide speed range of electric motors. While this arrangement can work well, the wide speed range of most electric motors comes at the price of a well-known loss of efficiency at higher motor speeds for most types of motors. Consequently, two-speed transmissions have been proposed for BEVs that can improve both tractive effort and efficiency although with the attendant additional extra gear shift hardware and controls. The Voltec 4ET50 multi-mode electric transaxle introduces a unique two-motor EV driving mode that allows both the driving motor and the generator to simultaneously provide tractive effort while reducing electric motor speeds and the total associated electric motor losses. This new operating mode, however, does not introduce the torque discontinuities associated with a two-speed EV drive. For ER operation, the Voltec transaxle uses the same hardware and controls that enable one-motor and two-motor EV operation to provide both the completely decoupled action of a pure series hybrid, as well as a more efficient powerflow with decoupled action for driving at light loads and high vehicle speed. Construction of the General Motors Company Voltec 4ET50 transaxle employs significant re-use of the General Motors Company front-wheel-drive Two-Mode Hybrid 2MT70 transaxle with modifications to enable all-speed and full-power EV operation. A new high power driving motor, optimized generator, and modified control elements allow the two EV driving modes and the two ER driving modes to be realized in the Chevrolet Volt.
Miller, Michael A.Holmes, Alan G.Conlon, Brendan M.Savagian, Peter J.
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