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VDI Wissensforum GmbH - Dritev – Drivetrain For Vehicles 2018

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VDI Wissensforum GmbH (ed.)

Dritev – Drivetrain For Vehicles 2018

Series: VDI-Berichte

Volume 2328 2018

Results in this title

C. Sibla, A. Donges, F. Jauch Third Generation of ZF’s 8-speed automatic transmission – Reducing CO2 emissions in the 8HP transmission

„… losses. If a larger gear ratio spread can also be applied with 8 gears, adding more gears does not offer …” „… . Market shares for the hybrid transmissions have been low thus far due to the additional weight, limited …” „… functional enhancements, such as in the shifting sequence or the transmission system – increases in the gear …”

T. Nishikawa, Tomoo Kubo The development of a low friction and low viscosity final drive oil

„… speed. Previously, we developed a synthetic F/D gear oil (SAE grade 75W-90) with lower viscosity for …” „… : F/D Torque loss ratio Fig. 2: Development strategy of differential gear oil in Nissan VDI-Berichte …” „… , we tried to reduce friction by Churning loss reduction (Lower viscosity) in Hydrodynamic lubrication …”

G. Bednarek, K. Geratz, H. Chariou The all-new 8-speed AT for the Opel Grandland X

„… developed super low viscosity oil together with improved gear surface finishing and improved friction …” „… material reduce heat generation and accompanying losses. A chain driven off-axis low loss oil pump, dynamic …” „… [3], [4], [5], the spread and the gear ratios in the lower gears have been increased, see Fig. 3. The …”

R. Buchberger, O. Grieshofer, K. Puchner, R. Sereinig System optimization of electric drives in terms of lightweight design, acoustics and efficiency by means of modern transmission simulation methods

„… tasks related to NVH, efficiency and low weight: Gear macro geometry Selection of number of teeth …” „… is trying to use low loss bearings (deep groove ball bearings, low loss taper roller bearings …” „… losses are considered as they occur in a standard eDrive gearbox: Gears (mainly load dependent) acc …”

M. Bahne, U. Frey, G. Schlager Transmission technology contribution to CO2 roadmap – a benchmark

„… ), torsional dampers (SMF, DMF, pendulum damper), transmission design (hydraulic and mechanical losses, gear …” „… gears (DCT and AT), torque-converter and hydraulic losses (AT and CVT), and clamping forces for …” „… lower only at higher gears and low torque level. The 7DCT is primarily deployed in medium-torque …”

T. Smejkal, C. Wirth Innovative transmission topologies using the example of a P2-hybridtransmission for front-transverse applications

„… because of the synchronizers connecting the gears to the shafts and having less drag losses compared to …” „… closed, resulting in two open LSE, which produce drag losses (except for Gear 5, where LSE 6 is closed …” „… gears is split to more gear meshes and results in a high power density. Because of the relatively low …”

M. Roßhuber, G. Schromm, K. Kranz The new BMW automatic transmission – Challenges in development

„… long as die minimum dynamics requirement is met in the highest gear. Powerful engines (low volume …” „… , shorter transmission ratios were realized in the lower gears. An important enabler for further …” „… lower power input and less mechanical losses. The drag torques in the transmission were further …”

R. Stehr, A. Götz, M. Ciesek, S. Köpfler, M. Finsterbusch, R. Willeke Future Schaeffler CVT concepts with an innovative actuation system

„… that is 15 % lower in the overdrive range), and especially the lower force requirement for gear ratio …” „… work at low currents [10], with the loss in power increasing in proportion to the square of the …” „… largest percentage of power loss today and is therefore the most important factor for improving the …”

T. Högnäs, G. Beldie 48 volt torque vectoring electric rear drive module (eRDM) – Excellent driving dynamics with significant CO2 savings

„… mass and low efficiency and implicitly negative impact on fuel economy and CO2. The eRDM showcases the …” „… high current losses at a nominal 12V standard, which constrains the electrical power, torque available …” „… disadvantage of high mass and low efficiency and implicitly negative impact on fuel economy and CO2. The …”

D. Güth, J. Haupt, T. Gassmann Seamless-shift two-speed eAxle with torque vectoring

„… step ratio should be lower than approximately iP = 1.7. For running the gearbox in second gear with …” „… lower shock factors. The complete torque flow of the gearbox for first and second gear is finally shown …” „… Twinster system, the proposed eAxles represents a very efficient system with very low drag-losses and very …”

W. Guo, M. Jordan, X. Xu The application of fast and efficient clutch coordination control in a P2 hybrid automatic transmission

„… invariant. If a lower target gear is needed, the first shift can cancel directly and start the next shift …” „… . In the initial speed phase the clutch slip state begins to change. If a lower target gear is needed …” „… to an even lower one. For example, if the second target gear becomes gear 2 during a 5-4 downshift …”

M. Hofstetter, D. Lechleitner, M. Hirz, M. Gintzel, A. Schmidhofer Multi-objective gearbox design optimization for xEV-axle drives under consideration of package restrictions

„… speed-dependent gear- and bearing losses for the given load spectrum. The gear efficiency is calculated according …” „… minimize a) costs, b) losses, c) axial width of the gearbox, d) gear tip radius on the output shaft …” „… gearbox-internal design parameters. They affect gear ratio, configuration of gearwheels, outer shape of the gearbox …”

F. Mühlfeld, M. Hochrein, N. Schmidt-Winkel, J. Buhl Electrified automated manual transmission (eAMT) – Synergies by combining an electric drive with an automated transmission

„… . The combination of existing products for the eAMT system keeps the costs for system development low …” „… . In particular, the low adaptation costs for the automation of the manual transmission allows a …” „… electric axle drive is able to fill up the systemic traction torque loss of the automated manual gearbox …”

G. van Spijk, A. Klaassen, A. van der Leest, A. Brandsma, M. Tweehuysen CVT: dedicated to hybrid solutions – Setting the benchmark on all KPI’s

„… ’ configuration with minimal components and gears further explains the low system losses and high efficiency …” „… the upstream e-machine configurations (like P2), the total torque transfer, especially in low gear …” „… Vehicle speed is further increased by increase of sun gear speed (ICE) while keeping the variator in low …”

C. Ahn Churning oil path optimization process development – Application of moving particle simulation method to design process

„… Abstract As demand of transmission efficiency goes higher, churning oil path and loss optimization is …” „… done on different gear speed and temperature to decide adequate particle size and simulation …” „… coefficients. This made possible to (1) Development on time with optimized churning oil path and loss (2 …”

D. Evenschor, D, Dennin, P. Tenberge Automated design concept generation of automatic transmissions – Design concept generation based on results of transmission synthesis

„… . Finally, the characteristic gear set values (required packaging space, weight and losses) can be …” „… Konstruktionsentwurfes der Aufwand für die Auskonstruktion reduziert werden. Abstract Today’s demands for both, low …” „… fuel consumption and low vehicle emissions, requires innovative drivetrain concepts. In the field of …”

I. Andrasec, B. Jeitler AVL’s future hybrid X mode – A modular transmission family concept

„… transmission incorporates a Ravigneaux planetary gear set, a manipulating idler with two gear meshes, two …” „… clutches and two brakes in a central housing. With interchangeable modules of electric machines, gears and …” „… an associated gear train, an inverter, a battery, a control unit, a charger and the wiring between …”

A. Schmidt, H.-P. Fleischmann Enhancement of a dual clutch transmission kit – AUDI S tronic – Version for All-Wheel Drive, Increase of Torque and HV Electrification

„… production lines in the Kassel and Tianjin Volkswagen plants, with the lowest possible additional overhead …” „… plants, with the lowest possible additional overhead and complete output volume flexibility. The …” „… transmission structure. The benefits of this inline design are fewer components and losses, and reduced mass …”

A. Viehmann, R. König, S. Rinderknecht Investigation of gear shifts in a parallel-series hybrid powertrain with dog clutches in a demonstrator vehicle (two-drive-transmission with range-extender, DE-REX)

„… shifting time has no effect on the evaluation of this gear change. The low VDV of 0.089 m/s1.75, which is …” „… EM1 is ramped up again. Due to the lower gear ratio in the second gear, the EM1 torque is …” „… Investigation of Gear Shifts in a Parallel-Series Hybrid Powertrain with Dog Clutches in a …”

R. Savelsberg, P. Griefnow, G. Birmes, A. Sehr Advanced powertrain functions of 48 V hybrid vehicles – Efficient powertrains does not exclude driving pleasure

„… available for comparatively low additional costs, but also offers the lowest CO2 potential. On the other …” „… significant system costs. For this reason, 48 V systems with low additional costs and relatively high …” „… components directly via the 48 V power net, since losses during conversion from 48 V to 12 V and the higher …”

C. Schmahl, W. Hildebrandt, D. Reith The impact of efficiency enhanced drivetrain components on the energy consumption of electric and conventional vehicles

„… because of the lower load independent losses of the drive system, nevertheless all results are …” „… l petrol engine, 6 gears manual gearbox). A second variation is the vehicle provided with an …” „… the loss characteristics, originally introduced for internal combustion engines, assumes a linear …”

M. Werra, A. Ringleb, C. Sieg, F. Küçükay Thermal behavior of 48 V hybrid systems

„… PSM’s stator winding are sharply higher than in the ASM’s. On the other hand, the losses are lower for …” „… limits show the complexity of finding the best topology in terms of cost efficiency and lowest …” „… module and ultimately VDI-Berichte Nr. 2328, 2018530 lead to speed and torque. After this the gear …”

M. Mileti, H. Pflaum, K. Stahl TorqueLINE cone clutch: Thermo-mechanical stability of cone clutches for ATs

„… clutch in terms of shifting comfort with the low drag losses and high transmittable torques via form-fit …” „… multiple disc clutch with the low drag losses and high transmittable torques of a synchronizer. However …” „… number of gear ratios and total spread, in order to optimize the ICE operation regions. Nonetheless, an …”

B. Chamberlin, E. Gold HEV P2 module concepts for different transmission architectures clutch and e-motor options

„… . This off-axis architecture provides additional benefits such as an applicable gear ratio or the …” „… complexity, improves efficiency, and lowers the system cost. The only compromise with this solution is the …” „… loss of engine braking when combined with an AT, CVT, or others. However, this disadvantage can be …”

C. Danzer, T. Voigt, T. Günther, R. Tröger From fleet requirements to optimized Dedicated Hybrid Powertrains

„… topology and the powertrain structure, the low-end torque of the engine can be reduced due to the …” „… full load performance of ICE and EM the combination of the consumption map and the EM-loss map is …” „… operating at high loads for charging the battery with low specific fuel consumption values (BSFC) needs to …”

K. Bennewitz, A. Mann Powertrain electrification exemplified by the VW Golf

„… to a low-loss fixed/floating bearing arrangement. Overall, the acoustic characteristics of the …” „… low-voltage hybrid system “Engine Off Coasting” (German: “Freilauf Motor Aus”, FMA) to high-voltage electric …” „… association with former vehicle projects. On the one part, advanced low-voltage hybrid systems are developed …”

R. Bredtmann, M. Beck, O. Mühlfeld, K. Olesen, O. Shajarati Robust multi-chip power module for effective integration to automotive powertrains – Danfoss DCM™1000 meets future automotive requirements

„… ) Electric axles with integrated chassis components, differential gear, electric motor and traction inverter b …” „… ®”: Due to a full cover with copper foil on the chips’ top metal surface, resistive losses can be reduced …” „… because of the relative low Reynolds numbers. This is good from a pressure drop perspective but not so …”

W. van Harselaar, M. Brouwer, T. Hofman A generic transmission model for hybrid electric drives – Integration of the dynamic behavior of all conventional-, electric-, and hybrid-transmission mode types in a single model

„… gears, planetary gear sets (PGSs), clutches, and brakes. All components that can be used to build a …” „… : Electric machine EM 2 3: Wheels W 1 4: Gear pair GP n.l. 5: Planetary gear set PGS n.l. 6: Clutch C n.l …” „… provide power. Both the ICE and EM1 have a fixed gear ratio to the wheels and can provide power. For a …”

doi.org/10.51202/9783181023280

VDI Wissensforum GmbH - Dritev – Drivetrain for Vehicles 2020

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VDI Wissensforum GmbH (ed.)

Dritev – Drivetrain for Vehicles 2020

Series: VDI-Berichte

Volume 2373 2020

Results in this title

M. Deiml High speed electric drive system – A solution for the next generation E-cars

„… required. NO20 lamination and segmented magnets ensure low rotor losses and the low stator surface …” „… considerably lower switching losses than state-of-the art IGBT solutions. This allows to increase the …” „… lower axial meshing velocity. Air and oil trapped in the gear mesh will pump out at lower speeds which …”

K. Sakai, T. Kishimoto, T. Kobayashi, T. Maekawa, T. Shinohara, M. Ogawa Development of the new chain CVT for middle capacity

„… : Breakdown for transmission power loss (80km/h road load) 2.2 Dynamic Quality Improvement Reduction gear …” „… ‘Dynamic Quality’ also in terms of low cost, which has features of chain CVT like compactness, high torque …” „… rotational speed at high way by reducing overdrive ratio, furthermore, its power loss was reduced by 22 …”

D. Kieninger, J. Hemsen, G. Witham The highly integrated ModulED drive module – Holistic concept design

„… that three-stage helical gear transmissions are both heavier and create higher losses at low overall …” „… ) switches. The advantage of very low losses of the GaN switches comes with the drawback of reduced current …” „… concepts (e.g. SiC material for high-speed concepts) or optimization targets (high-speed for low loss …”

K. Kim New high efficiency CVT for middle class FWD vehicle

„… , which is able to reduce drive torque loss by maximum 9% in comparison to gear-type pump. It allowed an …” „… competiveness of efficiency, weight and overall length is the best in the same class CVT. The planetary gear …” „… been newly designed for the wider ratio span, fewer components, and shorter overall length, lower the …”

S. Demmerer Next generation electric drives

„… element to lower drag losses. e2Drive is ZF’s 2-speed approach to simultaneously enhance driving …” „… be an advantage. VDI-Berichte Nr. 2373, 202066 With a lower second gear ratio, top speed can be …” „… . Fig. 3: Higher first gear ratio and lower second gear ratio spreads the usage of an e-motor …”

T. Casper, G. Spengler, M. Bromberger The high-efficiency fully electric drivetrain of the new Porsche Taycan

„… (Fig. 12): Low-viscosity lubricating oil with optimized power loss for lubrication systems …” „… gear and bearing losses from the planetary gear set. Use of efficiency-optimized bearings (for …” „… excess oil is avoided to reduce splash losses and bearings, gear teeth and other lubrication points are …”

M. Saborío, O. Sarmiento, C. Böhm High efficiency electric transmission oil pump – Transmission hydraulic efficiency improvement through hybridization

„… , meaning also lower system losses. 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Reference design Big …” „… efficiency losses due to the gears are shown in light blue. 5. Finally, the dark green bars show the energy …” „… losses are brought down to 9 % and 11 % for both solutions, which is considerably lower as the reference …”

F. Brezger, A. Moser Investigation and potential analysis of shiftable form-locked one-way clutches for hybrid and electric vehicles

„… disengaged at higher gears. Although, friction clutches can be modified to have low drag tor- VDI-Berichte Nr …” „… clutch) is engaged, there are low parasitic losses in normal driving mode. One possible architecture …” „… friction brake and OWC of Low/Rev gear with MMCM If replacing Low/Rev clutch in an 8-speed AT of a …”

P. Lück, K. Bennewitz, J. Tousen, J. Peter The front-axle drive of the MEB – Volkswagen expands the e-drive portfolio

„… by its ability to handle short-term overloads, as well as by low losses when it is driven through …” „… characterized by its ability to handle short-term overloads, as well as by low losses when not being actively …” „… all-wheel drive vehicles. While low internal friction losses are important for both drives, the focus for …”

S. Worrall, J. Foulsham, I. Stone, T. Gassmann CeDrive – Electric drive technology for a new era – Advanced cooling and control of high-speed eDrive

„… to deliver more power and better cycle efficiency at lower cost. Volume forecast are indicating that …” „… , number of gears & transmission ratio - Motor type and layout, peak and nominal torque, max speed …” „… , helical gears, offset design VDI-Berichte Nr. 2373, 2020 35 A more detailed description of the DSD ePOP …”

P. Ramet Dedicated hybrid transmissions (DHT) by PUNCH Powerglide – Innovative concepts for optimized DHT in terms of efficiency, cost and packaging

„… electric and mechanical states using a limited number of gears and dog clutches to maximize efficiency …” „… items, further improvements in efficiency (reduction of losses) of the DHT is one of the key success …” „… solution with four mechanical gear states (ICE) and one electric gear state is sufficient to meet the …”

H. Gürbüz, S. Ott, A. Sutschet, J. Kern Highly efficient clutch system for multispeed BEV

„… the clutch. Due to the lower number of gears and higher transmission spread, the maximum differential …” „… relevant for drag losses is set as low as possible and active coupling of the discs is achieved. Newly …” „… influence on the system. The lower these variables can be kept, the lower the power loss and the resulting …”

L. Wittmann, M. Wein, M. Wolf Consistently quattro

„… characterised by a high overload capacity and low loss in no-current mode. This type of motor is therefore …” „… differential, which was soon complemented by the asymmetric-distribution crown gear differential. Having …” „… models. A bevel gear differential distributed the forces evenly between the front and rear axle. On …”

F. Völkel, M. Tietz, A. Schamin, S. Giehl Rolling into the future – Bearing solutions for electric mobility

„… difference between the bearing’s inner and outer rings Low frictional losses of the shunt ring (2 – 7 Ncm …” „… density to be increased while reducing costs at the same time. Using an electric axle with spur gear …” „… via the gear and/or a parking lock gear. A specific problem that additionally occurs on the rotor and …”

P. Tenberge, A. Alnahlaui E-drive and hybrid-drive with 2 high-speed E-motors and a 2-speed gearbox

„… 6 the driving and the driven elements as well as from the low hydrodynamic losses in the …” „… 14 speed and with minimal gear losses. This state corresponds to the dotted pink line in the Fig. 8 …” „… operate at very high speeds. Two of such motors can cooperate through a planetary gears system in a …”

C. Danzer, T. Voigt, A. Forell, M. Sens, E. Schreiterer, R. Kockisch, J. Müller, E. Schneider The systematic way to your sustainable powertrain platform – holistic and customizable – Systematical methods to investigate mobility scenarios of tomorrow

„… power flow in the first speed for a low mechanical effort and a short gear set with only 3 gear set …” „… , which helps to achieve better operating points of the e-motor and lowers the speed dependent losses …” „… primary energy is increased considerably by the relatively low efficiency of these power-to-gas/liquid …”

D. Schöneberger, S. Rinderknecht, D. Reitmeier, A. Mertens Development of a transmission control for an innovative high-speed powertrain using motor-related control – Simulative approach to develop an angular position controlled engagement of dog clutches in ...

„… using SIC semiconductors to achieve low losses at a switching frequency of 48 kHz. Both, power …” „… powertrain Speed2E and the hybrid powertrain DE-REX [2,3,4]. In these projects the gear engagement under …” „… could be achieved for gear changes with dog clutches with the aid of an angular position control. In …”

D. Vietze, M. Hein, K. Stahl Method for a cloud based remaining-service-life-prediction for vehicle-gearboxes based on big-data-analysis and machine learning

„… Stahl, FZG – Gear Research Centre, Technical University of Munich 0. Zusammenfassung Die meisten …” „… operating time of the machine. Especially if a failure can result in a high economic loss, this fact …” „… service-life and state of health with as little effort as possible. Centerpiece of gearboxes are the gears. A …”

P. Ramminger, R. Jäger Evolution of the drivetrain and high voltage system in the new Corsa-e

„… energy. Otherwise, the CO2 avoidance benefit for the environment will be lower at begin of operation and …” „… ), one kWh electrical energy creates 337g CO2 [1]. Assuming 20% distribution and charge losses source …” „… temperatures and thermal mass of the Battery may frequently limit fast charging to lower than peak power …”

G. Gardner 10R80 – Cost efficient modular hybrid transmission (MHT)

„… drive applications, the lack of a mechanically connected reverse gear is an inhibitor to using these …” „… gear for towing applications, and package into existing rear wheel drive architectures. In order to …” „… that is totally hidden from the customers delivers enhanced powertrain efficiency, delivering lower CO …”

G. Gardner Ford MACH-E Primary Electric Drive Unit

„… . The integrated cooler is used to cool the ultra-low viscosity PDU fluid that is used to provide …” „… lubrication and cooling to the mechanical gear box components and cooling ot the motor assembly. To provide …” „… cooling functions. To keep cost low the e-pump is based off of the 10R80MHT pump design with a unique …”

C. A. Spangler Borg Warner’s P1 and P2 hybrid drive modules – Modular kit for P1 and P2 hybrids

„… for a certain time. Besides very low electrification of an entry level of 12V dual storage hybrids …” „… electric boosting on the crankshaft. P0 applications are simple to install, however, the losses on the …” „… perspective, the energy portion which can be harvested in the battery is influenced by the losses in the …”

T. Korb, M. Nussbaumer, S. Rinderknecht Generic optimization environment and knowledge-based guided evolutionary algorithms for automated transmission calibration – Method to generate a knowledge base through impact analysis of parameters a...

„… addressed in this work, as well as it focuses on the mentioned loss of time-based characteristics and the …” „… described inherent characteristics of scalar criteria and the information loss is transferrable to common …” „… information loss in common, which could mislead optimization algorithms. Derived from the fictive example …”

doi.org/10.51202/9783181023730

VDI Wissensforum GmbH - International Conference on Gears 2022

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VDI Wissensforum GmbH (ed.)

International Conference on Gears 2022

Series: VDI-Berichte

Volume 2389 2022

Results in this title

S. Vonderschmidt, A. Ott, A. Vonderschmidt High speed machining with magnetically geared driven tools on rotatory milling machines S. 1415-1428

„… electrical conductivity and thus no electrical losses. With 7.27 W/Nm, the magnetic gear has the lowest …” „… losses: In a magnetic gear, additional bearings and seals may be installed, which generate friction …” „… serves as reference. (2) Losses in magnetic gears with laminated magnets (surface magnets at IM and OM …”

B. Legrady, M. Taesch, G. Tschirschnitz, C. F. Mieth Prediction of churning losses in an industrial gear box with spiral bevel gears using the smoothed particle hydrodynamic method S. 651-664

„… Prediction of churning losses in an industrial gear box with spiral bevel gears using the smoothed …” „… churning losses of a spiral bevel gear transmission using the novel meshless particle method, smoothed …” „… for an automotive transmission at its top gear ratio [2]. Power losses within a gearbox are classified …”

Y. Marchesse, M. Ruzek, F. Ville, P. Velex On windage power loss reduction achieved by flanges S. 665-676

„… are located around the gears. It is shown that the windage power loss highly decreases when the flange …” „… . Background The windage power loss (WPL) of gears has been studied for almost forty years. In his pioneering …” „… windage power loss curve as a function of speed.4.1 Spur gearsTwo different pinions were tested (i.e …”

J. Vorgerd, P. Tenberge, M. Joop Scuffing of cylindrical gears with pitch line velocities up to 100 m/s S. 903-914

„… highspeed gears has been derived. 1. Introduction Turbo gearboxes almost exclusively use low …” „… properties. This leads to higher power losses and can ultimately cause a gear failure. The standardized …” „… temperature ? °C up to 100 Power losses of the test gears are determined with the use of a calorimetric …”

A. Gebhard, W. Kassem, M. Oehler Cylinder-on-ring model wear tests as an input data source for the simulation of friction and wear of plastic gears S. 1133-1148

„… of plastic gears A. Gebhard, Leibniz-Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany; W …” „… . Kassem, Manuel Oehler, MEGT – Institute of Machine Elements, Gears and Transmissons, Department of …” „… polymer/steel gears. 1. Introduction Polymers and polymeric composites exhibit a series of favorable …”

L. Maccioni, F. Concli, C. Paschold A Novel Concept of Nested Cycloidal Speed Reducer S. 969-984

„… configuration allows reaching Gear Ratios (GRs) comparable with Wolfrom-based planetary gearboxes with a lower …” „… (?). Depending on the gearbox, other power losses (?) from auxiliary units, for example, may also occur. Gear and …” „… gearing of FZG type-C (C), a low loss gearing (LL) and a deep tooth form gearing (SH). Their main geometry …”

G. Hlebanja, M. Hriberšek, M. Erjavec, S. Kulovec Influence of the tooth flank shape on wear for a steel-POM gar pair S. 1295-1304

„… energy loss, can be attributed to the meshing gear pair flank load, to the friction coefficient (material …” „… spur S-gears can operate with a low number of teeth down to 6 or even 4. c) S-gears feature …” „… higher radii of curvature and thus lower contact pressure. e) S-gears develop higher contact oil film …”

B. Reetz, T. Munch, W. Kappeler Challenges for lead-free brass alloys in worm gears S. 1467-1488

„… eliminated without any loss in the operational performance of worm gears. For the future, the aim is to …” „… choice a worm gear set are - Low vibration - Low noise level - Insensitivity to load bumps - Power and …” „… and low speeds. Due to the contact situation the efficiency is lower than for standard types of gear …”

D. Park, A. Rezayat, Y. Gwen Gear design optimization for multi-mesh and multi-power flow transmissions under a broad torque range incorporated with multibody simulations S. 849-862

„… design of low-noise gear trains that also maintain high performance for efficiency, durability, and …” „… Gear design optimization for multi-mesh and multi-power flow transmissions under a broad torque …” „… robustness has been a longstanding goal for the gear engineers in the automotive industry. As gear train …”

M. Zalfen, J. Lovenich, O. Malinowski, C. Brecher, J. Brimmers, S. Neus, S. Stark, D. Kruger Test rig concept for high power VHCF gear testing S. 485-498

„… power circle amounts roughly P = 5 MW. Considering 5-7 % losses within the power circle (gears, journal …” „… efficiency ηGear, the losses in each tooth mesh are calculated to Ploss/mesh = 50 kW. Using the heat capacity …” „… results for the VHCF range of gears is low and not statistically verified, but the effects for the VHCF …”

P. I. Pedrero, D. Martinez–Lopez, M. Pleguezuelos, J. Calvo–Irisarri, M. B. Sanchez, A. Fernandez–Sison Minimum friction losses in wind turbine gearboxes S. 715-730

„… the gears are calculated to minimize the friction losses. 1. Introduction High efficiencies are not …” „… losses can be found in literature relating to cylindric parallel-axis gears [4-6]. But due to the high …” „… are commonly used [7]. Literature on power loss of planetary gears are scarcer, although it has been …”

A. Baumann, B. Bertsche Coefficient of friction behavior of gear oils and significance for the meshing process of spur gears S. 745-762

„… of a gear oil depends on the oil viscosity and above all on the chemical composition. The lower the …” „… impacts of meshing gear pairs under vibration excitation and the gear transmission thus generates lower …” „… determination of the coefficient of friction in meshing gears is important for prediction of power losses and …”

K. Daubach, M. Oehler, B. Sauer Wear simulation of worm gears based on an energetic approach S. 329-342

„… varies during the gear meshing, friction power loss PR needs to be integrated over time to obtain …” „… Wear simulation of worm gears based on an energetic approach Dipl.-Ing. K. Daubach, Jun. Prof …” „… . Dr.-Ing. M. Oehler, Prof. Dr.-Ing. B. Sauer, Institute of Machine Elements, Gears & Transmissions …”

K. Stahl, T. Tobie, C. M. Illenberger Standardized methods of load capacity calculation of plastic gears S. 1173-1180

„… by means of lower friction losses due to lubrication but heat is also removed from the gear contact …” „… power is to modify the tooth geometry in order to reduce friction losses by means of loss-optimized gear …” „… Standardized Methods of Load Capacity Calculation of Plastic Gears Prof. Dr.-Ing. K. Stahl …”

H.-J. Dennig, L. Zumofen, A. Kirchheim, S. Winterberg, D. Stierli Increasing the safety against scuffing of additive manufactured gear wheels by internal cooling channels S. 1345-1364

„… ). As expected, the pressure loss is significantly lower in the parallel pattern. Fig. 3: Parallel and …” „… of the gears. As mentioned above, the FZG type A gear is cooled from the inside with a low …” „… Increasing the safety against scuffing of additive manufactured gear wheels by internal cooling …”

F. Reinle, D. Mangherini, E. Morgano, A. Bongiovanni Combining improved gear efficiency and improved fatigue performance through mass finishing S. 609-620

„… % reduced load dependent gear losses, with a mean of 0.6 percent points of improved efficiency. Across …” „… fatigue behaviour of 60 % in combination with increased efficiency of around 40 % lower losses. For more …” „… Combining improved gear efficiency and improved fatigue performance through mass finishing M.Sc …”

M. Weigand, C. Gachot Improved rotorcraft drivetrain safety and related research with special focus on improved lubricants for rotorcraft transmissions S. 561-572

„… to 30 minutes after complete loss of lubrications ha been percepted by the crew (e.g. by low pressure …” „… projects of the research unit: - Together with Zoerkler Gears in Austria TU Wien developed the complete …” „… ) - Together with TU Munich and Zoerkler Gears TU Wien develops a rotor system with variable speed …”

B. Zhmud, M. Bengtsson, L. Everlid Improving the tribological and nhv behavior of gears by mechanochemical surface finishing S. 1365-1370

„… gears are expected to reveal improved scuffing resistance, reduced friction and wear, and lower noise …” „… done using a thermal elasto-hydrodynamic model [4]. Fig. 3: TCG finished gears exhibit lower …” „… Improving the Tribological and NHV Behavior of Gears by Mechanochemical Surface Finishing The …”

J. Koenig, D. Kehle, K.-P. Heinzle Investigation of the failure mechanisms of plastic materials with and without fiber reinforcement S. 1269-1280

„… is significantly lower, compared to steel gears. Also, application of plastic gears is usually …” „… one order of magnitude lower than the strength of a similarly sized steel gear [5]. Also, the strength …” „… steel/steel gear pairings. Due to the comparably low Young’s modulus, plastic gears suffer from a high …”

T.-T. Mac, D. Iba, Y. Matsushita, S. Mukai, T. Inoue, A. Fukushima, N. Miura, T. Iizuka, A. Masuda, I. Moriwaki Application of genetic algorithms for parameters identification in a developing smart gear system S. 239-252

„… . The experimental return loss data is measured by a network analyzer from a practical smart gear system …” „… smart gear system where the coupling return loss is the most important data for the gear health …” „… gear system are the targets of the identification procedure. LCRs circuits and a return loss equation …”

W. Kassem, M. Oehler, B. Sauer, S. Schmidt, J. Hausmann Investigation of the time-dependent behavior of plastic gears with local tribological simulation S. 1281-1294

„… . Introductions Plastic gears have been used since the mid-20th century in low-load drives such as in watches …” „… gears is the low manufacturing costs in mass production by injection molding [1]. Other advantages …” „… , and the ability to self-lubrication [4]. The main disadvantage compared to metallic gears is the lower …”

L. Hildebrand, F. Dangl, M. Sedlmair, T. Lohner, K. Stahl CFD analysis on the oil flow of a gear stage with guide plate S. 677-694

„… out the influence of the interaction between rotating gears and oil on the no-load gear loss. Mauz [32 …” „… ] performed extensive experimental investigations on the loss behavior of spur gears. Based on his results, a …” „… set of empirical equations has been derived by which the no-load gear loss can be VDI-Berichte Nr …”

K. J. Winkler, T. Tobie, K. Stahl Influence of grinding zones on the tooth root bending strength of case carburized cylindrical gears S. 287-304

„… Influence of grinding zones on the tooth root bending strength of case carburized cylindrical gears …” „… Karl Jakob Winkler, M.Sc., Dr.-Ing. Thomas Tobie, Prof. Dr.-Ing. Karsten Stahl, Gear Research Center …” „… strength plays a decisive role in the design of gear sets. Due to dimensional and shape changes resulting …”

C. M. Illenberger, T. Tobie, K. Stahl Operating behavior and performance of oil-lubricated plastic gears S. 1117-1132

„… conditions results in a low heating of the plastic gears due to the effective heat dissipation with oil …” „… Operating behavior and performance of oil-lubricated plastic gears C. M. Illenberger, M.Sc …” „… ., Dr.-Ing. T. Tobie, Prof. Dr.-Ing. K. Stahl, Gear Research Centre (FZG), Technical University of Munich …”

C. A. Celikay, A. Donmez, A. Kahraman An experimental study of parametric resonances of a spur gear pair at speeds above its primary resonance S. 511-522

„… instabilities. These might not be relevant to other types of gears with significantly lower ( )k t and ( )e t …” „… nf f indicating that the gear pair has intermittent contact loss at the first super-harmonic …” „… since the lower branch 1 motion maintained its stability. 4. Conclusion Response of a spur gear pair …”

A. Miltenovic, M. Banic Investigation of the meshing friction heat generation of worm gears and influence of the contact shape S. 803-810

„… Niš, Serbia Abstract Two interesting research topics for worm gears are friction losses and scuffing …” „… Investigation of the meshing friction heat generation of worm gears and influence of the contact …” „… failure. The main cause for scuffing is heat generated in the contact of gear teeth. Contact geometry of …”

S. Sklenak, J. Brimmers, C. Brecher Analysis of local wear within the dry lubricated rolling- sliding contact of coated surfaces S. 305-316

„… Measurement for Gears Operating Under Loss-of-Lubrication Conditions. Geartechnology Juni 2019:46–54 2019 [6 …” „… K (Hrsg) 2013 Low Friction Powertrain. Tragfähigkeit Low Loss Verzahnung. FVA (Forschungsvereinigung …” „… Machine Tools and Production Engineering, Gear Department, RWTH Aachen University Abstract Tooth …”

N. Sagraloff, T. Tobie, K. Stahl Suitability of the test results of micropitting tests acc to FVA 54/7 for modern practical gear applications S. 469-484

„… , micro-pitted area and mass loss over the test. For each variant and test gears type “C-GF,” the scouring caused …” „… Suitability of the test results of micropitting tests acc. to FVA 54/7 for modern practical gear …” „… applications M. Sc. Nadine Sagraloff, Dr.-Ing. Thomas Tobie, Prof. Dr.-Ing. Karsten Stahl, Gear Research …”

R. Longato, M. Turci The effect of temperature on the SN curve for bending stress measured on a new test rig for plastic gears S. 1209-1222

„… , etc. There are several advantages when compared to metal gears: low mass and inertia, no lubrication …” „… gears Dr. Riccardo Longato, Longato Srl, Rovigo, Italy; Dr. Eng. Massimiliano Turci, Studio Tecnico …” „… Turci, Cesena, Italy Abstract Plastic gears have been in use for more than 50 years and research and …”

M. Matzke, A. Elter Ensuring reliable grease service life in high temperature plastic gears S. 1249-1256

„… Ensuring Reliable Grease Service Life inHigh Temperature Plastic GearsDr. Markus Matzke, Dr …” „… . Alexander Elter, Robert Bosch GmbH, Renningen Many automotive and industrial plastic gears lubricated by …” „… Gears°C 1x DIN 51808: Determination of oxidation stability of greases – oxygen methodpressurized oxygen …”

B. Guilbert, P. Velex Influence of thin rimmed/-webbed gears on transmission dynamic behaviour – Approximate dynamic factor formula S. 523-532

„… , the major critical speeds for tooth loading are slightly lower when gear flexibility is simulated …” „… Influence of thin rimmed/-webbed gears on transmission dynamic behaviour – Approximate dynamic …” „… and consequently flexible gear bodies on dynamic tooth loads. To this end, an approximate dynamic …”

T. Matsumura, K. Mioki, M. Kada, R. Okuizumi, A. Pogačnik Improved calculation methodology for the prediction of tooth temperature of plastic gears S. 1237-1248

„… Improved calculation methodology for the prediction of tooth temperature of plastic gears Takuma …” „… polyoxymethylene (POM) gears. As a result, the temperature calculation in the VDI 2736-2 [1] guideline is not very …” „… friction (COF) is unclear, 2) the equation for the gear temperature calculation is not precise enough. In …”

D. Drummer, D. Schubert, C. Herzog In situ measurement of geometric and structural influences on the operating properties of polymer gears S. 1099-1116

„… form lower product quality and function [16]. This is especially true for gears. Different tooth …” „… gear is subjected to the testing conditions. The load in the “low” cycles is reduced as far as possible …” „… gears Prof. Dr.-Ing. Dietmar Drummer, Dominik Schubert, M.Sc., Christoph Herzog, M.Sc., Institute of …”

B. Schalley, J. Brimmers, T. Bergs Potential and challenges of profile gear grinding with vitrified bonded cBN S. 1569-1582

„… single part production of large gears, rejects lead to high financial losses and are therefore …” „… tool wear, the resulting costs per gear for grinding with cBN are lower than for corundum. Machine …” „… Potential and Challenges of Profile Gear Grinding with Vitrified Bonded cBN Analysis of Tool Life …”

S. Ebrahimi, J. Langhart, D. Marano NVH calculations for drivetrains, a methodology for selection of the best suitable calculation approach for a specific purpose S. 75-90

„… Marano, Gear Lab, Modena, Italy Abstract In this paper, some guidelines are given how to apply the …” „… typical gearbox. Two different variants of gear designs regarding the microgeometry are considered for …” „… confirm that the microgeometry modifications lead to the lower level of the noise emission by reducing the …”

A. Wedmann, M. Stein, K. Kniel Gear calibration in tactile scanning mode on CMMs S. 1539-1552

„… point density to obtain more information about the gear teeth. It has been proven that there is no loss …” „… 1. Abstract In industry, gear measurement on coordinate measuring machines (CMMs) is done almost …” „… . This is why PTB has up to now only provided gear measurement standard calibration by means of …”

P. Tenberge, R. Uelpenich, P. Dong, R. He Very fast tooth root optimization – general tool geometry for much smaller tooth root stresses S. 457-468

„… LowLoss-Verzahnungen, Dissertation Technische Universität München, München (2012) [7] Z. Roth, J. Opferkuch, High Load …” „… stressesFig. 1 illustrates the critical load condition on a tooth of a gear and the resulting stress condition …” „… in the tooth root. Under overload, teeth of spur gears can break in the tooth root. This leads to …”

L. Bonaiti, F. Rosa, P. Mahendra Rao, C. Gorla, F. Concli Gear root bending strength: statistical treatment of single tooth bending fatigue tests results S. 15-30

„… been observed. Table 1 summarizes the spur gear main data; as the module is lower is lower than 5, the …” „… the gear shows a lower load carrying capacity than the one referred to the teeth. Furthermore, meshing …” „… running gear data,” Gear Technol., 2008. [12] F. Dobler, T. Tobie, and K. Stahl, “Influence of low …”

P. Roth, M. Hein, K. Stahl Scuffing load capacity calculation of worm gears S. 811-824

„… loss-of-drive of the gearbox, the accountable design of worm gears of such materials requires a reliable …” „… Scuffing load capacity calculation of worm gears Philipp Roth, Dr.-Ing. Michael Hein, Prof. Dr.-Ing …” „… . Karsten Stahl, Gear Research Centre (FZG), Technical University of Munich (TUM), Garching near Munich …”

D. Zorko, Z. Bergant, B. Černe Potential of woven carbon fiber reinforced polymer composite gears S. 1071-1082

„… Potential of woven carbon fiber reinforced polymer composite gears Damijan Zorko, Zoran Bergant …” „… composites have so far received little attention as a potential material for gear drive applications. In the …” „… gears was investigated. Test gears of size m = 1 mm, z = 20, and b = 2 mm were milled from a …”

doi.org/10.51202/9783181023891

VDI Wissensforum GmbH - Powertrain Systems in Mobile Machines 2022

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Powertrain Systems in Mobile Machines 2022

Series: VDI-Berichte

Volume 2402 2022

Results in this title

L. Serrao Driving the electric transformation – The evolution of off-highway powertrain S. 135-150

„… number of gears (1 or 2) and spread between gears. The higher the spread, the lower the performance area …” „… : - Significantly higher speed compared to hydrostatic motors - Higher efficiency (lower mechanical power losses …” „… differential housing and viscous losses in wet disc brakes. The other sources of power loss (e.g. gears …”

S. Mutschler eLION: A New Platform Approach for the Electrification of Mobile Machines S. 151-162

„… injection system, avoiding gear splashing losses. Fig. 4 shows the efficiency map of the gearbox in 1st and …” „… very low increase of losses towards maximum speed. Fig. 4: The efficiency of the eGFZ9275 is …” „… standard speed motor and variable displacement eOC pump. To eliminate stand-by losses, the supply of …”

R. Morrison, J. Legner Future Electrified Drivetrain for Off-Highway in the 60-80kW Power Range S. 163-170

„… efficiency is ensured by the purely mechanical power flow while maintaining low windage losses. Both brake …” „… design keeps drag losses low when the clutch is open. The aspect of serviceability was also considered …” „… using single speed transmissions and low to high voltage electric motors. But when considering the …”

M. Pußack, L. Frerichs Electrification of linear positioning and working functions in mobile machines S. 199-210

„… actuator. Since the other mechanical components in the system have low elasticities, a smooth and fast …” „… very reliably thanks to the brake, supplemented by the self-locking behaviour of the gear unit. 3.3 …” „… significantly be-low the maximum efficiency of the prototype motor. Since the side brush adjustment has to work …”

S. Eichler, C. Guernsey The Wheel Loader of Tomorrow: Proof-of-Concept Vehicle & Learnings from Full-Electric Drivetrain Conversion S. 185-198

„… still experiences some of the same losses and is not optimized to achieve all the benefits of …” „… also improves energy consumption, which can lead to either a smaller battery size (lower cost) or …” „… output by the different gear ratios. The wheel loader’s hydraulic work function uses our EM-PMI240-T180 …”

doi.org/10.51202/9783181024027

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Dritev 2022

Series: VDI-Berichte

Volume 2401 2022

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Z. Liu, V. Stegmayer, S. Rinderknecht, U. Fechter Multiphase CFD investigation of splash lubrication S. 169-184

„… sump by the gear teeth. The viscous force causes however lower torque losses with the increasing oil …” „… lubricant flow be-havior and the churning loss on the gears are analyzed in three dimensions. Besides the …” „… the gear surfaces. The detailed normal and shear stresses help to understand the churning loss …”

A. Eßer, J. Mölleney, S. Rinderknecht Potentials to reduce the Energy Consumption of Electric Vehicles in Urban Traffic S. 133-152

„… compared with the other BEV variants using a comparative optimization approach. The TDT uses low-cost and …” „… . Dynamic programming is applied as operational strategy for all simulations considering shifting losses to …” „… and lead to relatively high losses compared to a simple dog-clutch and the use of active …”

J. Gindele, U. Franzmann, L. Herdle, A. Pawlenka The Magna 7HDT400 for BMW’s new 48V hybrid drive family S. 1-12

„… thus increases the transmission efficiency. Fig. 3: Lower friction losses through asymmetrical tooth …” „… , mounted outside the transmission case – seven gears and reverse – main center distance 197 mm – nested wet …” „… – park-by-wire (normally stay) – optional AWD The main components – dual-clutch, gear set, differential, and the …”

T. König, L. Stütz, L. Bauer, M. Kley Model-based simulation of a longitudinal dynamics vehicle model with a single-wheel drive S. 381-396

„… determining the efficiency of transmissions, a distinction is made between power loss measurement and power …” „… power loss measurement, the power loss ? and the input power ? are measured. The measurement can be …” „… carried out with a stress test rig, a pendulum gear suspension or a calorimetry [10]. The efficiency ? is …”

M. Hein, S. Prinke, A. Damm, P. Fischer Testing of shift elements – Standardized Methods, State of the Art and Future Challenges S. 73-94

„… engagement is more important, since due to the lower number of gears, the ratio step is much bigger between …” „… gear position in the gearbox is the main requirement for a synchronizer system. From a calculation …” „… failure modes are decreasing CoF or axial wear. Both lead to a loss of functionality and clashing during …”

F. Lagier, N. Freund, K. Bause, S. Ott, A. Albers Simulation-based evaluation of high-speed PEEK gears in automotive powertrains and design of a validation environment for high-speed gears S. 223-240

„… the high-performance polymer poly-ether-ether-ketone (PEEK) in high-speed, low-torque gears in …” „… comparison to metal gears, and are far less dense, allowing for a lighter system with low inertia [1]. This …” „… , especially thermoplastics, are a possible gear material due to their low density but show a low …”

A. J. Wimmer High-Speed Testing: The Fast Lane towards a Running System S. 365-380

„… demands increase at the same time more and overcompensate the lower speed requirements, so that power …” „… power-split gear-box which allows higher speeds in combination with a neat rolling bearing solution of the …” „… gearbox for large balancing machines with three gear shifts [P = 1,500 kW]. Unlike in balancing …”

D. Held The EtelligentReach Project – A new Level for Range and Dynamics S. 267-276

„… smaller conversion losses – this again contributes to a higher electric driving range. Magna will launch …” „… optimized gears, a new bearing concept with new bearing arrangement and bearing types to optimize efficiency …” „… mainly depends on the requested reconnect time, the e-motor is driven at a defined low speed with low …”

S. Cortès, A. Albers, C Dettmann, P. Boche Chassis Dynamometer – a development environment for calibration and validation of vehicle drivetrains in context of RDE legislation? S. 347-364

„… account the geometric relationships, the roller inertia as well as variables describing losses that can be …” „… position % Controlled Engine speed rpm Measured Engine torque Nm Measured Gearbox actual gear - Measured …” „… both variables. Furthermore, other measured, dependent variables such as engine speed and gears also …”

G. Göppert, M. Adrian AI Approach to Wet Friction Torque Model Adaptation S. 321-334

„… clutch supported ICE starts. In addition, multi-gear e-axle systems or mechanical torque vectoring units …” „… , ? is the friction coefficient, and ? denotes the applied force. Without loss of generality the positive …” „… optimizer, such as adam, and a loss function, such as Mean Squared Error (MSE): ? ∑ ? ? with the reference …”

doi.org/10.51202/9783181024010

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