Browse Publications Technical Papers 2019-26-0140
2019-01-19

Electrification and Automation of Manual Gearbox Technology to Reduce Fuel Consumption and CO2-Emissions of Passenger Cars 2019-26-0140

To meet the targets of Indian future emission legislation, an electrification and automation of today’s manual transmission technology is necessary. For this reason IAV invented an electrified automated transmission family, based on well-known manual transmission technology. This low cost AMT approach is equipped with a 48V electric motor and can be used as pure electric or hybrid drivetrain. Furthermore it is possible to realize power shifts by using just one dry friction element. A low number of standard components combined with a low voltage electric motor and an electro mechanic actuation system is sufficient to create a maximum of flexibility to meet the emission fleet targets of the future, without having the disadvantageous high costs for a high-voltage electric system. Beside this low cost drivetrain approach, IAV has developed an electro mechanic AMT-kit to convert current manual transmissions easily into automated transmissions. Only this small technology change can cause a fuel consumption benefit of up to 5%. The advantage of an electro mechanic AMT-kit compared to today’s well-known hydraulic actuation systems is the easy-to-mount and easy-to-replace principle, together with the high energy efficiency of this power-on-demand actuation systems. This paper will show IAV’s innovations on different transmission actuation systems starting with low cost approaches for the automation of manual transmissions, ending up with highly integrated systems for dedicated hybrid transmissions. To choose the right actuation technology for the customer specific requirements, IAV invented an advanced development methodology which is called Actuation Synthesis. This newly developed, consistent simulation method makes it possible to analyze, evaluate and optimize transmission actuation systems in relation to efficiency, package and shifting characteristics as early as possible within the product development process.

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