Electrification and Automation of Manual Gearbox Technology to Reduce Fuel Consumption and CO ₂ -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 automated manual transmission (AMT) approach is equipped with a 48 V electric machine 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 small number of standard components combined with a low voltage electric machine and an electromechanical actuation system is sufficient to create a maximum of flexibility to meet future emission fleet targets, without having the disadvantageous high costs for a high-voltage electric system. To detect the optimal powertrain configuration, IAV used a unique advance development tool called Powertrain Synthesis.

Beside this low-cost drivetrain approach, IAV has developed an electromechanical AMT-kit to convert current manual transmissions easily into automated manual transmissions. Only this small technology change can cause a fuel consumption benefit of up to 10 % [1]. The advantage of an electromechanic AMT-kit compared to today’s well-known hydraulic actuation systems is the “easy-to-service” and “easy-to-replace” principle, together with the good? energy efficiency of this power-on-demand actuation systems.

To choose the right actuation technology for the customer specific requirements, IAV developed an advance methodology called Actuation Synthesis. This new consistent simulation method makes it possible to analyze, evaluate and optimize transmission actuation systems in relation to efficiency, package, shifting characteristics and costs as early as possible within the product development process.