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01/09/2007
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In a development that must rate as one of the finest examples of technology integration seen this year, ZF has designed an electric motor module into its new eight-speed automatic gearbox using only the space normally occupied by the torque converter, writes Roger Bishop.
This ‘drop in’ technology, which includes clutch packs and launch mechanism, should considerably ease the technical and packaging burden on car-makers keen to include hybrid vehicles within their model ranges. It will be shown to the industry at IAA, Frankfurt this month.
Readers will recall the announcement of ZF’s new eight-speed gearbox (European Automotive Design, May) which itself represents a considerable advance on the company’s current six-speed auto. We hinted then that this unit – based on four planetary gearsets and five shift elements – could be part of an even more advanced parallel hybrid system.
Engineers at a recent briefing at Gross-Dölln driving centre, near Berlin, said the design could accommodate electric motors of 10 to 40kW, covering mild to strong hybrid range. The arrangement allows for both torque boosting of the internal combustion engine and full electric drive at ‘city speeds’ (up to 50km/h) in which case the internal clutch disconnects the engine in response to signals from the powertrain management.
Other systems being developed by ZF include the micro-hybrid crankshaft starter-generator known as DynaStart that delivers peak capacities of up to 10kW using both 14 and 42V architectures. And in cooperation with Continental Automotive Systems, ZF is developing complete hybrid solutions including brakes.
In this partnership, ZF provides the hybrid modules and their functional integration in transmissions while Continental specialises in power electronics, software integration, energy management and electronic brakes, particularly for mild and full hybrids that include brake energy recovery and charging an electric accumulator.
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Author
Roger Bishop
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