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ZF 6-Speed Automatic Transmission For Passenger Cars
ZF 6-Speed Automatic Transmission For Passenger Cars
PAPER SERIES
2003-01-0596
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2003-01-0596
ABSTRACT
6
INTRODUCTION
In the European market, 5 speed automatic
transmissions are state of the art in the midsize and
upper class car segment since the beginning of the 90s.
In comparison to the world wide market, where
4 speed transmissions still have the biggest volume,
these transmissions represent a high quality standard
and their contribution to fuel efficiency, reduction of
noise and emissions, improved performance and driving
comfort has led to a constant increase of the market
share.
The aspect of fuel efficiency is gaining importance in the
requirements of future transmission systems. Therefore
all transmission producers and suppliers are
investigating new concepts like automated manual
transmissions, double clutch systems or different types
of continuously variable transmissions to be prepared
for future applications. For the stepped transmissions
types, these requirements need to provide a bigger
overall ratio spread and improve the efficiency
accordingly. In addition, transmission functions need to
be developed or improved to support those targets.
Basically, it was necessary to find a transmission
concept, which provides an overall ratio spread of about
6.0. Calculation and simulation results clearly
demonstrated that it was necessary to be able to divide
3 speed
tot
2,3 to 2,8
4 speed
tot
2,7 to 4,2
5 speed
tot
4,2 to 5,2
6 speed
tot
6,0
TRANSMISSION CONCEPT
The solution to solve this problem was provided by
Lepelletier. In 1990, he filed a patent for different
arrangements of automatic transmissions. This patent
showed a system with a single planetary gear set and a
Ravigneaux gear set. In conjunction with the multiple
use of 5 shift elements, a 6 speed transmission with an
overall ratio of 6,0 and good ratio steps could be
derived.(Figure 1).
The comparison to the ZF 5 HP 24 (Figure 2)
transmission shows a reduction of one shift element and
some gear set parts. In combination with the
development of ZF shift sequence strategy, it was also
possible to remove all one-way-clutches without
negative consequences to shift quality.
SCC
A
Gear
Clutch
A
1
2
3
4
5
6
R
Figure 1
6 HP 26 Lepelletier concept
SCC
Table 1
Brake
E
OWC
SSC
1st gear
i=4,171
Figure 2
5 HP 24 Wilson concept
SSC
2nd gear
i=2,340
SSC
3rd gear
i=1,521
n = 0,66
E
Figure 3
n = 1,0
SSC
4th gear
i=1,143
SSC
5th gear
i=0,867
SSC
6th gear
i=0,691
SSC
reverse
i=-3,403
Figure 4
GEAR TRAIN
R2
P2
R1
RATIO
C1
Gear
Gear Step
st
4,171
1,78
2nd
2,340
3rd
4th
6th
- 3,403
nd
2
gear
Sun S2
1,32
Sun S3
1,25
Planet P3
Ring gear R3
n
T
n
n
T
n
T
n
n
T
rd
th
3
gear
S3
th
4
gear
th
5
gear
6
gear
R.
gear
0
0,52
1,52
0,66
1,52
1,0
1,0
0
0,52
1,52
0,66
1,52
1,0
1,0
0
0,52
1,52
0,66
1,52
1,0
1,0
0
0,14
1,52
0,66
0,42
1,0
0,27
0
0,13
1,52
0,66
0,39
1,0
0,26
0
0
1,52
0,66
0
1,0
0
0
0,52
1,52
0,66
1,52
1,0
1,0
-0,54
0
0,89
0
2,65
0,66
1,52
-0,85
0,24
4,17
0
0,82
0,49
0,30
0
0,66
1,52
-0,47
0,43
2,34
0,66
0,53
0
0,66
0
0,66
0,99
0
0,66
1,52
1,28
0
-0,46
1,0
0,73
0,66
0,42
0,44
0,88
1,14
0,66
0,39
0,57
1,0
1,26
1,42
0
-0,54
1,15
0,87
0
0,31
1,65
1,0
1
2,23
0
-1,58
1,45
0,69
0,66
1,52
-1,09
0
4,9
-0,81
0
1,04
-0,29
3,4
Planet P2
Carrier C2
0,691
Reverse
st
1
gar
1,33
0,867
S2
S1
Ravigneaux-gear set
1,143
5th
P3
1,54
1,521
C2
P1
Total Ratio
6,04
TOOTH EFFICIENCY
5 HP 24
6 HP 26
100%
Efficiency in %
Table 2
90%
80%
70%
60%
50%
1
Figure 5
st
nd
rd
th
th
th
Tooth efficiency
TECHNICAL DATA
To be able to cover the whole range of engines from
midsize to the luxury car segment with 4, 6, 8 and 12
cylinders Petrol and Diesel engines, it was necessary to
define a modular system with 3 transmission types. Due
to the increase of torque, especially in the Diesel engine
applications, the torque capacity of the transmission had
to be increased accordingly. (Figure 6)
800
700
6 HP 32
600
6 HP 26
5 HP 30
500
400
5 HP 24
300
6 HP 19
5 HP 19
200
Figure 6
6 HP 26
Tmax Engine
Pmax
st
th
th
nmax 1 to 4 /5 gear
th th
nmax 5 /6 gear
nmax Kick-Down shift
Tmax Turbine forward
Tmax Turbine reverse
Converter
Weight (incl. oil)
440 Nm
-1
at 4200 min
230 kW
-1
at 6600 min
-1
7200 min
-1
5600 min
-1
7000 min
700 Nm
400 Nm
W 260 S
84 kg
5 HP 24
420 Nm
-1
at 4200 min
230 kW
-1
at 6600 min
-1
7200 min
-1
6200 min
-1
7000 min
800 Nm
500 Nm
W 260 S
95 kg
5 HP 24
666
6 HP 26
100
- 29 %
470
200
Figure 7
300
400
500
Parts
700
5 HP 24
697
6 HP 26
100 200
Figure 8
-6%
653
300 40
500
Length [mm]
Table 4
600
Transmission length
60
700
80
DESIGN
CONVERTER
For engine torque up to 440 Nm, a converter W260 S
with a torus of 260 mm is used, up to 600 Nm, a
W280 S converter is available. Both converters use the
same design concept and are equipped with a 2-surface
lock-up clutch. These clutches can be run in a
continuous slip mode and are able to handle friction
power up to 2 kW. Herewith, the operation range of the
slip mode can be extended which helps to save fuel by
further reducing speed ranges with open converter.
120
5 HP 24
80
40
6 HP 26
Figure 10
0
Figure 9
1000
2000
6000
Oil pump
OIL PUMP
Similar to the ZF 5 speed transmissions, the 6 HP 26
uses a internal crescent moon pump. By reducing
leakage within the transmission, within the hydraulic
control unit and by reducing oil consumption for
lubrication and converter flow, the diameter of the pump
gears could be reduced. This leads to a delivery
3
capacity of 19,1 cm . Compared to the 5 HP 24 pump,
this means a reduction of about 20%. Figure 9 shows
the delivery rate in correlation to the engine speed at
operating temperature of 100C.
Brake D
GEAR SETS
The design of the planet carrier and the gears was
focused with priority for low noise. Supported by FEanalysis, the carriers are very stiff and rigid and a wide
bearing base for the planets was defined. Herewith, the
gears do not twist much under load, which helps to
ensure good contact pattern of the teeth in all torque
ranges.
OIL PAN AND FILTER
Another innovation is represented by the plastic oil pan.
In a Simultaneous Engineering project with the
supplier, the integrated design includes the oil pan, the
oil filter the magnets, an oil drain screw and a rubber
gasket. The design improves the ground clearance, as
the suction point of the filter is directly located on the oil
pan bottom. This design has 43 % less weight compared
to a sheet metal design. (Figure 11)
5HP24
28
6HP26
1,0
Figure 11
- 43 %
16
2,0
Weight in kg
3,0
TRANSMISSION FLUID
TCU
PLUG
SPEED
SENSOR
TEMPERATURE
SENSOR
POSITION SENSOR
HYDRAULIC CONTROL UNIT
Figure 12
Mechatronic module
TRANSMISSION FUNCTIONS
MECHATRONIC MODULE
ACTUATOR
FUEL ECONOMY
4
th
5 gear
Losses in %
st
1 gear
5 HP 24
2
th
5 gear
st
1 gear
6 HP 26
1000
2000
3000
4000
5000
DRIVING PERFORAMNCE
30
37,6
34,5
20
10
0
5 HP 24
Rear axle 2.93
6000
6 HP 26
Rear axle 3.15
speed [rpm]
Power loss grade
4
3
2
Total ratio 6.04
1
0
Figure 14
8
6
Fuel economy
7,4
7,7
4
2
0
Figure 15
6
5
Advantage 0,3 s
Figure 13
5 HP 24
Rear axle 2.93
6 HP 26
Rear axle 3.15
Acceleration
120
weight [kg]
5 speed
6 speed
90
60
4 speed
30
200
Figure 16
300
400
500
600
700
engine torque [Nm]
800
CONCLUSION
The mytronic6 6 HP 26 represents a real milestone in
the passenger vehicle drive train technology. An
automatic transmission was developed which has
significant advantages in all major areas compared to
the ZF 5 HP 24 transmission. The Lepelletier system
provides an overall ratio of 6 without increasing the
design complexity. The transmission uses fewer parts,
has less mass and is smaller in transmission length to
comparable 5 speed transmissions. The higher torque
capacity up to 600 Nm enlarges the application range
and together with the other two transmission types, the
new 6 speed family covers a whole range of engines
from 4 to 12 cylinder including diesel engines.
With the increased overall ratio and improved
transmission efficiency, the major benefits are in fuel
economy as well as in driving performance.
All the improvements and the convincing technical data
of the 6 speed transmissions will help to enlarge their
REVERENCES
1. Scherer, Gierer
ZF 5-speed transmissions for passenger cars
SAE Paper 970689, SAE 1997 Detroit , USA
2. Wagner
Einsatz von Getriebesystemen fr unterschiedliche
Triebstrangkonfigurationen in PKW
VDI-Report Nr. 1565 / 2000,
SAE Paper 2001-1-0882
3. Wagner
Automatische 6-Gang-Getriebe fr PKW
Engine Symposium Wien 2000
VDI Report12 Nr. 420
4. Rhringer, Danz, Deiss
Stand-By-Control, eine neue Funktion in
Automatgetrieben
VDI-Report Nr. 1393 / 1998
5. Rhringer, Birkenmaier, Engelsdorf
Mechatronikeinsatz im hydraulischen
Planetengetriebe
VDI-Report Nr. 1533 / 2000
6. Wagner, Bucksch, Scherer
Das automatische Getriebe 6 HP 26 von ZF
VDI-Report Nr. 1610 / 2001
7. Hall/Bock
6-Speed Automatic transmission for the new BMW
7-Series
ATZ 9/2001 Jahrgang 103
Appendix 1
Cross section 6 HP 26
01
02