SYNCHRONIZATION SYSTEMS
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1 SYNCHRONIZATION SYSTEMS Partners for Solutions
2 TWO PARTNERS ONE JOINT SOLUTION Dear Customer, This cooperation highly suggests itself, not only because of our close proximity to each other at several locations around the globe, but also due to the way our products complement each other, our development and manufacturing expertise and, not least, due to our family-led company cultures, rooted in the German region of Franconia. We are confident of offering our customers the best system solutions together with Diehl Metall. We are delighted to announce to you the cooperation between our two Franconian companies, Schaeffler and Diehl Metall, in the field of synchronization systems. Schaeffler, with its extensive systems and transmissions expertise, as well as its capabilities in manufacturing technologies, is the ideal partner for Diehl Metall in meeting the customer s growing request for holistically developed synchronization systems and new, innovative solutions. Diehl Metall, with its expertise in tribology, its time-tested brass alloys and carbon friction layers, supports the heart of our synchronization systems. By combining the competencies of our two companies, both being global leaders, we can now offer you solutions for today s and tomorrow s world of transmissions. As our manufacturing and development locations superbly complement and are in close proximity to each other around the globe, we are now able to manufacture synchronization systems based on German high technology in Brazil, China, Germany, India, Slovakia and Thailand, and provide you with local application engineering consulting support as well. As a result, you will have a partner you can trust and rely on in the field of synchronization systems around the world. 2
3 GLOBAL LOCATIONS CLOSE TOGETHER SYNCHRONIZATION LOCATIONS: EUROPE Steinhagen (Germany) Herzogenaurach (Germany) Röthenbach a.d. Pegnitz (Germany) Distance between the two plants approx. 16 km Skalica (Slovakia) ASIA Pune (India) Pune (India) Distance between the two plants approx. 21 km Taicang (China) Wuxi (China) Distance between the two plants approx. 50 km Chonburi (Thailand) SOUTH AMERICA Sorocaba (Brazil) São Paulo (Brazil) Distance between the two plants approx. 100 km 3
4 ECO-SYSTEM Standardized yet tailor-made solutions Time-tested technologies carefully coordinated with each other. The utilization of existing solutions saves time and costs in the development process of synchronized transmissions. The functional requirements in terms of torque transferability, synchro performance and shifting quality have already been met by appropriate solutions. The integration of functions by means of forming technologies for components such as sliding sleeves and sync keys, as well as the optimization of the system as a whole, provides the basis for cost-efficient solutions with high performance capabilities. In a modular structure, single- and multi-cone synchronizers can be selected as needed. The carbon and brass friction materials that have become established for the wide range of applications enable optimal price-performance designs. Easy adaptability of the contact interface dimensions of the clutch bodies and synchronizer hubs allows their integration into the transmission concept. Benefits Time-tested components and standardized design Carbon friction layers proven in mass production Brass alloys adapted to transmission oil Components coordinated for best system performance Modular system with single- to triple-cone synchronizers Cost-efficient manufacturing technologies 4
5 SHORT-SYSTEM Solutions for mobility for tomorrow Here the full potential of coordinated components and technologies is tapped for saving assembly space without sacrificing performance. Using the Schaeffler Technologies Short Synchro (STSS), the axial assembly space can be reduced by as much as 25 % by fully taking advantage of the forming technology. Smaller gear modules and innovative detailed solutions make it possible to retain the performance-relevant width of the friction cones, the loads acting on the mesh and the air space which is important for low drag torques! If the reduction in assembly length is implemented in transmission design, as much as 3.5 kg of weight can be saved. The assembly space gained can be used for a variety of purposes, depending on the application. Examples include improved meshing torque and thus performance, the additional millimeters needed for expanded functions or even the opportunity for hybridization of the powertrain. Benefits Approx. 25 % shorter than conventional designs Innovative, yet still featuring the Borg-Warner principle Full wear reserve Equal or even greater shift overlap Saves space, and thus weight and costs Assembly space gain, e.g. for hybrid powertrains 5
6 ENVIRONMENTALLY- FRIENDLY DRIVES URBAN MOBILITY INTER-URBAN MOBILITY ENERGY CHAIN MOBILITY FOR TOMORROW Schaeffler is known as an innovation leader with a wide range of technologies that improve the economy, environmental friendliness and safety of automobiles, as well as offering products for rail, aircraft, wind turbines and many other industrial uses. Schaeffler can be found wherever things are in motion. And motion means mobility as well. The challenges posed to the mobility of the future are immense. That is why Schaeffler has committed to a holistic strategy concept billed as Mobility for tomorrow in order to find sustainable solutions for the world of tomorrow. System expertise is a key factor in this endeavor. SYSTEM EXPERTISE IN EVERY DETAIL At Schaeffler, system expertise to optimize the internal combustion engine powertrain, and for hybridization and electrification, includes every detail. Optimal proof of this is the company s wide-ranging product portfolio that encompasses precision components and precision systems in the areas of the engine, the transmission and the chassis/suspension, as well as in electric mobility. In addition, the entire portfolio meets the requirements with respect to reducing carbon dioxide emissions and fuel consumption another aspect in which Schaeffler optimally supports its customers. Schaeffler, as a supplier with a global footprint, thinks and works in systems, using a holistic approach. Synchronization systems are a particularly descriptive case in point. Customer-optimized tuning and modular adjustments to practically any gear train result in ideal synchronization systems with synergetic linking to other assembly components. This is where Schaeffler offers benefits to the automotive industry that can hardly be matched by any other supplier. 6
7 TEAMING UP TO SHAPE TOMORROW S FUTURE Diehl Metall, a Corporate Division of the Diehl Group, recognized mobility as one of the key trends of the future many years ago. This trend, among other things, includes the automotive industry s requirements in terms of miniaturization and alternative drives. Diehl Metall responds to them with innovative materials and solutions, making a crucial contribution to sustainable mobility of the future. The product portfolio encompasses synchronizer rings made of special brass and steel, semi-finished products for further processing into automobile components, connectors and contact systems for battery packs. ALWAYS ONE GEAR AHEAD The synchronizer ring is the keystone of any mechanical manual transmission. More than half a century ago, Diehl Metall produced the first synchronizer ring for manual transmissions. Today, the company is the market leader in this field and successful development partner of the international automotive industry. With tribology solutions covering the entire performance range, Diehl Metall creates optimum prerequisites for tailored concepts of modern engine and powertrain technologies. Brass synchronizer rings with friction threads, steel synchronizer rings with innovative coatings to improve friction and wear behavior, and combinations of all materials meet the most exacting demands in terms of geometry, strength and high wear resistance. 7
8 Schaeffler Technologies AG & Co. KG Industriestraße Herzogenaurach Germany Tel.: Fax: info@schaeffler.com Schaeffler Holding (China) Co., Ltd. No. 1 Antuo Road Anting, Jiading District, Shanghai, China Tel.: Fax: info_china@schaeffler.com Diehl Metall Stiftung & Co. KG Diehl Metall Schmiedetechnik Heinrich-Diehl-Straße Röthenbach a.d. Pegnitz Germany Tel.: Fax: sales-schmiede@diehl.com Diehl SynchroTec Manufacturing (Wuxi) Co., Ltd. No. 59 Ximei Road, Wuxi Xinwu District, Wuxi, China Tel.: Fax: sales-wuxi@diehl.com Published by Schaeffler Technologies AG & Co. KG Communication and Marketing Automotive Industriestraße Herzogenaurach Germany While every care has been taken to ensure the accuracy of the information in this publication, we can accept no liability for any errors or omissions. We reserve the right to make technical changes. Schaeffler Technologies AG & Co. KG Edition: 2017, February Reproduction in whole or in part without our authorization is prohibited.
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