CVT - Expansion by Exceeding Expectations

Transcription

1 CVT - Expansion by Exceeding Expectations History Market trends Product innovations Opportunities of electrification Conclusion FISITA WORLD AUTOMOTIVE CONGRESS Francis van der Sluis Bosch Transmission Technology B.V. 1

2 History of Bosch Transmission Technology February 13, 1958: Introduction DAF 600 with Variomatic Start of metal pushbelt development. 1970: 1 st patent application 1972: Founded Van Doorne s Transmissie B.V. Mass production of the metal pushbelt starts for the Subaru Justy CVT enters Formula 1 but is banned from the race Van Doorne s Transmissie B.V. becomes part of Bosch 2009: named Bosch Transmission Technology B.V. 2 nd production facility: Vietnam Production milestone: 25 million th pushbelt 2

3 Production (Million Units) FISITA World Automotive Congress 2014 Cumulative production volume vehicle diversity 50 Compact conventional Opel/GM Spark Honda Civic hybrid Honda CR-Z Honda Insight Mitsubishi Lancer Nissan Sentra Suzuki SX4 Compact CUV Compact MPV 25 Mio. pushbelt produced Jeep Compass Jeep Patriot Mitsubishi Outlander Mitsubishi Outlander sport / RVR Nissan Juke Nissan Rogue / X-Trail Nissan Cube Large conventional Midsize conventional Midsize CUV Midsize Van Sub-compact conventional Nissan Maxima Nissan Altima Suzuki Kizashi Honda Accord Nissan Murano Nissan NV200 Nissan Versa Start of mass production 10 Mio. pushbelt produced Year 3

4 Top 5 best selling vehicles in the USA Vehicle Sales FE 2 [MPG] (Automatic) FE 2 [MPG] (Manual) #1 Toyota Camry 3 408,484 6AT 28 - #2 Honda Accord 366,678 CVT #3 Honda Civic 336,180 CVT #4 Nissan Altima 320,723 CVT 31 - #5 Toyota Corolla 302,180 CVT 32/ ) Sales numbers from 2) FE numbers based on OEM data 3) Next update: ) ECO variant USA is a growth market for CVT 4

5 PC / LCV Vehicle Market FISITA World Automotive Congress 2014 Market trend world - Driveline Engine types in mio. units Automated Transmissions in mio. units ) 26.8 (26.2) 55.1 (60.4) EV PHEV HEV CNG/LPG GDI PFI PG AMT DCT CVT (25.2) Diesel AT Share of electrification [%] CAGR : 4.2% Share of total number of vehicles [%] CAGR : 6.9% ICE = Internal Combustion Engine, PC = Passenger Car, LCV = Light Commercial Vehicle, CAGR = Compound Annual Growth Rate ICE remains dominant. Shift to drivelines with high electrification level. 5

6 Market trend - Transmission AT Advantages High torque capacity Smooth launch w/ torque converter Symmetric design fit for RWD CVT Advantages Most efficient engine operation Smooth launch and variator device Easy adaptable for Hybrids Disadvantages Hydraulic losses Drag losses in clutches DCT Advantages High efficiency Easy adaptable for Hybrids Sportiveness (European view) Disadvantages Creeping capabilities (US view) Dry clutch is problematic Disadvantages Hydraulic losses Torque capacity limit at 450Nm AMT Advantages Highest efficiency Cheapest automated transmission Resembles manual option Disadvantages Driveability (torque interruption during shifts) NVH 6

7 Market trend Regions Conclusion on market shares by regional preference NAFTA Japan Asia / China EU Fuel consumption improvement required Smooth launch torque converter Comfortable with AT and CVT CO 2 legislation enforces switch to CVT Lack of system commitment increases diversity Good fuel consumption at low cost Manual shifting provides sportive image DCT growing fast Preference AT CVT AT AT Runner up CVT AT DCT CVT DCT 7

8 CVT Market overview EUROPE JAPAN CHINA NAFTA REST of ASIA Korea, Indonesia, Thailand WORLD CVT production (Mio. units)* *) combined volume: chain + pushbelt CVT Bosch foresees a strong increase of CVT production

9 Pushbelt and pushbelt CVT production Belt CVT Production capacity New location Strong increase of pushbelt CVT production Source: OEM press releases 9

10 Market Drivers Trends like : Urbanisation Aging population Natural resource reserves Climate change Emerging markets Efforts of the automotive industry Are driving : Mobility The demand for automated transmissions Improvement of Key Performance Indicators Several trends drive the transmission technology of the future 10

11 Key Performance Indicators (KPI) Comfort Fuel Economy Power Density NVH Cost Several indicators define the performance of the pushbelt CVT 11

12 JD Power IQS [pp100] FISITA World Automotive Congress 2014 Comfort Comfort Fuel Economy Power Density NVH Cost Viewpoint US consumer JD power IQS (FWD vehicles) SM IQS: Initial Quality Study rough shifts erratic shifts shifts at wrong times hesitation noises Better Belt CVT Transmission types 1.9 IQS: Initial Quality Study, PP100: reported Problems Per 100 vehicles after 90 days of ownership Comfort OEMs of the value pushbelt the level CVT of is comfort well accepted offered by US the customers CVT 12

13 Fuel Economy Comfort Fuel Economy Power Density NVH Cost Fuel consumption latest CVT applications over vehicle classes 1,2 Mitsubishi Mirage Toyota iq Nissan versa Toyota Corolla Nissan Altima Honda Accord Audi A4 Mini Light Compact Medium Heavy 1) Data from 2) According NHTSA classification by curb weight Latest CVT applications show good performance in every vehicle class 13

14 Fuel Economy Comfort Fuel Economy Power Density NVH Cost Driveline losses - Energy distribution over NEDC 16% 16% 8% 8% 66% 66% 10% 10% Engine Engine Engine (66%) idle Engine Transmission idle (10%) Transmission Road (8%) Fuel ICE Transmission Road 100% 76% 8% 16% Road (16%) Measures in the transmission influence ICE and transmission loss 14

15 Fuel Economy Engine performance Comfort Fuel Economy Power Density NVH Cost Improve engine performance by ratio coverage increase - belt requirements Smaller running radius elements Smaller bending radius loops Improved clearance angle Allow an increase of ratio coverage Running radius Clearance angle Bending radius Engine performance is improved by belt measures that increase ratio coverage 15

16 Fuel Economy Transmission loss Comfort Fuel Economy Power Density NVH Cost Losses in the variator 10% 1 2/ % 45% 1 3 2% 2 32% Difference in in height running radius 4 5 Element-pulley Element-loop Element-ring Loop-loop Ring-ring Element-element Bearings No No pure rolling Element-pulley and element-loop friction are main variator losses 16

17 Variator efficiency [%] FISITA World Automotive Congress 2014 Fuel Economy Transmission loss Comfort Fuel Economy Power Density NVH Cost Increase variator efficiency by increased element-pulley friction 10% % 95 slip region 0.12 Margin 45% 1 3 Clamping force 2 32% Element-pulley Element-loop Element-ring Loop-loop Ring-ring Element-element Bearings 2% Clamping force [kn] [-] Margin Oil (1979) variator & belt (1981) 1985 Margin New oil types New Variator & belt 2012 Time Future oil Future Variator & belt Future Increase of element-pulley friction enables reduction of all frictional losses 17

18 Fuel Economy Transmission loss Comfort Fuel Economy Power Density NVH Cost Increase variator efficiency by reduced internal belt loss 10% % Ultimate efficiency increase mm 45% % Element-pulley Element-loop Element-ring Loop-loop Ring-ring Element-element Bearings 2% Recessed areas 1mm mm Measured efficiency increase [%] Speed ratio [-] OD LOW Geometrical changes of the element design enable reduction of internal loss 18

19 Power Density New Ti-free loop material new failure mode Nitrided zone Residual fracture Fatigue fracture Comfort Fuel Economy Power Density NVH Cost Loop Dimple structure Fatigue structure Fatigue initiation Surface defects TiN inclusion Initiation area New failure mode for Ti-free material means further optimization is possible 19

20 Power Density Comfort Fuel Economy Power Density NVH Cost Further optimized Ti-free maraging steel loop materials* : Ti-free Reduce Co Add Al Add Cr prevent TiN inclusions to improve fatigue strength cost sensitive element increase hardness & tensile strength increase compressive residual stress surface layer Previous : Durimphy Current : Phytime % 18 New alloys Ni Co Ti Al Cr Elements (balance: Fe) % Ni Co Ti Al Cr Ni Co Ti Al Cr Continuous material research improves power density of the pushbelt Fe = Iron, Ni = Nickel, Co = Cobalt, Ti = Titanium, Al = Aluminium, Cr = Chromium content in [%], * also see presentation Bosch/Bert Pennings % 20

21 p FISITA World Automotive Congress 2014 NVH Comfort Fuel Economy Power Density NVH Cost Polygon effect p Pitch distance elements t Running radius r Passing frequency Local differences in element speed p v max v v max min 100% Principle Effect on speed differences r t p v max v min max 1 st pushbelt (1985) VDT block belt (1970) r min r max Current belts The polygon effect dominates the NVH behaviour of the pushbelt variator 21

22 Amplitude FISITA World Automotive Congress 2014 NVH Comfort Fuel Economy Power Density NVH Cost NVH improvement by consequent research 1 New measurements methods Planar Nearfield Acoustic Holography (PNAH) Optimal sequence of elements with varying thickness t 1 and t 2 Acoustic hologram (PNAH) Secondary pulley Strong reduction of NVH 2 Excitation at pulley eigenfrequency 70% 100% Primary pulley t 1 t 2 Pulley speed [rpm] 1 also see presentation Bosch/Erik van der Noll 2 element thickness not on scale Further improvements in variator NVH behaviour underway 22

23 Latest introductions with pushbelt CVT Mitsubishi Mirage Chevrolet Spark Honda Civic Nissan Altima 1.2ltr 100Nm Jatco CVT7 Bosch 24/6 belt 1.2ltr 113Nm Jatco CVT7 Bosch 24/9 belt 1.8ltr 175Nm Honda CVT Bosch 24/12 belt 2.5ltr 250Nm Jatco CVT8 Bosch 28/12 belt Pushbelt performance supports excellence of new customer products 23

24 The next generation Three stories recently in the news : Small EV PHEV SUV Energy : Availability increases. Driving range needs to be improved. : Popular with company car driver. Gasoline usage too large. : Holland to build 600MW wind park. Fear for horizon pollution. 76km 110km 100km 169km City traffic Highway traffic Winter stop&go 222km Heavy traffic stop&go Ideal EV driving range [km] The electric era is coming but issues on multiple levels to be overcome 24

25 The next generation Three needs for a successful product : A good product A healthy business case A customer Also for electrified driveline, customer acceptance is based on KPI Comfort Fuel economy Power density NVH Cost Driveability - Shift comfort Start-stop and launch behaviour Driving range in all cycles Downsized engine/e-motor Optimal engine/motor operation at every speed Continuous energy recuperation Low speed-high torque capability Compact Reduced weight Low noise No shift shocks Continuous Carry-over parts with conventional driveline Reduced size E-motor/power electronics/battery Mild & full hybrid option - modular KPI remain essential for acceptance next generation electrified products Solution: CVT and parallel hybrid 25

26 Fuel consumption [%] FISITA World Automotive Congress 2014 The next generation Example Honda Jazz hybrid * 1.4L i-dsi i-vtec engine Continuously Variable Transmission 24/12 Pushbelt SM 100 Better l/100km Manual 5.5 l/100km CVT 4.5 l/100km -19.6% Hybrid + CVT * Europe, NEDC combined fuel economy KPI remain essential for acceptance next generation electrified products 26

27 Conclusions The pushbelt CVT has become a strong transmission option This success is based on the Key Performance Indicators comfort, fuel efficiency, NVH and power density The introduction of new pushbelt types continue to set the next milestones Bosch dedicates itself to a continuing effort to improve the pushbelt variator Bosch will continue to support the Success of the Pushbelt CVT 27

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