Synchronizers. Rivoli, May 2007

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1 Synchronizers Rivoli, May 2007

2 Why? EFFICIENCY SIMPLICITY DIMENSIONS WHY SYNCHRONIZERS? EASY AUTOMATIC SHIFTING TORQUE COST

3 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

Key Figures TURNOVER: ANNUAL PRODUCTION: 700.

4 Key Figures TURNOVER: ANNUAL PRODUCTION: SYNCHRONIZERS 87 mn MARKETS: TRACTORS FULL DESIGN & TESTING CAPABILITIES RANGE OF SIZES: PASSENGER CARS TRUCKS CONSTRUCTION SPECIAL VEHICLES FROM 62 mm UP TO 135 mm WORLD LEADER FOR TRACTORS APPLICATIONS

5 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

6 The Products TYPOLOGIES STRUT TYPE S/C D/C T/C PIN TYPE FRICTION MATERIALS: BRONZE MOLY HIGH MOLY LOW SINTERED BRONZE CARBON

7 The Products CATALOGUE

8 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

9 Manufacturing PLANTS Noida Plant (Uttar Pradesh) Components, H.T. and assembly Headquarters and Plant Cascine Vica (To) Sliding sleeves Comp. finishing Final assembly Garessio Plant Hubs Clutch body rings I.T.T. Plant Heat Treatments WORLDWIDE INDIAN MARKET

10 Manufacturing Hub machining PRODUCTION FLOW Sliding sleeve machining Clutch body ring machining H.T. H.T. H.T. finishing finishing finishing Balls Springs poppets Dimensional and functional 100% assembly Test Oiling and packaging customer Friction rings

11 Manufacturing SLIDING SLEEVE PROCESS FLOW stoppers milling tooth chamfering tooth rulling from broaching to final H.T. fine broaching

12 Manufacturing ELECTRON BEAM WELDING CLUTCH BODY RING UP TO 15mm WELDING DEPTH GEAR

13 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

14 Design INPUT DATA FROM CUSTOMER..PLEASE FILL IN THIS DATASHEET: Customer name: Transmission code: Vehicle type: Synchronizer displacement: Speed Range Forward-Reverse Other Axial load on synchronizer slinding sleeve [N] Min: Max: Reflected inertia on synchronizer cone [kgm 2 ] Max Drpm to be synchronized [rpm] Max engine rpm [rpm] Max continuous torque on synchronizer [Nm].....

15 Design SYNCHRO TIPOLOGY DEFINITION Synchronizer Synchronizer type: type: Application: Application: single single cone cone d.82 d.82 mm mm moly moly 1st/2nd; 1st/2nd; 3rd/4th 3rd/4th Outside cone diam. Mean diam. Cone angle Cone band Cone area Friction Friction material coeff. Total inertia Delta RPM Relative speed Axial force Torque Drag torque Total torque Synchro. time Specific energy Specific power Specific pressure SHIFT [mm] [mm] [deg] [mm] [mm 2 ] [Kgm 2 ] [rpm] [m/s] [N] [Nm] [Nm] [Nm] [sec] [J/mm 2 ] [W/mm 2 ] [N/mm 2 ] I-II ,5 8, Moly 0,1 0, , , ,66 0,105 0,13 1,24 6,27 II-III ,5 8, Moly 0,1 0, , , ,66 0,102 0,12 1,20 6,27 III-IV ,5 8, Moly 0,1 0, , , ,66 0,103 0,125 1,21 6,27 IV-III ,5 8, Moly 0,1 0, , , ,66 0,516 0,25 0,48 6,27 III-II ,5 8, Moly 0,1 0, , , ,66 0,505 0,24 0,47 6,27 II-I ,5 8, Moly 0,1 0, , , ,66 0,531 0,26 0,499 6,27

16 Design FEM ANALYSIS ON CRITICAL COMPONENTS

17 Design ITI-SIM SIMULATIONS FOR SHIFTABILITY IMPROVEMENTS DRIVELINE MODEL ANALITICAL RESULTS

18 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

19 Testing FRICTION COMPONENTS (test (test bench bench picture picture confidential) confidential) COMPARATIVE TESTS ON: FRICTION MATERIALS GEOMETRIES RING-C.B.R. MANUFACTURING PROCESS STICKING SUPPLIERS

20 Testing COMPLETE SYNCHRONIZER: ENDURANCE TESTS MEASUREMENT OF: SHAFTS SPEED FRICTION COEFF. SYNCHRO. TIME AXIAL LOAD RPM GAP WEAR Speed shaft 2 Speed shaft 1 (test (test bench bench picture picture confidential) confidential) Friction Coefficient Stroke

21 Testing COMPLETE GEARBOX CLIMATIC CELL FOR LOW TEMPERATURE TESTS (-40 C) (test (test bench bench picture picture confidential) confidential)

CHART X=24,70 mm Punto di arresto Asta comando Y=10,00 dan X=31,43 mm

22 Testing COMPLETE GEARBOX Y=20,00 dan X=50,00 mm Y=10,00 dan X=39,58 mm X=32,31mm Punto di arresto asta comando SHIFTABILITY: TRAVEL-LOAD CHART X=24,70 mm Punto di arresto Asta comando Y=10,00 dan X=31,43 mm Y=20,00 dan X=41,34 mm KINEMATIC SHIFTING CHAIN STIFFNESS: LOAD-STRAIN CHART

23 Testing VEHICLE TESTS NOISE COMFORT SHIFTABILITY

24 Testing TRUCKS

25 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

26 New Projects SINGLE CONE D74 FOR CARS AND TRACTORS SAME ASSY DIMENSIONS AS D68 WITH LARGER CONE SELF-QUENCHING SINTER MATERIAL RING INTEGRATED SPRING-BALL-POPPET ACTUATORS (ON PRODUCTION 2005)

New Projects D/C T/C D 90/95/100 TO PREVENT DOUBLE BUMP AND IMROVE SHIFTABILITY Initial Initial geometry geometry (geometries (geometries picture picture

27 New Projects D/C T/C D 90/95/100 TO PREVENT DOUBLE BUMP AND IMROVE SHIFTABILITY Initial Initial geometry geometry (geometries (geometries picture picture confidential) confidential) Final Final geometry geometry (geometries (geometries picture picture confidential) confidential) MODULAR DESIGN LOW MODULE NOT-SYMMETRIC CHAMFERINGS

28 New Projects MODULAR DESIGN S/C D/C T/C D 105/113/119 FOR HEAVY APPLICATIONS (UNDER DEVELOPMENT STUDY)

29 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

30 Environment UNI EN ISO 9001:2000 UNI EN ISO 14001: 1996 ISO/TS 16949: 2002

31 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

32 The Customers AGRICULTURAL MARKET

33 The Customers CONSTRUCTION, TRUCKS, PASSENGER CARS, SPECIAL VEHICLES

34 Agenda Key Figures The Products Manufacturing Design Testing New Projects Environment The Customers Contacts

35 GRAZIANO TRASMISSIONI S.p.A. Via Cumiana Rivoli (Torino - Italy) T : F : info@grazianotrasmissioni.it

Oerlikon Graziano worldwide leader in the field of precision gearing, transmission solutions and driveline systems

Press Release Oerlikon Graziano at Excon 2009 in Bangalore (India) 25-29 November 2009 Oerlikon Graziano worldwide leader in the field of precision gearing, transmission solutions and driveline systems