Future Development Targets for manual Transmissions

Future Development Targets for manual Transmissions International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Wulf Leitermann, Platform Director Manual Transmissions & Components, GETRAG GmbH & Cie K

Agenda Global market trends for manual transmissions Market specific customer requirements Impact on transmission engineering process Requirements Engineering Design cost optimization Functional integration Optimization of transmission attributes Efficiency improvement by passive oil management Weight reduction by structural optimization Weight reduction by new materials Weight reduction by new manufacturing processes Additional Customer Functions Clutch-by-Wire Summary

Global Market Trends for manual Transmissions Market share for manual transmission is expected to be stable Global volume of manual transmissions is growing within this decade Source: IHS Automotive March 2013

Global Market Trends Regional Development for Europe (excl. Russia) Characteristics of European market: Slightly market growth expected Manual transmission share becoming lower Major volumes below 300 Nm engine torque Permanent refinement of vehicle attributes Vehicle Production Engine Torques MT 2013 16.9 mn units HVAN = VAN > 3.5t 2020 20.5 mn units Source: IHS Automotive March 2013

Global Market Trends Regional Development for China Characteristics of Chinese market: Significant market growth expected Manual transmission share becoming smaller Major volumes below 250 Nm engine torque Focus on product costs Vehicle Production Engine Torques MT 2013 20.4 mn units HVAN = VAN > 3.5t 2020 30.7 mn units Source: IHS Automotive March 2013

Global Market Trends Regional Development for BRI (BRIC excl. China) Characteristics of BRI market: Significant market growth expected Manual transmission share remains stable Major volumes below 200 Nm engine torque Focus on product costs Vehicle Production Engine Torques MT HVAN = VAN > 3.5t 2013 9.5 mn units 2020 15.0 mn units Source: IHS Automotive March 2013

Book Ends of Manual Transmission Engineering based on Global Market Requirements Emerging Markets Characteristics: Low engine torque Base technical attributes required Minimized design costs Consider market specific duty cycles and driving conditions Platform product for several customer Local supply base Mature Markets Characteristics: Full range of engine torque Sophisticated technical attributes required due to further refinement of vehicles - Weight - Efficiency Optimized design costs Well known duty cycles and driving conditions Customer specific product Global supply base

Road Load Data Basic Input for Transmission Design Requirements Vehicle Measurements Market specific customer profiles Dynamic Vehicle Simulations Torque Market specific load profiles Torque Torque level counting (RAL) Time Revolutions

Key Success Factor Simultaneous Engineering Standardization Functional optimization Target Costing Modularity Robust manufacturing processes Transmission Requirements, functions, components, modules Avoid overengineering Optimized Assembly Functional integration Simultaneous Engineering through complete supply chain

Cost Optimization by functional Integration Functional Integration leads to Significantly reduced number of parts Simplified assembly process Supply chain complexity reduced but Complex design with added functionality Need for cross functional approach Close communication with manufacturing engineering and suppliers Example: 23 parts removed from bill of material of successor transmission Parts with modified function

Efficiency Improvement by passive Oil Management (1/2) Initial situation: Churning losses are major contributor to transmission losses Challenges: Reduce immersion depth of gear set Secure lubrication in each driving condition Limitation of power consumption under high-speed conditions Control complexity and on-cost of oil management system Vehicle 96,76 % Transmission 3,24 % 0,22 l/100km Gears 0,88 % Bearings 0,88 % Churning losses 1,03 % Seals 0,29 % Synchros 0,15 %

Efficiency Improvement by passive Oil Management (2/2) Simulation / CFD CFD Analysis of base MT Design solution Hardware Tests oil shield Optimization with oil shield Results of drag torque rig test 2.000 1/min Legend: red: with oil blue: with oil and oil shield green: dry Operating conditions: - 6th gear engaged - Input speed 2.000 1/min 50 % 100 %

Weight Reduction Structural Optimization of Output Flange Initial situation: Running mass production and stable processes Challenges: Weight reduction by optimizing raw part geometry Cross functional collaboration with supplier under consideration of forging process capability Functional development of geometry to optimize stiffness and eigenfrequency of powertrain Weight reduction potenzial [%]

Weight Reduction new Material for Shift Forks Current status @ GETRAG for a typical FWD MT: Aluminum die cast shift forks with steel inserts Under development: 1. Magnesium shift forks with steel inserts 2. Glass fibre reinforced plastic shift forks with steel inserts (plastic compound) without steel inserts (pure plastic) Challenges: Limitation of peak loads Temperature profile of MT Keep cost under control Weight reduction potenzial [%]

Weight Reduction hollow Layshaft for inline MTs Initial situation: Potential for weight reduction of layshaft limited, due to Root diameter of direct cutted gears Stress at press fits Challenges: Development of a combined extrusion and rotary swaging process Ensure process stability under all conditions (e.g. quench distortion) Keep cost under control Weight reduction potenzial [%]

Additional Customer Functions Clutch-by-Wire

Summary Global market requirements are specific Emerging markets cost driven Mature markets attribute driven One-size-fits-all approach does not match to market needs State-of-the-art engineering processes are needed to develop required products Simultaneous engineering Requirements engineering Further optimization of components is the key for improving attributes Consequent usage of simulation Implementation of new materials into mass production Development of manufacturing processes MT has potential for additional customer functions, e.g. clutch-by-wire