DIWA.5 Combiig Ride Comfort with Ecoomy
DIWA.5: The evolutio of moder bus trasmissios Startig, gear shiftig, acceleratig, gear shiftig, brakig, gear shiftig: bus trasmissios have a lot to edure. Especially with the start-stop coditios i ier-city traffic, but also o coutry roads ad motorways. Therefore, over 200 000 buses worldwide have oe thig i commo: a DIWA automatic trasmissio from Voith Turbo. a Egie output 0 Startig rage DIWA automatic trasmissio hydrodyamic proportio mechaical proportio a = gear shift Drivig: power split with differetial torque coverter b a b Covetioal automatic trasmissio Egie output 0 Startig rage hydrodyamic proportio mechaical proportio a = gear-shift b = Closig of the lock-up Brakig: retarder fuctio with torque coverter Wear reductio ad comfort become visible thaks to the flexible DIWA startig rage The DIWA priciple: drivig ad brakig with oe hydraulic circuit With the DIWA.5 trasmissio, its E 300.1 ad its ALADIN diagostic software, Voith offers the ideal solutio for automatic trasmissios i buses. The prove DIWA power-split priciple allows smooth acceleratio across a speed rage where other trasmissios eed to shift gears two to three times. This makes DIWA the epitome of ecoomical bus trasmissios, up to 50 % fewer gearshifts meas less wear ad higher drivig comfort. The elimiatio of exteral pipig or hoses for the oil circulatio ad the heat exchager built ito the output cover are just a few features of the DIWA.5 trasmissio. This makes it easy for vehicle maufacturers to build the trasmissio ito the vehicle, eve where space is at a premium. Operators beefit from high availability as well as low maiteace ad operatig costs. The DIWA D 884.5 is a valuable additio to the product lie: Whe faced with meetig icreased demads, for istace, i Bus Rapid Trasit (BRT), the ew DIWA D 884.5 represets the ideal solutio for egie torques up to 1900 Nm. The DIWA D 884.5 is capable of hadlig almost 20 % more egie torque ad 10 % higher egie power ad that withi almost idetical dimesios ad oly a slight icrease i weight. 2
Voith DIWA Ecoomy ad comfort made to measure 103 753 272,5 242 886 274 263 Typical assembly dimesios of the Voith DIWA.5 trasmissio (864.5 icludig coectio flage, i mm) O the basis of idividual criteria such as wear, weight distributio, oise levels, passeger compartmet desig, etc., bus maufacturers ad operators ofte select highly differet drive solutios ad overall cocepts for their vehicles. Voith Turbo is flexible to these eeds ad, i additio to its stadard product rage, also offers compoets for the adaptatio to differet egies ad axles. Stadard scope of supply Voith DIWA stadard trasmissio Corrosio-resistat heat exchager Torsioal vibratio damper Electroic cotrol Set of cables Additioal program* Coectig flages betwee egie ad trasmissio Suspesio flages Output flages / yokes Output agle drives Pushbutto switch for gear selectio Permaet brake operatig lever * These parts are ot icluded i the stadard delivery package, but ca be supplied upo request. 3
Desig ad operatio of the DIWA trasmissio The mature desig of Voith automatic trasmissios is up-to-date with the latest techological developmets. It is simple, logical ad clear. 8 5 4 3 10 2 1 6 7 9 Idlig/eutral positio, iput clutch ope Startig DIWA rage (stepless), iput clutch ad turbie brake are closig: smooth start with high tractio. Rapidly icreasig mechaical power trasmissio via differetial trasmissio (power-split priciple). Illustrated: D 864.5 1 Couter-rotatig torque covert er 2 Impeller brake 3 Direct gear clutch 4 Differetial gear 5 Iput clutch 6 Epicyclical gear 7 Plaetary gear uit with lamellar brake for reverse gear/coverter brake 8 Torsioal vibratio damper 9 Heat exchager 10 Overdrive clutch The heart of the DIWA trasmissio is the hydrodyamic couter-rotatig torque coverter. Situated i frot of it are the impeller, the direct gear clutch, the differetial trasmissio, the iput clutch ad the overdrive clutch. Behid the coverter, a epicyclical gear combies the hydrodyamic ad mechaical forces. The fial set of epicyclical gears activates the reverse gear ad, durig brakig, also the retarder. A hydraulic torsioal vibratio damper at the trasmissio iput reduces egie vibratios effectively. Gear shiftig occurs electro-hydraulically, with pateted soleoid valves; the gear-shiftig commads are placed by the cotrol system. The heat exchager of the Voith automatic trasmissio is itegrated ito the coolig circuit of the vehicle egie; geerated heat is immediately dissipated. The trasmissio oil circuit is desiged as a full flow system esurig that the oil temperature ad trasmissio compoets ru ad operate as cool as possible. Eve whe the vehicle s coolig system is ruig hot, the temperature of the trasmissio remais relatively stable with o dager of overheatig. Performace data DIWA.5 trasmissio Types D 824.5 D 854.5 D 864.5 D 884.5 Iput power P 1max [kw] 180 220 290 320 Iput torque M 1max [Nm] 650 1 100 1 600 1 1 900 Iput speed 1max [rpm] 2 500 2 500 2 500 2 200 Retarder brakig torque M BR [Nm] 2 000 2 2 000 2 2 000 2 2 000 2 Trasmissio mass (dry) icl. retarder [kg] approx. 329 approx. 334 approx. 339 Max. vehicle weight [t] 15 28 28 34 3 approx. 344 4 1 1 700 Nm uder certai coditios 2 Maximum value, depedig o retarder cofiguratio 3 depedig o the axle ratio
A trasmissio that sets stadards for fuel cosumptio as well as service ad maiteace costs Power flow durig gear shiftig ad brakig Overdrive Clutch for the overdrive closes, clutch for direct gear opes. Reversig (R) Power is trasmitted hydrodyamically/mechaically just as durig startig. Brakig (Retarder fuctio with the coverter) The turbie wheel acts as axial pump which delivers oil agaist the stalled impeller ad the guide wheel. Heat resultig from the coversio of kietic eergy is dissipated via the heat exchager. Active power flow Rotatig compoets Locked rotatig compoets Statioary compoets Clutch plates closed ANS Automatic Neutral Switch I order to save fuel, the power flow betwee the egie ad trasmissio, icludig the coverter, is automatically iterrupted whe the vehicle is at a halt. I operatig terms, fuel cosumptio plays a major role. The overdrive esures that fuelfriedly egie speeds are achieved both i city ad i logdistace traffic. This is also aided by the torsioal vibratio damper which protects the trasmissio from low speed egie vibratios. The oil circulates solely iside the trasmissio. The Voith DIWA.5 is desiged without exteral oil hoses or pipes. This simplifies trasmissio istallatio ad improves the overall reliability of the oil circuit savig service ad maiteace costs. Filter replacemet without havig to chage the oil? Oil chage itervals up to 180 000 km? Eve that is possible with the DIWA.5, agai helpig to reduce maiteace costs. Reliability starts i the detail Specially developed sesors esure that the trasmissio is extremely reliable. However, o those occasios whe a sesor eeds to be replaced they are all accessible from the top of the trasmissio reducig maiteace times. Istallatio space is scarce i buses. The compact outer dimesios (e. g. by omittig pipes ad tubes) facilitate the istallatio of the trasmissio eve i the most cofied of spaces. Last but ot least, trasmissio istallatio ad removal times from the vehicle chassis are also sigificatly reduced owig to the straightforward coectio of the torsioal vibratio damper. Hydrodyamics are oe of the core competeces at Voith: that is why over 100 years of experiece have bee put ito our coverter, the key compoet of the DIWA trasmissio. 5
E 300.1 a ew-geeratio trasmissio cotrol The ew E 300.1 trasmissio cotrol adjusts itself optimally to its eviromet: whether it is the topography ad the axle ratio, or the electroic architecture of a moder commercial vehicle. Previously: BASP 4 BASP 3 BASP 2 BASP 1 Egie speed SesoTop: SesoTop Egie speed SesoTop Itelliget cotrol uit E 300.1 SesoTop: topography-depedet shiftig program The acceleratio-depedet shiftig programs commo today take ito cosideratio the axle ratio, the vehicle s acceleratio ad the load; However, the grade or slope that the vehicle is operatig o ca oly be estimated. The DIWA.5 Electroic Cotrol Uit (E 300.1) has bee equipped with a maiteace-free icliatio sesor that idetifies the topography quickly ad precisely. Oly this feature allows the optimum adaptatio of gear speeds to the prevailig coditio at all times. The SesoTop topographydepedet shiftig program reduces fuel cosumptio by up to 7 % while providig eve greater drivig comfort by avoidig gear hutig our cotributio to the eviromet. ad optimizatio of the vehicle operatio or i the selectio of a drivelie that meets all requiremets. The E 300.1 cotrol icludes the secodgeeratio operatig data recordig system ad thus the ability to obtai a more detailed aalysis of the service coditios uder which the vehicle ad trasmissio are beig used. Evet storage The cotrol uit ot oly reports failures, but also all detectable evets which idicate wear, icorrect operatio or the eed for maiteace work. The thoroughess of the diagostics offered by the E 300.1 eables a precise, detailed ad therefore fast localizatio of the cause. Secod-geeratio DIWA operatig data recordig The Voith DIWA trasmissio is the first automatic trasmissio for buses that has a operatig data recordig system. Operators ad vehicle maufacturers have leared to appreciate this ot just sice yesterday e. g. i the aalysis CAN pushbutto switch ad electroic type plate The CAN pushbutto switch is coveiet to use, simple to istall ad extremely reliable. The Trasmissio Idetificatio Module (TIM) offers optimum ad automatic cofigurig of the E 300.1 cotrol to the trasmissio. 6
ALADIN the user-friedly diagostic software for the DIWA.5 trasmissio The Aladi diagosis ad aalysis software presets service ad operatig data i clear, compact ad ready-to-prit reports. All importat iformatio from the cotrol uit is take ito accout: Evet storage, idetificatio data, key data, operatig data, stadstill times, adaptatio values ad much more. Aalysis ad diagosis software Evet storage Key data ad operatig data Simple, ituitive operatio Fast, detailed ad precise diagostics Direct icorporatio of repair istructios ito OEM diagostic systems possible The evet storage ca accommodate up to te idepedet evets. A evet may be either a fault message, e. g. about a short circuit i the lead to a soleoid valve, or a low oil level alert, for istace. The operatig data serve as a source of iformatio about the vehicle ad cotribute sigificatly to optimizig the drivelie desig, reducig operatig costs ad icreasig availability. The data are recorded, classified ad accumulated by the electroic cotrol uit durig the etire time that the trasmissio is i operatio. I additio, vehicle-specific key data are derived from the operatig data. Your beefits Less time required for diagostics Miimizatio of stadstill times Reductio i fuel cosumptio Ability to pla maiteace ad servicig Icreased vehicle availability Lower operatig costs 7
Voith Turbo GmbH & Co. KG Bus Drive Systems Alexaderstraße 2 89522 Heideheim, Germay Tel.: +49 7321 37-8579 Fax: +49 7321 37-7818 diwa@voith.com www.voithturbo.com G 1747 e KO/WA 09/2010. Prit ru: 2000, Dimesios ad illustratios without obligatio. Subject to modificatios.