Continuously Variable Transmission: Benchmark, Status & Potentials
Continuously Variable Transmission: Benchmark, Status & Potentials
Klaus Martin Mäder Van Doorne’s Transmissie b.v. Bosch Group 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Content Benchmark CVT, DCT & AT Status CVT Volumes and Forecast Future CVT Potential
4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Content Benchmark CVT, DCT & AT Status CVT Volumes and Forecast Future CVT Potential
4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark CVT, DCT & AT Benchmark scope: Fuel consumption Performance Packaging Cost
CVT
Benchmark Premises FWD transmissions only: CVT, DCT & 4/5/6AT Focus on high comfort state-of-the-art transmissions Latest commercially available vehicles on EU market (MY >2002) Separate Gasoline and Diesel applications
Used Data Sources, a.o.: KBA, PwC, Bosch Vehicle dbase, Ricardo, OEM Technical Data 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
DCT
6AT
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Gasoline
better
Fuel consumption [ltr/100 km] Fuel consumption [l/100 km]
Fuel Consumption by engine torque 12
4/5 AT
11
6 AT
10
DCT
9
CVT
8 7 6 5 50
100
150
200
250
300
Max. engine torque [Nm]
Max. engine torque [Nm]
350
400
Fuel Consumption based on NEDC Combined Cycle
CVT scores significantly better than 4/5 & 6AT 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Gasoline Fuel consumption km] Fuel consumption[ltr/100 [l/100 km]
Fuel Consumption by engine torque - example CVT vs. DCT 12
DC A200 Turbo
VW Golf GTI
2.0
2.0
142 / 280
147 / 280
1310 / 0.31
1347 / 0.32
Transmission Type
CVT
DCT
7 Ratio Coverage [-]
6.41
4.87
6 Fuel Consumption [ltr/100km]
7.9 (7.9)*
7.9 (8.0)*
11
Engine Displacement [ltr] 10
Engine Power / Torque [kW] / [Nm] 9
Vehicle Weight [kg] / cw [-] 8
5 50
100
150
200
* Fuel Consumption [ltr/100km] for manual transmission
250
300
Max. engine torque [Nm] Max. engine torque [Nm]
350
400
CVT scores equal to DCT for comparable vehicles 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
4/5 AT 6 AT DCT CVT
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Gasoline Fuel consumption km] Fuel consumption[ltr/100 [l/100 km]
Fuel Consumption by engine torque - example CVT vs. 6 AT 12
DC B170
11
Engine Displacement [ltr] 10
Engine Power / Torque [kW] / [Nm] 9
Vehicle Weight [kg] / cw [-]
VW Golf Plus
1.7
1.6
85 / 155
85 / 155
1360 / 0.30
1356 / 0.32
Transmission Type
CVT
6AT
7 Ratio Coverage [-]
6.41
6.01
6 Fuel Consumption [ltr/100km]
7.1 (6.8)*
8.0 (7.3)*
8
5 50
100
150
200
* Fuel Consumption [ltr/100km] for manual transmission
250
300
Max. engine torque [Nm] Max. engine torque [Nm]
350
400
CVT scores significantly better than 6AT in comparable vehicles 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
4/5 AT 6 AT DCT CVT
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Gasoline
Handout only
Fuel consumption [ltr/100 km] Fuel consumption [l/100 km]
Fuel Consumption by vehicle weight 12
4/5 AT
11
6 AT
10
DCT
9
CVT
8 7 6 5 1000
1100
1200
1300
1400
1500
Vehicle weight [kg]
1600
1700
1800
Vehicle weight [kg]
CVT scores significantly better, DCT comparable 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Gasoline Fuel Fuel consumption [ltr/100 km] consumption [l/100 km]
Fuel consumption by vehicle performance 12
4/5 AT
11
6 AT
10
DCT
9
CVT
8 7 6 5 6
8
10
12
14
16
18
Vehicle acceleration 0-100 km/h [sec] Vehicle acceleration 0-100 km/h [sec]
CVT scores best, DCT comparable in some niche applications 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Gasoline
Handout only
Performance 0-100 [sec] km/hr [sec] Performance
Vehicle performance as function of vehicle weight - engine torque ratio 18
4/5 AT 6 AT
16
DCT
14
CVT
12 10 8 6 4.0
5.0
6.0
7.0
8.0
9.0
10.0
Vehicle / Max.engine engine torque [kg/Nm] Vehicleweight weight/Max. torque [kg/Nm]
CVT scores slightly better, DCT comparable in niche applications 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Diesel Fuel consumption [ltr/100 km] Fuel consumption [l/100 km]
Fuel Consumption by engine torque 9
4/5 AT 6 AT
8
DCT CVT
7
6
5 100
150
200
250
300
350
Max. engine torque [Nm]
400
450
500
Max. engine torque [Nm]
CVT scores significantly better than 4/5 & 6AT and slightly better than DCT 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Diesel Fuel km] Fuelconsumption consumption [ltr/100 [l/100 km]
Fuel Consumption by engine torque - example CVT vs. DCT 9
VW Golf TDI
DC A180 cdi
Engine Displacement [ltr] 8 Engine Power / Torque [kW] / [Nm]
Vehicle Weight [kg] / cw [-] 7
2.0
1.9
80 / 250
77 / 250
1355 / 0.29
1301 / 0.32
Transmission Type
CVT
DCT
Ratio Coverage [-] 6
6.41
5.96
Fuel Consumption [ltr/100km]
5.4 (5.2)*
5.6 (5.2)*
5 100
* Fuel Consumption [ltr/100km] for manual transmission
150
200
250
300
350
Max. engine torque [Nm]
400
450
500
Max. engine torque [Nm]
Comparable vehicles demonstrate CVT as benchmark 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
4/5 AT 6 AT DCT CVT
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Diesel
Handout only
Fuel consumption [ltr/100 km] Fuel consumption [l/100 km]
Fuel Consumption by vehicle weight 9
4/5 AT 6 AT
8
DCT CVT
7
6
5 1300
1400
1500
1600
1700
Vehicle weight [kg]
1800
1900
Vehicle weight [kg]
CVT scores significantly better than 4/5 & 6AT, DCT comparable 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Diesel
Handout only
Performance 0-100 [sec] km/hr [sec] Performance
Vehicle performance by vehicle weight - engine torque ratio 16
4/5 AT 6 AT
14
DCT CVT
12
10
8 4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
Vehicleweight weight/Max. engine torque [kg/Nm] Vehicle / Max. engine torque [kg/Nm]
CVT scores better than 4/5AT, DCT comparable 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Diesel Fuel km] Fuelconsumption consumption [ltr/100 [l/100 km]
Fuel consumption by vehicle performance 9
4/5 AT 6 AT
8
DCT CVT
7
6
5 7
8
9
10
11
12
13
14
Vehicle acceleration km/h [sec] Vehicle acceleration0-100 0-100 km/h [sec]
15
16
CVT scores significantly better than 4/5 & 6AT, slightly better than DCT 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Transmission Length Length by transmission torque capacity 420
6 AT
400
Length [mm]
Length [mm]
4/5 AT
VW DSG
Honda 2.4ltr CVT
380
DCT
ZF CFT23
Jatco X-tronic CVT1
CVT Jatco X-tronic CVT3
360
Jatco X-tronic CVT2 AW TF-80SC
340 AW TF-60SN
AW XA-15LN
320 50
100
150
200
250
DC Autotronic
300
350
400
450
500
Transmission torque torque capacity Transmission capacity[Nm] [Nm]
CVT comparable to or better than alternatives 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Transmission Length Length by transmission torque capacity 420
6 AT
400
Length [mm]
Length [mm]
4/5 AT
VW DSG
Honda 2.4ltr CVT
380
DCT
ZF CFT23
Jatco X-tronic CVT1
CVT Jatco X-tronic CVT3
360
Applicable CVT range
Jatco X-tronic CVT2 AW TF-80SC
340 AW TF-60SN
AW XA-15LN
320 50
100
150
200
250
DC Autotronic
300
350
400
450
500
Transmission torque torque capacity Transmission capacity[Nm] [Nm]
CVT offers best degree of freedom for component layout 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Transmission Weight Transmission weight by transmission torque capacity 120
4 AT
Weight [kg] Weight [kg]
110
5 AT
100
6 AT
90
DCT
80
CVT
70 60 50 40 50
100
150
200
250
300
350
400
450
500
Transmission torque [Nm] Transmission torquecapacity capacity [Nm]
No significant difference between different transmission types 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark Transmission Cost Estimated production costs 300-350 Nm class Transmission
Production Costs [€]
1500 1400 1300
DCT 350 Nm
71
6AT 320 Nm
55
CVT 350 Nm
49
1200 1100 1000 900 800 700 100
500
1000 K Transm./Yr
CVT costs best in class 4th International CTI Symposium - Innovative Automotive Transmissions
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A+B parts
Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Benchmark conclusion: CVT is benchmark Why? Latest generation makes full use of unique CVT advantages Implemented innovations on pushbelt, variator & CVT system level result in improved performance & fuel consumption increased power density of pushbelt
ratio coverage
optimized actuation strategy
variator η / hydraulics η
torque fuse (secondary clutch)
clamping force
optimized hydraulics
hydraulic η / pump η
optimized synergy CVT and engine
powertrain η
4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Content Benchmark CVT, DCT & AT Status CVT Volumes and Forecast Future CVT Potential
4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
CVT Volume Forecast 14.3%
12.4%
World 7.1% 0.3
1.9
2005
9.4% 0.3
7.1 4.8
2.7
2006
2010
2015
17.4 % / a
4th International CTI Symposium - Innovative Automotive Transmissions
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Mio Chain CVT on market
Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Mio Pushbelt CVT on market X.x%
CVT share total AT market
X.x %/a
Annual growth 2005-2010
Continuously Variable Transmission: Benchmark, Status & Potentials
Pushbelt Torque Capacity Evolution 3rd Generation Belt
Torque Capacity [Nm]
500 450
2nd Generation Belt 1st Generation Belt Phase 5
400
Phase 7
Phase 6
350 30 mm Belt
300 250 200 150
24 mm Belt
100 1985
1990
1995
2000
2005
2010
Continuous improvement of pushbelt power density 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
2015
Continuously Variable Transmission: Benchmark, Status & Potentials
Pushbelt & Engine Torque Evolution 3rd Generation Belt 2nd Generation Belt
Torque Capacity [Nm]
500
1st Generation Belt
450 400
Pushbelt Torque Capacity
350
Ø T-Max [Nm] FWD 2ltr Diesel Ø T-Max [Nm] FWD 2ltr Gasoline
300
Ø T-Max [Nm] FWD 1.8ltr Turbo Gasoline
250 200 150 100 1985
1990
1995
2000
2005
2010
2015
CVT covers full range of current and future FWD engine torque 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Content Benchmark CVT, DCT & AT Status CVT Volumes and Forecast Future CVT Potential
4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
CVT Potentials: New Innovative Phase 7 Belt Customer benefits of new pushbelt:
6.0 5.5 5.0
e7 as Ph 2006
6.5
e6 as Ph 2002
ratio coverage [-]
7.0
e5 as Ph 1997
Power: higher Power & Torque level Cost: downsizing less rings / smaller belt Fuel consumption: larger ratio coverage better belt efficiency Size: smaller center distance
4.5
100
200
300
400
engine torque [Nm] Current applications
Phase 7 Spec
CVT belt can handle all FWD applications, including torque levels > 400 Nm 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
CVT Potentials: Innovative Actuation Strategy
New
Force control
Current strategy. New strategy .
leads to overclamping
Slip control
Fclamp
∆F
Force [N]
Current
Fclamp
Fmin
matches exact clamping requirement
0
Engine torque [Nm]
Tmax
Opportunities for fuel consumption reduction: Slip control, optimized clamping : 3-5%
(Increased variator efficiency & reduced actuation power requirement)
Optimized pump / hydraulics
(reduced actuation power requirement)
: 2-3%
CVT fuel consumption reduction based on actuation: 5-8% 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Summary Benchmark CVT, DCT & AT CVT is benchmark Price-performance ratio CVT significantly better than 6AT and DCT CVT status and outlook Forecast in 2010: 4,8 Mio CVTs / year CVT covers full range of current and future FWD engine torque CVT potentials New pushbelt handles torque >400 Nm CVT fuel consumption reduction based on actuation: 5-8 %
4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | Š Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Drive into a step-less world with BOSCH/VDT CVT Pushbelt technology
∞ Transmission Steps AT - steps
CVT
3
7/8/9AT? 6AT 5AT 4AT 3AT
Time Time 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Continuously Variable Transmission: Benchmark, Status & Potentials
Drive into a step-less world with BOSCH/VDT CVT Pushbelt technology
∞ Transmission Steps AT - steps
CVT
3
7/8/9AT? 6AT 5AT 4AT 3AT
Time Time 4th International CTI Symposium - Innovative Automotive Transmissions
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Business Unit CVT | 07.Dec.2005 | © Robert Bosch GmbH / Van Doorne´s Transmissie B.V. reserve all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.