CTI_2005_Benchmark_Bosch-CVT

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.