printReview 2009
The 3rd CTI Symposium + Exhibition 'Automotive Transmissions North America' took place at the MGM Grand Hotel in Detroit, MI from 12 to 14 May 2009.
150 participants listened to 40 speeches presented by the most important car manufacturers and suppliers. Three sponsors and 18 exhibitors displayed their products and solutions on the Transmission Expo.
Although the global economic crisis is impacting the automotive industry harder than ever, many high-level delegates from Europe, Asia and the US came to Detroit to share the latest experiences in transmission technology at the CTI symposium.
Together with the members of the advisory board – Ernie DeVincent from GETRAG Transmission Corporation (Chairman), Phil Gott from Global Insight, Bert Martin from Chrysler and Professor Kücükay of the University of Braunschweig , CTI created a program that gave an overview of the latest developments in transmission engineering.
The symposium on days one and two was divided into plenary speeches, and specialized sessions A to D. Hybrids and alternative drivetrains were the focus of the special program on day three.
Plenary sessions
Ernie DeVincent from GETRAG pointed out in his opening speech that bankruptcy now dominates the landscape, with 50% of suppliers forecast to go down.
In his plenary speech on day one, Phil Gott of Global Insight stated that the diesel-gas spread will increase, and the US market will not be back until 2012. The current crisis is hitting hard because unlike recent depressions, it is global. Asia will remain the engine of growth. By 2019, every third vehicle will be produced in Asia (excluding Japan and Korea). Bert Martin and Mircea Gradu from Chrysler predicted that planetary transmissions will be dominant in the future.
In the plenary speech on day two, Alexander Edwards from Strategic Vision demonstrated with surveys that only 5% of US customers are 'very aware' of transmissions as a product. Transmissions have a significant impact on characteristics to purchase cars. Power and transmissions are among the top ten decision priorities, whereas green issues have a very low impact on US customer decisions. Finally, he explained how transmissions contribute to safety – for example to passive safety due to quietness, and active safety through acceleration potential and responsiveness. In the plenary discussion on day, two Phil Gott of Global Insight, Steve Thomas of Ford Motor Company and Bukhard Pollak of GETRAG concluded that fuel prices have a direct impact on decisions to buy fuel-efficient cars. Although lots of new features and technology have been built into transmissions, it is hard to make customers give up something they are used to.
Parallel sessions
The parallel sessions on days one and two focused on DCT, lubrication, materials, development methods. all-wheel drive, torque converters, fuel economy, transmission electronics and thermo management. New technologies were presented under the moderation of Dave Old, formerly of General Motors (A), Dr. Carl Andersen, Michigan Technological University (B), Dr. Sankar K. Mohan, Magna Powertrain (C) and Dr. Houssein Dourra, Chrysler (D).
Session A
Among other presentations John Maten of GM Powertrain reviewed the technical details of an experimental, high power capacity RWD 7 speed DCT – with the unique feature of torque converter launch. Dr. Faust described the entire product line of GETRAG DCT transmissions – wet FWD, wet RWD and dry FWD, which improves both performance and fuel consumption.
Session B
Transmission technologies are changing – and fluid technologies must change too, explained Scott Halley of The Lubrizol Corporation: additive packages for DCTs are now being developed that optimize both friction and wear performance, using new VM technology. Mark Hoosier of Hirschvogel showed a concept for globally producing hollow forgings that reduce weight (15-30%) and machining costs, yet maintain technical strength. Eric Schueler of Sulzer explained that Sulzer has developed a comprehensive rubric for evaluating carbon materials properties that can help in matching carbon material technologies to applications . There is an opportunity for meeting required CO 2 reduction targets by reducing bearing losses. SKF has developed a simulation tool that can identify sources of power loss; this was presented at the symposium by Thomas M. Wolf. Andrew Yermak of Robert Bosch showed the Design for Six Sigma in the Bosch transmission component process.
Session C
Jean Schweitzer of GM Powertrain presented a small torus torque converter as an enabler for future transmissions. Dr. Wolfgang Reik of LuK talked about the changing powertrain challenges for NVH. Many factors contribute to higher torque engines, including larger number of gears and low friction bearings and seals. He stated that there is a need for more damping to reduce rattle and NVH+. Kiran Govindswamy of FEV, Inc explained the influence of driveline losses on vehicle fuel consumption. Dr. Mark Patton of BorgWarner presented a chain alternator starter for a strong hybrid drive. The hybrid drive fuel economy benefit is about 30% in NEDC cycle.
Session D
Dr. Markus Eglinger presented Continental's modular approach to transmission control units. This includes the design and assembly of lead frames and the sealing of the electronics cavity, manifold, hydraulic and solenoid. Michael Allen Hall of Chrysler presented a new approach to shift scheduling. In this approach, engine torque reserve is used to initiate shifts, which improves the overall drive strategy. Gianluca Vitale of AVL presented a method for automating shift quality calibration. Yuji Fujii of Ford Motor Company explained a pressure-resistive elastomer sensing device. This low-cost load sensing device was tested on band broke and clutch plate load sensing with excellent results.
Hybrid Day
Under the chair of Dr. Andreas Truckenbrodt of Automotive Fuel Cell Cooperation, the specialized day three presented an impressively broad overview of how the automotive industry is reacting to government pressures to reduce CO 2 emissions and the need to reduce oil consumption.
Scott Miller of Synovate said consumers are excited about the fuel efficiency of hybrids, and that plug-in hybrid will gain ground in the coming years One in three consumers are willing to spend $ 2000 more on a car with this new technology. Dr. Donald Hillebrand of the U.S. Department of Energy presented the America Plan (Obama/Biden) for new energy. Among other things, this foresees 1 million plug-in hybrid cars (150 mpg) by 2015. Larry Nitz of General Motors pointed out that customers do not buy a technology – they buy a car. Michael G. Andrew of Johnson Controls described Li-Ion batteries as the obvious next step, and the target of every OEM. Dr. Neil Armstrong of Daimler explained the roadmap for future mobility: combustion engines, hybridization, emission free battery/fuel cell vehicles, supported by clean fuels, electricity and hydrogen. The Daimler approach is a modular design of battery-electric, range-extender and fuel cell vehicles (“blue zero”). Roland Ehniss of Robert Bosch presented the two developments paths at Bosch, which are based on existing HEV technology and new EV components. Nancy Lee Gioia of Ford Motor Company presented the Ford technology strategy with its near term (-2011), mid term (-2020) and long term (-2030) goals. Various types of electric systems (HEV, PHEV, BEV) will be on a single global platform. There will be an integrated world made up of utilities, the automotive industry, governments and consumers. Finally, Mike Donoughe of Tesla Motors explained the Tesla focus on battery, power electronics, motor, controls and software. There will be common powertrains for different platforms – roadster, model S, OEM EV powertrains.
Networking
To give participants sufficient opportunities to communicate with their peers, the coffee and lunch breaks were held in the exhibition area. Three sponsors and 18 exhibitors of the latest transmission technologies made this conference a special platform for specialist discussion about transmissions, hybrid and alternative drivelines.
At the end of day one, an after-conference party in the 'Ignite Bar' in the MGM Grand Hotel provided an ideal setting in which to continue the exchange of ideas in a more private atmosphere.
Conclusion
Looking back over the three days, it is safe to assume that the transmissions landscape of transmission companies and technology will change significantly. Transmissions will continue to be a key topic in a form of mobility that will deliver fuel economy, while meeting the needs of consumers who demand comfortable, enjoyable driving.
