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The automated transmission system for modern cranes
GB
Introduction In recent years vehicle manufacturers have been directing a substantial share of their activities at relieving drivers of some of their workload so that they can fully concentrate on safe and economical goods transport.
To this end, mechanical transmissions were used, automated with add-on technology such as shift cylinders, valves, sensors and so on.
ZF has abandoned this approach and developed a new transmission concept which is setting standards. ZF´s tried-and-tested transmission technology wedded with state-of-the-art electronics have brought forth the promising ZF-AS Tronic system – and, sure enough, at reasonable cost.
All transmission functions have been integrated in one single unit. The driver can choose in favor of the automatic mode or opt for manual shifting of gears. In any case, he has been relieved of any clutch work and can fully concentrate on steering his truck.
The ZF-AS Tronic stands for: ➽ Economic efficiency ➽ Reliabilitiy ➽ Environmental acceptability
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ZF-AS Tronic – A means to what end?
New technological solutions open up a whole world of novel opportunities of design for the entire driveline: ➽ EDC-engines have gone into production ➽ Standard dry clutches have become fully automatable ➽ EDC and other electronics systems can communicate (CAN-communication)
Increased
reliability and raised economic efficiency of vehicles have been and still are core issues in development work. ZF fully supports these objectives and has made a major contribution with the ZF-AS Tronic.
➽ The entire driveline is relieved of substantial load by the fact that gear changes are automatic and shift processes automated. ➽ Reduction of the number of sources for malfunction by integral construction. ➽ The new automatic ZF-shift strategy permits operation of the engine in the most economical range (automatic mode). ➽ Simple operation (also facilitates change of drivers). ➽ If needed, the driver can intervene in any traffic situation and initiate gear changes at his own discretion (easy correction by means of a tip lever).
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ZF-AS Tronic – By all means!
It is the optimum drive system for trucks with electronically controlled diesel engines (EDC) and modern CAN-technology.
009399
➽ Automatically shifting transmission system on the basis of a robust, mechanical transmission. ➽ If needed, semiautomatic operation (manual gear selection). ➽ Alternative operating concepts (e.g. console selector, steering column/steering wheel selector). ➽ Electronic/pneumatic clutch control; no clutch pedal. ➽ Electric/pneumatic shifting ➽ Speed adjustment of the gears (synchronization) in the main gear during gear shifts performed via EDC-engine and transmission brake.
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ZF-AS Tronic – By all means!
A perfectly communicating driveline. Engine
EDC
integrated Transmission Control
ABS/ASR
3
000
565
01046
The ZF-AS Tronic offers: ➽ ➽ ➽ ➽
CAN-system network continuous monitoring of vehicle condition info readout for driver via display Selection of drive program and correction option via tip lever (joystick) ➽ Diagnosis possible direct on vehicle MKS-KD3 333 21089 e
This is ZF-AS Tronic
T he first completely integrated transmission system. clutch
shifting module with integrated electronics
clutch actuator ➽ ➽ ➽ ➽
No "add-on" operating elements. Only few central connections for compressed air and electric system. Electronic control system integrated in shifting module. Space and weight-saving construction: Two countershafts and 2-speed planetary gear. ➽ The basic gear is dog clutch-operated (non-synchronized); Splitter and range-change group are synchronized. ➽ Simpler, shorter, lighter and more versatile than anything else the market can offer today.
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ZF-AS Tronic – Two Performance Classes
Optimum installation space, weight and costs. ➽
12 AS 2301
12-speed transmission for vehicles up to 2 300 Nm (ca. 450 HP)
Specifically for this price-conscious vehicle class!
➽
16 AS 2601
16-speed transmission for vehicles up to 2 600 Nm (ca. 550 HP)
Ideal for demanding transport tasks in international transportation!
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Transmission Design
009931
Double-countershaft transmission with • integrated splitter group and • planetary-designed range-change group Splitter group
12 AS 2301 =
2
Main Range-change transmission group
x
3
x
2
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Installation Dimensions
953 (910) 5
395 3
278
5
221
622.5 (579.5) 7
(109) 116.5
301
Ø25
Ø511
Ø180
32
9
7
6
1
4
9
8
10
2 011524
Legend: 1 2 3 4 5
Input Output Shifting module Clutch actuator Breather
Connection site for clutch-dependent PTO 7 Compressed-air connection 8 Oil fill opening and oil level check 9 Oil drain opening 10 Speedo sensor ( ) Dimensions in parentheses for 12 AS 2301 6
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Technical Data
12 AS 2301 Nm
2 300
1 900 250
kg
11
L
Direct Drive
Gear 1 2 3 4 5 6 7 8 9 10 11 12 R 1 R 2
Overdrive
15.86 12.33 9.57 7.44 5.87 4.57 3.47 2.70 2.10 1.63 1.29 1.00
12.33 9.59 7.44 5.78 4.57 3.55 2.70 2.10 1.63 1.27 1.00 0.78
14.68 11.41
11.41 8.88
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Internal Structure and Function 16 AS 2601 Sp
K1
transmission brake
litte
rg rou p K2
R-gear reversing gear 4 3
Range-change group
2 1
16 (12 AS 26 01 AS 230 : four 1: t hre speed R-gear e-s pee sectio reversing n ds ect gear ion )
Output flange
➽ Housing: Light alloy, three parts; integrated clutch bell. ➽ Power distribution: Constant K1 or K2 on both countershafts. ➽ Return of power distribution in 4-speed section onto main shaft in corresponding gear (or reverse gear). ➽ Drive via range-change group. In slow driving range speed 1 to 8 (12 AS 2301: 1-6) with range group ratio. ➽ In fast driving range speed 9 to 16 (7 to 12) direct to universal shaft. ➽ The 12-speed transmission 12 AS 2301 has no gear set Therefore, the transmission is about 43 mm shorter.
1
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Gear Shifting Shifting module Shift Cylinder for range group section
Selector cylinder for main transmission
Shift cylinder for main transmission section Shift cylinder for splitter group
12
e -sp
ed
GV 2/3
1/R GP
➽ Gearshifts are perfomed by the shifting module (pneumatically) ➽ For splitter and range groups one shift cylinder each ➽ One shift cylinder for actuation of main transmission section ➽ One shift cylinder for gear selector of main transmission section ➽ Valves, cylinders, sensors and external connections integrated in transmission shifting module ➽ Shifting commands from the electronic system or, if needed, from the driver
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Clutch Actuation
Clutch
Transmission Control Unit
travel sensor
valves clutch open
0108
valves clutch closed
42
actuator piston control electronics
clutch actuator
air supply
010833
➽ No clutch pedal or hydraulic system ➽ Electro-pneumatic control of clutch processes • when starting-off and when stopping • when shifting gears • when maneuvering ➽ Standard dry clutch actuated by clutch actuator ➽ Automatic clutch re-adjustment ➽ Driver automatically warned (display) if clutch is overloaded ➽ Display readout if clutch needs to be replaced
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Shifting Module
Shifting module
with integrated Transmission electronics
Integrated Transmission Control Unit
010833
010291
Vehicle plug (CAN)
Transmission plug
The shifting module is installed on the top of the transmission, and easily accessible It contains: ➽ ➽ ➽ ➽ ➽ ➽
the integrated transmission electronics the valves for "shifting", "selecting", "transmission brake" the shift cylinders sensors for speed, pressure, etc. pressure relief valve the electric and pneumatic connections for vehicle and transmission
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Transmission Control Unit
CAN-communikation with EDC, ABS, ASR Clutch control Transmission control, gear changes Automatic system (Driving strategy)
010832
The transmission electronic system controls all processes in the transmission and continuously communicates with linked-up vehicle systems. 8
7
1
3
9
2
4 6 5 air supply
1
Electronic Diesel Control (EDC) 2 Shifting module with integrated Transmission Control Unit 3 EDC-engine 4 Dry clutch
5 6 7 8 9
Clutch actuator Intarder electronics Display Range selector ABS / ASR
Electrics Pneumatics CAN-communication
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Operating Concept Console Range Selector Several upshifts (several taps)
upshifting (1 gear)
A/M
reverse shifting (1 gear)
switch over (only whilst driving)
several downshifts (several taps) 63
0104
D ... Drive (forward, automatic or manual) N ... Neutral R ... Reverse A ... Automatic M ... Manual
010464
The display keeps the driver informed: 000
565
➽ Operational mode (Drive mode, actual gear, etc.) ➽ Warnings ➽ Info on system malfunctions
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Display Readouts Warning Operating mode
System malfunction
System self-check (when ignition on)
Air pressure insufficient (airless)
Transmission in Neutral position
Foot off pedal
Automatic mode
Engaged starting-off or driving gear (here: 5th gear). Versions : 12-speed Start. speed: 1st - 6th Drive speed: 1st - 12th
Clutch overloaded Select lower gear
Communication error to display Clutch wear indicator
Gear selected, downshift options
Reverse gear "Low" engaged
System error. Journey can be continoued with restrictions System error. Stop!
Reverse gear "High" engaged PTO 1 ist activated (P). Transmission Neutral (N). PTO 1 und 2 are activated (P). Starting-off gear 3 engaged (3) speed
Example error code: 153 (Lines = "1") Auxiliary gear shift system: L1 = forward speed engaged L2 = higher forward LN = Neutral LR = Reverse gear
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Operating modes
Automatic Mode
010832
➽ Transmission shifts automatically ➽ Both hands always on steering wheel ➽ Optimum gearshifts in any situation "Dynamic" or "economical" drive style: the electronic system recognizes the style and responds ➽ If needed, correction of gear selected via tip lever ➽ The electronic system preselects a starting gear; the driver may adjust it to the situation given ➽ Maneuvering and PTO-operation only in manual mode
M anual Mode
010463
➽ Gearshifts at driver´s discretion (via tip lever) ➽ Automatic clutch operation of transmission ➽ Shifting of transmission by repeated tapping: 1x = 1 gear; 2x = 2 gears ➽ The electronic system preselects a starting gear; the driver may adjust it to the situation given ➽ Wrong gearshifts are precluded
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Features Technology and Function ➽ High-performance helical gears - new technology ➽ Central hydraulic oil supply ➽ Customary dry clutch ➽ Central cable harness; few external connections ➽ Robust housing with integrated clutch bell ➽ Full integration of all components ➽ Low temperature level for long service life of components ➽ Automated transmission functions for swift gearshifts ➽ Shifting in a manner that relieves the driveline of peak loads ➽ Jolt-free gear changes due to controlled clutch ➽ Display warning in case of clutch overload or if clutch needs to be replaced ➽ Diagnostic mode recognizes and indicates malfunctions on display, activates alternative functions and allows journey to be continued ➽ Simple trouble-shooting on vehicle by means of system-immanent error memory and ZF-diagnosis unit
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Benefits for the Driver
➽ Optimum relief for the driver: • No clutch pedal • Swift, automatic gear changes • No operating errors (electronic overspeed protection etc.) • Continuously updated info via display • All concentration focused on traffic • Suitable starting gear always available • Economical driving supported by most modern drive strategies provided by transmission electronics • Low noise level ➽ Smooth clutch control for maneuvering and reversing ➽ At any time – depending on the traffic situation – the driver can change from the automatic mode to manual gear selection. The driver remains "in command" of his vehicle. ➽ Easy vehicle operation, promptly understood by rotating drivers; vehicle and driver are ready to go within a short time.
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Benefits for the Vehicle Manufacturer ➽ No shift lever with shift block and shifting linkage. ➽ No connections and lines for clutch pedal (hydraulics, kinematics). ➽ Spatial flexibility regarding installation of display and range selector. ➽ Flexible driver cabin arrangement. ➽ Noise encapsulation not necessary (simple, robust basic transmission with helical gears). ➽ Long service life and high functional safety of the transmission through integration of all components. ➽ Complete system with final inspection from a single supplier (only one supplier). ➽ Improved economic efficiency of the transmission due to automatic program (more favorable operating costs). ➽ No operating errors ➽ Simple check of electronic components and interfaces on the assembly line by means of electronic diagnosis. ➽ Error memory integrated.
Benefits for vehicle manufacturer: • • • •
Less installation costs Parts and systems omitted Less diagnosis and repair costs Less training costs MKS-KD3 333 21114 e
Benefits for the Fleet Owner
➽ More payload (ca. 60 kg more as opposed to Ecosplit transmissions) ➽ The driveline is relieved of peak loads; therefore less clutch wear ➽ Economic efficiency improved by automatic program (Rental vehicle, etc.) ➽ Simple operation, no operating errors ➽ No clutch pedal, driver stays fit and motivated ➽ Ideal for unskilled drivers (driver rotation) ➽ High brake efficiency due to ZF-Intarder ➽ Only one contact partner for queries regarding entire transmission / Intarder system ➽ Easy procurement of spare parts
Benefits for fleet owner: • Less training costs • Less maintenance and repair costs • Less operating costs (fuel, clutch, brake linings, brake drums)
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Benefits for the Environment
➽ Promotes fuel-saving drive style = less exhaust / particulate emission ➽ Optimum efficiency = low power loss ➽ 95% of all system components can be recyled = raw material savings ➽ No environment-critical material such as asbestos, cadmium = eco-friendly ➽ No hydraulic oil for clutch actuation = eco-friendly ➽ Prolonged oil change intervals = less waste oil ➽ Reduced transmission weight = increased transport efficiency ➽ Varnishing with water varnish = Savings in solvents = eco-friendly
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Self-Diagnosis The AS Tronic system continuously performs self-diagnosis. It recognizes malfunctions, activates alternative functions and ensures continuance of journey. For the driver this means: ➽ In case of malfunction: • info by means of a symbol shown in display • in addition: buzzing signal • the driver can react accordingly ➽ The driver is informed whether he has to stop immediately or whether the malfunction permits to continue the journey to a suitable checking point.
011707
01046
3
➽ There he can activate the check mode to define the malfunction (error code). Any measures to be taken will be found in the operating manual. ➽ There are several options: • Journey can be continued without any restrictions • Journey can be continued with restrictions • Journey can be continued with severe restrictions (auxiliary control system) • Journey cannot be continued. ZF comes to the driver´s aid: in the operating manual he will find hot lines, addresses and actions to take.
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