Impact of Driveline on System Optimization

Michael P. Kirk
Impact of Driveline on System
Optimization
International Society for Terrain-Vehicle Systems Conference
Director, Axle, Driveline & Manual Transmissions
Powertrain Engineering
FCA US LLC
ISTVS 2016 Troy, Michigan USA
September 13, 2016 ©2016 FCA US LLC

Panel Topics/Questions and
Outlines:
#1: Worldwide AWD trends, GHG Requirements, and Efficiency
Improvement
#2: 4WD Performance – Past, Present, Future
9/13/2016 2ISTVS - Impact of Driveline ©2016 FCA US LLC

Question/Topic #1:
Worldwide AWD trends, GHG
Requirements, and Efficiency
Improvement

Worldwide industry trends in Driveline and 4WD
9/13/2016
 Worldwide industry trends in Driveline and 4WD
● AWD is showing growth in all segments
● B-, E-Segments will experience significant growth by the year 2021
4
Automobiles(thousands)
Calendar Year
Source: IIHS
ISTVS - Impact of Driveline ©2016 FCA US LLC

Global AWD Growth in Small Vehicle Segment
9/13/2016
 AWD technology is being applied to smaller, low cost/low margin segments
to meet customer expectations & wants
0
10
20
30
40
50
60
70
80
90
100
2015
2016
2017
2018
2019
2020
2021
Thousands
B Segment AWD Vehicles
~274% growth over 2015 CY volumes
Source: IIHS
5
Calendar Year
ISTVS - Impact of Driveline ©2016 FCA US LLC

50
70
90
110
130
150
170
190
210
230
250
2000 2005 2010 2015 2020 2025
CO2(g/km)
Year
FE/GHG Stringency Increasing Globally
U.S.
101 g/km
EU
95 g/km
China
117 g/km
Brazil
135 g/km
Dotted Lines: Non-Mandatory
Solid Lines: Final Rule (Mandatory)
• No normalization for
regulatory differences

Role of Driveline in GHG Reduction
9/13/2016
Driveline Engineering must make efficiency improvements to maximize
the benefits of GHG Technologies by:
– Reducing or eliminating friction losses through the Driveline components and
systems through:
• System and component weight reduction and optimization
• Friction reduction through gear design, finishes, and lubrication improvements
• Technology improvements to Driveline components and systems.
– Clearly understanding customer functional requirements:
• Basic durability/reliability
• All weather performance and customer confidence
• 4WD and Off-Road performance
– “Right sizing” of Drivelines
• Sizing vehicle driveline systems
to customer requirements
– Providing innovative solutions as enablers
FCA US LLC provides leadership:
– Leading USCAR and SAE Measurement Standards
– Providing Innovative methods of Efficiency Improvement
7ISTVS - Impact of Driveline ©2016 FCA US LLC

Accurate Measurement of Driveline Efficiency
9/13/2016
FCA US LLC provides strong Technical Leadership in defining
measurement techniques and standards for Axle and Driveline
components and systems:
Transmission Working
Group –
Axle Subcommittee
Formed May 2013; current working
Chair – Jasbir Singh; FCA US LLC
Mike Kirk
FCA US LLC
Mike Kirk
FCA US LLC

SAE J-Standard on Accurate Measurement of
Spin Loss in Power Transfer Units
9/13/2016
0
5
10
15
20
25
30
35
40
45
0 100 200 300 400 500 600 700 800 900 1000
Torque[Nm]
Speed [rpm]
Mfgr-A
Mfgr-B
Mfgr-C
PTU Input (Wheel)
Results shown on a 3-run average basis
MfgrA = 3-Axis
MfgrB = 1-Axis
MfgrC = 2-Axis
Mfgr-A
Mfgr-B
Mfgr-C
Mfgr-A
Mfgr-B
Mfgr-C
Mfgr-A
Mfgr-B
Mfgr-C
Example of Completed
Work with SAE, USCAR

MY16 Jeep® Cherokee Trailhawk - Driveline
9/13/2016
Jeep® Cherokee Trailhawk Driveline Functional Objective:
• Provide Jeep® 4WD On-road and Trail Rated Off-Road capability
• Meet driveline efficiency targets to enable city and highway fuel
economy improvements
Industry-Unique Driveline solutions developed for the Cherokee included:
• Single-speed disconnecting
4WD system providing all
weather performance
• Two-speed disconnecting 4WD
which provides Trail Rated Off-
Road performance
• Trailhawk 4WD System with
features including 4-Low range,
Neutral, and rear axle
mechanical locker

9/13/2016
Jeep® Cherokee Trailhawk Driveline, 4WD System Description:
• 9-Speed Hydraulic wide-ratio Automatic Transmission
• Unique single and two-speed two-stage Power Transfer Units with electro-
mechanical disconnect
• The two-speed PTU also incorporates the center differential (moved from the
transmission) and open neutral (for flat towing capability)
• Unique single and two-speed Rear differential modules; with hydraulic clutch
control for front-rear torque distribution
• Trailhawk Rear Differential Module also features a mechanical locking axle for
rock crawling capability
Jeep® Cherokee customers get the following benefits:
• 4-Low 4WD provides a crawl ratio of 48 to 56:1 and up to 5600Nm of rear
driveline torque to provide full Trail Rated Off-Road capability
• Selec-Terrain functions include Auto, Snow, Mud, Rock, and Sport modes
• Both single and two-speed drivelines disconnect to 2WD (FWD) when 4WD
traction is not required to reduce drag and improve fuel economy
MY16 Jeep® Cherokee Trailhawk - Driveline

MY16 Jeep® Cherokee – FWD Operation

MY16 Jeep® Cherokee – AWD Operation
11/4/2016ISTVS - Impact of Driveline ©2016 FCA US LLC

MY16 Jeep® Cherokee – 4WD LOW Operation

Jeep® Cherokee Active Drive 2 RDU – Power Flow

9/13/2016
FCA Examples of High-Efficiency Disconnect AWD

Question/Topic #2:
4WD Performance – Past, Present,
and Future
179/13/2016ISTVS - Impact of Driveline ©2016 FCA US LLC

Jeep … Then and Now…Functional Objectives…. A Historical Jeep
®
Vehicle Comparison
9/13/2016ISTVS - Impact of Driveline 18©2016 FCA US LLC

D . S h e d l a r s k i
The Problem……..

New Functional Requirement Set……..
1. Must have 4WD and provide traction
2. Must carry a load and troops
3. Must Ford Water
4. Must Have Ground Clearance
5. Must Be Maneuverable good Turn Circle
6. Must Have Articulation
7. Must Have HP/Torque/Speed

U.S. Gov’t Bid: (135 Suppliers RFQ=11days POC=47 Days)
Bantam Blitz Buggy
Ford Pygmy
Willy’s Quad
- 2.2L Go Devil Engine
- 60HP/105lbs torque
- 65 MPH Top Speed
- 100hrs@WOT Dyno
- 350K Built in Toledo
- 2.2L Go Devil Engine
- 60HP/105lbs torque
1940 Jeep® Willys Quad Prototype
- Built by American Bantam
- Lead designer Carl Probst
- Delivered in 47 days
- No production capacity
- Ford built 280,000 Jeeps

The Solution

MB Axle Ratio(Spicer)= 4.88:1
MB Transmission 1st Gear= 2.665:1
MB Transfer Case(Spicer)= 1.97:1 Low Range
MB Crawl Ratio Total= 25.6:1
MB Crawl Speed = 3mph
MB Gradability Spec= 60%
Wrangler Crawl Speed = <1mph
Wrangler/Jeep® Gradability= 60%

MB Water Fording Goal =18” Jeep® Minimum =19” @ 10MPH

MB Ground Clearance= 8.7”
MB Approach Angle= 45°
MB Break Over Angle= 36°
MB Departure Angle= 35°

MB Wheel Base= 80”
MB Overall Length= 132.25”
MB Turn Radius= 17.3’

RTI= Ramp Travel Index
RTI= (Distance Traveled Up 20° Ramp x 1000)/Wheel Base
MB RTI Estimation = 450

• After 75 years, Jeep® Brand holds true to its “Capability” standards…..
• “Jeep® Brand is the do-anything, go-anywhere vehicle”
Thank You!
The Take Always…..

Impact of Driveline on System Optimization

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