Oerlikon Graziano will present a selection of its most recent high technology transmissions and drivelines at the CTI show in Shanghai from September 25 to 27. Technical highlights will include the company’s four-speed twin-motor seamless shift electric transmission and a dual-speed seamless-shifting transaxle that can be coupled with a transversal electric motor, for front or rear full electric axle. The company will be at Stand 5 in the show foyer.
“We have been at the forefront of automotive transmission technology, since developing and supplying our first complete gearbox in 1996, and of the electric market, with the production of the first electric axle for the golf cart market,” says Oerlikon Graziano’s Head of Performance Automotive, Paolo Mantelli. “Together with our controlled company VOCIS Ltd, contributing state of the art control software, a variety of business opportunities and potential supplier-partners connections have been opened and will follow from now on, with in mind the aim of reaching soon the status of key partner developer/manufacturer of Zero Emissions Driveline Systems for all the OEMs playing in this increasingly relevant automotive sector.”
Anticipating the need to improve the efficiency of electric vehicles, Oerlikon Graziano will present its two-speed, 2SED transmission and will display its four-speed seamless shift transmission, the 4SED. The first product has been studied for passenger cars and light commercial vehicles, it is a dual-speed seamless- shifting transaxle that can be coupled with a transversal electric motor, for front or rear full electric axle. It has been defined perfect for inner city transport, not only for the reduction of the CO2 emissions and environment noise but also for significant cost savings. The 2SED transmission has been demonstrated in a Mercedes E-VITO electric taxi and, compared to a single-speed, showed improved acceleration, gradient- climbing and top speed, or reduced energy consumption, depending on driving style.
Oerlikon Graziano’s four-speed seamless shift electric transmission - called 4SED - goes even further. By using two small electric motors instead of a single large unit, and by providing four ratios, the motors run close to their peak efficiency for more of the time, and shifts are accomplished without interrupting the drive. Overall energy consumption is reduced by up to 15% compared to a single-speed transmission, which translates into increased range or improved performance. The technology is scalable to suit a wide range of different vehicle types, urban electric cars, high performance cars, hybrid 4WD applications, electric city buses and trucks. It is suitable also for applications with 48V motors, allowing significant cost savings and reducing risks of high voltage.
The company has also combined its experience of high performance cars and electric drivelines to create the front transaxle for the exciting Lancia Rally 037 4WD-H project, a hybrid based on the legendary Group B rally car. Oerlikon Graziano developed and supplied the complete transaxle, consisting of electric motor, gearbox and self-locking differential, that transmits over 2000 Nm to the front wheels independently of the gasoline engine driving the rear axle.
To provide a complete design and manufacturing service, Oerlikon Graziano uses state-of-the-art analytical tools, such as Finite Element Methods (FEM) to model strength, stiffness and temperature gradients during initial design. Extensive test facilities including vertical and horizontal rigs, heavy-duty fatigue testing, climatic chamber and vehicle test facilities for noise, comfort and shift quality ensure that each new design is fully developed and validated.
“Our focus is on developing integrated powertain solutions, through strategic alliances with best in class partners, aimed at maximizing performance and efficiency. Our technical people work with customers from the outset, providing on-site engineering support to help achieve rapid programme implementation,” says Mantelli. “We just need to know the application, interfaces and envelope of the transmission or differential, then we take care of the rest.”
