EcoLife

The New Generation of Automatic Transmissions

ZF Friedrichshafen AG
 Ecomat / EcoLife - Produktionszahlen
Perspektiven 2010 - 2014
Anteil
30 Gangzahl
Ecomat 2009
EcoLife
25
Getriebe / Jahr [x 1 000]

20

15 6

10

Forecast 2010
5

5
0
1990 1995 2000 2005 2010 2014

M01_ 2_en EcoLife Bus

 How did the EcoLife Originate?

The selection process:

400
Operating principles
The selection criteria:
Service life
No interruption
of tractive force
Compact dimensions 34
Economical, efficient Systems
Feasible torque
etc.

The result:
Powershift planetary transmission with a torque converter for setting off and a
primary retarder!

M01_ 3_en EcoLife Bus

 Market Requirements
City Bus Drive Trends
For the next 15 years, the combustion engine will remain the primary source of power.

Ecomat 2, EcoLife EcoLife Hybrid Fuel Cell

2 plus, 4

2000 2005 2010 2015 2020 2025 2030

M01_ 4_en EcoLife Bus

 EcoLife
Characteristics

Engine torques of up to 2 000 Nm

(1 475 Ib ft)
New torque converter with torsional
vibration damper
New, powerful primary retarder
New cooling system
(2 heat exchangers)
New control system with
on-site electronics
TopoDyn Life shift program
Higher service life
even increased temperature
and performance requirements

M01_ 5_en EcoLife Bus

 Transmission Types

Maximum vehicle weight (examples)

6 AP 2000 B
up to
32 t*
6 AP 1700 B

6 AP 1400 B
up to
28 t
6 AP 1200 B

up to
6 AP 1000 B
19 t

Nm 1 000 1 200 1 400 1 700 2 000

Ib ft 738 885 1 033 1 254 1 475

* Applications for higher

vehicle weights upon request

M01_ 6_en EcoLife Bus

 Basic Technical Data

Transmission
Input torque Max. 2 000 Nm (max. 1 475 Ib ft)
Number of speeds 6
Weight 346 - 379 kg (763 - 836 lb), without oil
Oil volume approx. 42 I (11.1 US-gallons)
Ratios 3.36 1.91 1.42 1.00 0.72 0.62
R 4.24 (max. tractive force as in 1st gear)
Spreading (mech) 5.47
Stall torque ratio (mn=0) 1.9 ... 2.3

Total spreading (total) 11.4 ... 12.6

M01_ 7_en EcoLife Bus

 The Product Name:
EcoLife

Ecological Focuses on longer service life at

Optimized in terms of noise, increasing temperature and
emissions, and consumption performance requirements of
future engine generations
and

Economical
Optimized in terms of
service life, maintenance,
consumption, and comfort

EcoLife stands for a holistic profitability analysis over the entire service life of the
vehicle according to the LCC principle (LCC: Life Cycle Costs)

M01_ 8_en EcoLife Bus

 Standard Transmissions
(Coaxial Output)

Breather

On-site
electronics

Transmission
heat exchanger

Retarder
heat exchanger

M01_ 9_en EcoLife Bus

 Overview
Modular Transmission Design

Hydrodynamic Primary retarder Brakes mounted to housing

torque converter (CityBus retarder)
Output module
Lock-up clutch Planetary gear set with
6 mechanical forward
Electrohydraulic control unit
Turbine torsional damper gears + R gear
and oil sump
Multidisk clutches
Oil supply module Dual cooling system

M01_ 10_en EcoLife Bus

 Dual Cooling System
Coolant Circuit
Dual cooling system with Coolant circuit
two heat exchangers
On-site electronics
(ROC / TOC)
Integrated transmission
heat exchanger (TOC)
Mounted retarder heat
exchanger (ROC)
High cooling power
1/3
Optimized oil circuits for 2/3
driving and retarder
operation Integrated transmission
heat exchanger (TOC)
Thermally stable position
of on-site electronics Mounted retarder
heat exchanger (ROC)

M01_ 11_en EcoLife Bus

 On-Site Electronics

Transmission and electronics

constitute a single unit
Heat-resistant
Consistently high gearshift quality ECU,
vehicle system
Extended set of functions and power plug
very reliable
Integrated in the vehicle's CAN
communication.
Suitable for various diagnosis
protocols
Huge statistical data memory

M01_ 12_en EcoLife Bus

 Planetary Gear Set

6 gears
Polak gear set
Powerful
Helical-cut
Closely stepped
Low noise level

Helical-cut planetary gears

in the planet carrier

M01_ 13_en EcoLife Bus

 Ecofluid Life Transmission Oil For
Highest Requirements
Requirement:
Permanent temperatures >105 C
New development (with ZF)
especially for city bus applications
Oil change interval TE-ML20
- 240 000 km
(up to 100 C oil sump temperature)
- 180 000 km
(up to 105 C oil sump temperature)
- 120 000 km
(up to 110 C oil sump temperature)
Advantages
Lower service costs
Very reliable
Environmentally friendly

M01_ 14_en EcoLife Bus

ZF-EcoLife
The Standard Operating Concept

ZF Friedrichshafen AG
 Operating Elements

Brake pedal and

Pushbutton switch Accelerator pedal
retarder actuation

Retarder

3-button switchboard
or 6-button
switchboard,
horizontal or vertical
installation

Selecting the Accelerator pedal with Brake pedal

driving range kickdown function
and / or
hand lever
on steering
column

M01_ 16_en EcoLife Bus

 Advantages EcoLife vs. Voith DIWA
6-Speed Design + Torque Converter

EcoLife the best design for

maximum energy efficiency thanks to the short-time use of the converter
Lower fuel consumption and less noise thanks to lower engine speeds

EcoLife ZF advantage ZF advantage

DIWA driving mode * ZF advantage

2 000 3 1 Gear
ZF-EcoLife
Voith DIWA
Speed [rpm]

1 500
1 2 3 4 5 6 Comparative basis:
1 2 3 - Standard bus fully loaded
1 000 - Full-load acceleration
- Comparable driving programs
- (same connection speed)
- Rear axle ratio i = 6.2
500
0 10 20 30 40 50 60 70 Vehicle speed [km/h]

* Output is divided into mechanical and hydraulic path

M01_ 17_en EcoLife Bus

 Advantages EcoLife vs. Voith DIWA
Retarder
The best retarder for city and intercity buses
Lower brake lining costs, fewer downtimes due to:
the principle of the primary retarder:
Advantage: effective across the entire speed range,
nearly to a stop
greater braking torque
Voith DIWA: retarder function is fulfilled by converter
- Effect like secondary retarders that are typically used
in coaches and trucks
- Overall braking torque significantly lower

Typical braking torque course

[Nm] 0

- 1 000

ZF 6 AP 2000 - 2 000
Voith D864.5
0 20 40 60 v [km/h]

M01_ 18_en EcoLife Bus

Saving Fuel
with TopoDyn and Ecomat
ZF Friedrichshafen AG

ZF Friedrichshafen AG
 Consideration of the Topography
Powershift Transmission Generations

Software Standard TopoDyn TopoDyn Life

Ecomat Ecomat 4 EcoLife

Transmission
Ecomat 2 / 2 Plus
generation Ecomat 4 2004 2008

Recording the
topography No Calculation Calculation

Defined shift Automatic change Continuous

Active drive program adjustment
program
several shift
for the entire route programs of the shift points

M01_ 20_en EcoLife Bus

 Ecomat With TopoDyn
Fuel Savings

Chicago Trier Frankfurt Dresden Brisbane

-3%
-6% -7%

- 19 % - 19 %

Denver Montreal Lisbon Stuttgart Izmir

-5% -4%
-8%
- 10 % - 2 11 %

M01_ 21_en EcoLife Bus

 Reduction of fuel consumption
because EcoLife

TopoDyn Life

M01_ 22_en EcoLife Bus

 Hardware Optimization
to Reduce Fuel Consumption

Hydraulic Optimized height / width ratio, ideal gear transmission ratio

pump Energy of redundant oil is fed back
As a result considerable efficiency improvements

Hydraulic Stepless and adequate setting of system pressure

control unit Calculation base: parameters and functions saved in the ECU
Setting via proportional valves

Shifting Six gears, five shift components

compo- Only three simultaneously opened shift components in shifted gear
nents
Drag torque advantages: multi-segmentation, facing grooving

Converter Fast run-up of engine, Optimized

character- improved vehicle converter
characteristics conventional Closing
istics handling EcoLife EcoLife converter clutch

Turbine Scope of volume production supplies

Copyright ZF Friedrichshafen AG
without torsion damper
torsional Up to 150 rpm lower Efficiency with torsion damper

damper turbine torsion

connection speeds damper

M01_ 23_en
EcoLife_Standard_2009_23_en EcoLife Bus
 Software optimization
to reduce fuel
Ecomat with TopoDyn (shift change)
A - Downhill gradient B - Level road C
C - Uphill gradient
A
B
C
B
Terrain/ A Super-P / Downhill
Road pattern C Power
B
Eco

EcoLife with TopoDyn Life (shift adjustment)

Advantages of
TopoDyn Life Shift points
Terrain/ EcoLife with TopoDyn Life
Road pattern
Shift programs
Ecomat with TopoDyn

M01_ 24_en EcoLife Bus

 EcoLife fuel consumption
measurement Stuttgart SSB
Basic: Ecomat with TopoDyn 2007:
Teilmessung 1 Teilmessung 2 Teilmessung 3 Teilmessung 4 Teilmessung 5
Summe der 5
(04.03. bis (16.03 bis (14.04 bis (15.05 bis (24.06 bis
Teilmessungen
16.03.2009) 14.04.2009) 13.05.2009) 25.06.2009) 12.08.2009)
Teil 1 Teil 2 Teil 3 Teil 4 Teil 5 Gesamt
Verbrauch Ecomat
neu (7702) -1,89% -1,74% 2,00% -6,29% -2,6%

Verbrauch EcoLife
(7704) -5,66% -8,54% -5,54% -6,34% -3,74% -5,9%

Verlauf KV-Verbrauch Basis Ecomat Serie

4%
KV- Reduzierung in %

Verbrauch
2% Ecomat
0% neu
(7702)
-2%
Verbrauch
-4% EcoLife
-6% (7704)

-8%
-10%

Teil 1 Teil 2 Teil 3 Teil 4 Teil 5 Gesamt

Teil-/ Gesamtmessung

M01_ 25_en EcoLife Bus

 Consumption Advantage EcoLife
official SORT Measurement

Measurement by an important manufacturer in 2009

SORT 1 SORT 2 SORT 3

Consumption

- 3.3 % - 3.8 % - 6.8 %

100%

90%

Voith Diwa5 EcoLife

M01_ 26_en EcoLife Bus

 Bus Driveline Technology
Prospects

Reduce fuel consumption Reduce emissions

Optimize efficiency Conserve resources
100
95
-5%
85
80 - 15 %
Fuel consumption (%)

4-speed automatic transmission

75 - 20 %
- 25 %

50
- 50 %

with TopoDyn Life

6-speed Ecomat

6-speed Ecomat
5-speed Ecomat

6-speed EcoLife

EcoLife Hybrid
with TopoDyn
0
< 1983 1983 2002 2006 > 2008 > 2014

M01_ 27_en EcoLife Bus

 Highlights
Top Ten
Fuel - 10 %
Service life + 40 %
Retarder performance + 40 %
Shifting quality 100 %
Oil change interval + 20 %
Hybrid-ready 100 %
Simple diagnosis 100 %
Low-noise - 50 %
Optimized driving perform. 100 %
Standard: 100 %
TopoDyn Life
Torsional damper
Dual cooling system

M01_ 28_en EcoLife Bus

EcoLife for a better future!

ZF Friedrichshafen AG

ZF Friedrichshafen AG