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The powertrain efficiency deeply affects the performance of off-road vehicles like off-highway vehicles in terms of fuel economy, load capability, smooth control, etc.
The hydrostatic transmission (HST) systems have been widely adopted in off-road vehicles for providing large power density and continuous variable control, yet using relatively low efficiency hydraulic components.
Emerging technologies in commercial-duty transmissions and powertrains include Hydrostatic transmissions and electric drive powertrains. In a hydrostatic transmission system, when the engine runs, it will rotate the drive shaft and the input shaft connected to it.
In a closed-circuit system, the movement of this input shaft will turn both the charge pump and piston pump, incorporating different mechanisms to facilitate shifting the automatic transmission gearbox. Electric drive powertrains are also emerging in certain end markets, such as transit buses, and are in part driven by efforts to reduce fuel consumption and greenhouse gas emissions.
Companies have been developing, designing and manufacturing gearboxes for Construction & Agriculture industry and other sophisticated applications for many years and some have been working and developed the hydrostatic-mechanical powersplit transmissions. The different versions should be developed as a gearbox designed specifically for mobile machinery that can fulfil strict requirements in terms of dynamic performance and reversing.
Hydrostatic-mechanical transmissions have been used in tractors for years. Construction machinery is now also set to benefit from the advantages of these systems, which is why a great deal of development work is currently being undertaken in the supply industry.
Improvement in diesel consumption is the primary objective of these developments. Alongside the harmonious interaction between driver and machine, which itself has a huge impact on performance, the requirements in terms of dynamic performance play an equally important part and must therefore also be taken into account when designing transmissions.
Manufacturers offer the design of the whole system, combining its traditional mechanical know-how with strong electronic competences. Able to support all the electric architecture topologies, leading the complete e-powertrain through a dedicated ECU, then sizing and integrating the most suitable electric modules: from motors and generators, to inverters, batteries and battery management system to obtain the best performance for the entire system.
In order to better serve load-sensitive applications, ZF has developed its hydrostatic-mechanical power-split continuously variable technology, which is well known from agricultural machinery.
The new technology incorporates the ERGOPOWER transmission’s advantages, which are valued by numerous industries. Due to significant increases in consumption and productivity, the transmission is ideal for the material handling industry in addition to leading applications like forestry machines and wheel loaders.
The market is seeing an increase in demand for more efficient drive systems as a result of rising fuel prices and more awareness of CO2 emissions. It is challenging to comply with emission requirements using traditional drives because they are imposed by the US EPA and EU rules, which set technological limitations and constraints on diesel engines.
The unique demands for construction machines include high dynamics combined with heavy loads at low speeds. The brand-new ZF CVT gearbox technology meets these requirements precisely and to a level of economy that was previously unthinkable.
The adoption of new technologies, like CVT for industrial trucks, is accelerated by the rising demands for reduced fuel use and higher productivity.
Future challenges for the diesel engine lift truck industry include a tendency toward lower engine speeds and the need for engine stability accomplished by a lack of dependence on the motor speed and driving speed. Both conditions are satisfied by ZF’s continuously variable cPOWER.
In comparison to hydrodynamic transmissions and purely hydrostatic designs, hydrostatic-mechanical power-split transmissions offer significant advantages for these applications in terms of consumption.
The advantages of continuously variable transmissions are evident across all speed ranges of a normal forklift operation cycle, during the controlled movement of the load, the positioning of transported materials, and the actual transfer. Because of the minimal amount of hydrostatic power used during this operation, maximum efficiency can be attained.
The mechanical portion of the transmission provides the majority of drive power after startup. This means that even in extremely brief loading cycles, the advantages of CVT technology can be seen in terms of fuel consumption.
Driving functions are best completed by the use of a complex hydraulic transmission-control unit and an on-board electronic device incorporated into the transmission. This results in a power management that is aligned in terms of sensitivity and driving comfort.
ZF’s expertise in transmission and vehicle system engineering is utilised by the cPower transmission series, which also makes use of well-known and tested building kit components.
The global hydrostatic transmission market is estimated at $XX Billion in 2021 and growing at XX% CAGR till 2026.
Eaton Fluid Power, a Danfoss company, has opened a brand-new hydrostatics production line at its state-of-the-art facility in Pimpri, Pune, to meet the needs of the local farm sector.
Danfoss is the first company in India to be able to manufacture hydrostatic transmission solutions. Strategic investments in digitalization are yielding positive outcomes, as seen by the new hydrostatics production line.
The advent of this new hydrostatics line will aid in increasing the energy efficiency and sustainability of applications that use these solutions. The product’s quick return on investment and operating efficiency make it ideally suited for the Indian market.
This new state-of-the-art assembly line and test stand is MES-integrated, with a high level of safety and in-process Poka-yokec, all while maintaining the company’s strong safety culture and zero-defect philosophy. The product’s digitization potential, compactness, and accessibility benefits are also highlighted.
The Allison FracTran hydraulic fracturing transmission has been introduced, according to Allison Transmission. The transmission can handle up to 3,500 hp (2,609.95 kW) without requiring any hardware modifications. It was designed to handle 3,300 hp (2,460.81 kW) and 10,000 lb.-ft. (13,558.2 Nm) of input torque.
The new Boomer tractor series from New Holland Agriculture, a division of CNH Industrial, is Stage V-compliant and offers greater performance without increasing size. The effectiveness and operator comfort of the tractors have been enhanced by new features.
With a variety of features, the new Boomer range also improves operator comfort and decreases fatigue. They come with the Cruise Control as standard on versions with hydrostatic gearbox. The EZ Speed function, which synchronizes the forward hydrostatic pedal and engine speed on hydrostatic transmission models, increases efficiency and versatility.
The engine speeds up when the user depresses the hydrostatic pedal when the hand throttle is in the low position.
This guarantees they always have the appropriate ground speed and engine speed available. This is especially helpful in situations when, for instance, the operator wants to keep the tractor’s noise level low when it is stopped and only turn up the engine speed when the tractor starts to move.
Dana Incorporated launched the Spicer HVT1, an advanced powersplit transmission that enables performance and sustainability of agriculture telehandlers. Advanced electronic control system continually adjusts the mix of hydrostatic and mechanical power to maximize machine productivity in widely varying duty cycles, allowing the engine to maintain a consistent speed in its most efficient operating range.
Carraro featured an augmented reality tool to demonstrate the various applications in which its drivetrain products can be used, as well as its latest electrification technologies; FLS 3.2/Full Powershift Hydrostatic Gearbox will be able to fulfill the performance demand of several machines, ranging from small wheel loaders to teleboom handlers.
For all the powertrain applications Carraro can also achieve further fuel efficiency and productivity through the simultaneous control of the whole powertrain (i.e. engine and transmission) with competence in developing control software to be injected in its proprietary Electronic Control Units.
At IFPE 2020, Bosch Rexroth showed technologies which are helping create the next generation of smarter, IoT-ready mobile machines, presented The Hydrostatic Gear Drive Theory, Configuration, Operation and Suggestions Toward Best-practice Design with an informative presentation will examine in detail how hydrostatic gear drives can be better engineered to combine existing hydraulic, mechanical and electronic technologies into unique, compact, dynamic, efficient configurations that can be designed for a singular application, or toward a serialized solution.
