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Transmission Components

Innovative CAE

Optimal Layout of Transmission Components

I. Introduction

II. Simulation of powertrain vibrations for modern hybrid topologies

Figure 1 Illustrations in DYFASIM with various applications

Figure 2 Optimization process for the design of modern torsional vibration dampers

Figure 3 Maneuvers that must be taken into consideration in damper design

Figure 4 Simulation results for bumpy roads with driving range variations for four different damper systems

III. Rolling bearing optimization with OptiKit

Figure 5 Modeling depth of Bearinx from the system level of the complete transmission to an individual contact

Figure 6 Variety of parameters and influencing factors in the design and optimization of transmission bearings using a tapered roller bearing as an example

Figure 7 Comparison of the function of a classic optimization algorithm (left) and a real-life optimization based on development requirements (right)

Figure 8 Model of the rear axle drive to be optimized in Bearinx

Figure 9 Curve of the determined friction energy and service life evaluation based on optimization Both values are calculated using different design cycles that represent the respective target requirements

Figure 10 CAE-assisted optimization of tapered roller bearing parameters in the rear axle final drive analyzed

Figure 11 Comparison of calculated and measured friction torques for optimized on the rear axle final drive

IV. Thermal-mechanical clutch design

Figure 12 FEM calculations and life time profiles did not play a role until later on in the optimization process.

Figure 13 Interaction of pressure distribution with thermal and mechanical effects in the clutch

Figure 14 Schematic diagram of the optimized thermal clutch design

Figure 15 Excerpt from uphill start simulation with the thermal-mechanical model

Figure 16 Development and safeguarding of complex clutch systems by including thermal-mechanical effects

V. Virtual testing

Figure 17 Distribution of start frequencies in the analysis of real driving data from Germany and China

Figure 18 Analysis of real driving data on the distribution of the start frequency of individual driving ranges based on average speed

Figure 19 Traffic simulation model configured for city driving

Figure 20 Traffic flow simulation results with dispersion based on various dependencies

Figure 21 Use of traffic statistics for data prostratification

Figure 22 Optimized synthetic test cycle for testing the clutch actuation system

VI. Summary and outlook

The digital version of the Schaeffler Symposium 2018 “Mobility for Tomorrow” conference transcript

III. Rolling bearing optimization with OptiKit