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 2 ISTVS - 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

Au

tom

ob

ile

s (

tho

usa

nd

s)

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

20152016

20172018

20192020

2021

Tho

usa

nd

s

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

CO

2 (

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

7 ISTVS - 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

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0 100 200 300 400 500 600 700 800 900 1000

To

rqu

e [

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

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0 100 200 300 400 500 600 700 800 900 1000

To

rqu

e [

Nm

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Speed [rpm]

Mfgr-A

Mfgr-B

Mfgr-C

0

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60

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100

0 100 200 300 400 500 600 700 800 900 1000

To

rqu

e [

Nm

]

Speed [rpm]

Mfgr-A

Mfgr-B

Mfgr-C

0

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100

0 100 200 300 400 500 600 700 800 900 1000

To

rqu

e [

Nm

]

Speed [rpm]

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

11/4/2016 ISTVS - 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

17 9/13/2016 ISTVS - Impact of Driveline ©2016 FCA US LLC

Jeep … Then and Now…Functional Objectives…. A Historical Jeep®

Vehicle Comparison

9/13/2016 ISTVS - Impact of Driveline ©2016 FCA US LLC

9/13/2016 ISTVS - 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’ 9/13/2016 ISTVS - Impact of Driveline 26 ©2016 FCA US LLC

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…..
