12 - Eehpc 28 Nov

An Introduction to Hydromechanical Transmissions
Mike Cronin
28 Nov 2012
Product Development & Global Technology
(Previously titled: Cost Savings With Hydro-mechanical Transmissions)
Introduction
Hydro-mechanical transmission architectures are growing in popularity as a
cost effective means to provide continuously variable transmission (CVT)
functionality in the heavy-duty off-road market segment. This presentation will
introduce the audience to the basics of operation and commonly used terms.
Topics Covered:
Speaker Background
Simple Hydro-mechanical Transmission Schematic
Current Industry Examples
Important Design Characteristics
How Fuel Is Saved
Other Beneficial Characteristics
Caveats:
Not A Design Guide
Limited To Off-road Perspective
Mike Cronins CV
Joined Caterpillar upon graduation from Michigan State University with a
BSME in 1973
Entire career working on off-road drivetrain performance and design:
Hydro-mechanical transmissions for a broad range of applications
Electric drive for TTT
TTT & Belted machine steering systems and components
Assorted lower powertrain projects
Assorted powershift transmission concepts
Drivetrain related patents
23 Granted
10 Pending
9 Notifications
Retired in 2010
Rejoined Caterpillars Drivetrain Research Dept on a part time basis to
continue work on hydro-mechanical drivetrains.
General Parallel Path Transmission Schematic

a.k.a. Split Torque, Power Split, Hydro-mechanical, Electro-mechanical etc.
A variator is a device that can vary the speed or torque ratio

across its two shafts in a continuous manner.
Several types are available: hydraulic, electric, traction etc.
Transmission
Hydraulic Power Path

Wheel
Or
Sprocket
Variator
Gear
System
Engine
PlanetaryG
ear
System
Gear
System
Transfer Gear
And/or Axle
Reductions
Mechanical Power Path
In addition to gears these systems may contain clutches,

brakes or other familiar transmission components
connected in various ways.
A very large number of combinations are possible.
There must be at least

one planetary
Planetaries Are Splitters and Adders

General Planetary
Gear System
Output Torque1 = A*Torque
Torque
Splitter
Torque
Output Torque2 = B*Torque
Speed 1
Speed
Adder
A*Speed1
Output Speed =
B*Speed2
Speed 2
Output speed is the sum

of the input speeds.
Hydro-Mechanical CVT
General Planetary
Gear System
Engine
Speed
Final
Drive
Engine
Pump
Wheels
or
Tracks
Output Speed =
Motor
A*Engine Speed
+
B*Variable Speed
Variable
Speed
Hydrostatic Variator Shown
Even if engine speed is

constant, if the other speed
is variable then the output
speed is still variable.
Why choose hydro-mechanical?
Scaling
Variators are only available in a limited number of sizes.

A given size variator matches to a larger machine when used in a hydromechanical configuration.
Larger machines now have access to CVT behavior.
Efficiency
The power path carries a fraction of engine power

Less hydraulic power means fewer losses.
Less fuel
More power to ground
Cost
Most cost effective CVT technology for 200-400 hp wheel loaders.
Hydro-mechanical Transmission Examples

AG
Vario
Eccom/IVT/S-matic
IVT
IVT
CVT
Hydro-mechanical Transmission Examples

Wheel Loader
ZF
cPower
Dana/Rexroth
HVT
Cat
CVT
Important Design Differentiators

Variator Type
Discussed Above
Coupling Type
Input
Output
Compound Split
Number of Ranges or Modes
One
Two
Three
Four
Variator Examples
Used in ZF Designed cPower Shown @ 2010 Bauma

Variable Pump
Variable Motor
Pump and Motor Displacements Linked
Motor Displacement Decreases while Pump
Displacement Increases
Integrated, U Package
Variable Pump
Fixed Motor
Integrated, Inline Package
Explaining the term Coupled

The Variator is Coupled to the Input
Double Coupled
/ Unsplit
Input Coupled
/ Output Split
Output Coupled
/ Input Split
Planetary
Gear
System
Planetary
Gear
System
Planetary
Gear
System
In
Out
In
Out
In
Planetary
Gear
System
Out
Hydraulic
Variators
Out
Uncoupled
/ Compound Split
914
ST125 1st
Rexroth HVT 1st
Cat CVT
JD 6000, 7000 IVT
S-Matic
Graziano
Fiat/Ag
ZF Eccom
Rexroth HVT 2nd,3rd
Vario
8000 IVT 1st,3rd
ZF CP
8000 IVT 2nd,4th

ZF CP 2nd,3rd
Electric
Variators
In
The Variator is Coupled to the Output
D6E
D7E
795AC
Volt
Prius
Dual Mode/AHSII/EP40 1st
Dual Mode/AHSII/EP40 2nd
Discrete Ratio Powertrain Schematic

Discrete Ratio Transmission
Several selectable gear ratios
Slipping clutch for launch
Wheel
Or
Sprocket
Aux Loads
Engine
Engine Speed vs Ground Speed

w Discrete Step Transmission
Two Engine Speeds

Possible at Ground
Speed 1
2200
2000
Engine Speed rpm
Ground Speed 1
Transfer Gear
And/or Axle
Reductions
Transmission
1800
One Engine Speed

Possible at
Ground Speed 2
1600
1400
1200
1000
800
Ground Speed 2
600
0
10
15
Ground Speed mph
20
25
Ground Speed 1
Approximate Minimum
Fuel Consumption
Ground Speed 2
Hypothetical Engine Fuel Rate Contours

g/min
230
220
210
200
190
180
170
800-900
150
700-800
140
130
120
110
100
90
80
70
60
50
40
30
20
10
Engine Speed rpm
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
Engine Gross Power kW
160
600-700
500-600
400-500
300-400
200-300
100-200
0-100
Continuously Variable Ratio Powertrain Schematic
Continuously Variable Transmission

Ratio continuously managed for
performance and launch
Wheel
Or
Sprocket
Aux Loads
Engine
Transfer Gear
And/or Axle
Reductions
Transmission
Engine Speed vs Ground Speed
Any Engine Speed

Possible at Any
Ground Speed
2200
Engine Speed rpm
2000
1800
1600
1400
1200
Functional Definition of CVT:
1000
Engine speed can be placed and maintained at the

desired level regardless of ground speed.
800
600
0
10
15
Ground Speed mph
20
25
END

12 - Eehpc 28 Nov

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An Introduction to Hydromechanical Transmissions

(Previously titled: Cost Savings With Hydro-mechanical Transmissions)

Product Development & Global Technology

General Parallel Path Transmission Schematic

A variator is a device that can vary the speed or torque ratio

Hydraulic Power Path

Mechanical Power Path

In addition to gears these systems may contain clutches,

There must be at least

Planetaries Are Splitters and Adders

Output speed is the sum

Product Development & Global Technology

Even if engine speed is

Why choose hydro-mechanical?

Variators are only available in a limited number of sizes.

The power path carries a fraction of engine power

Most cost effective CVT technology for 200-400 hp wheel loaders.

Product Development & Global Technology

Hydro-mechanical Transmission Examples

Product Development & Global Technology

Hydro-mechanical Transmission Examples

Product Development & Global Technology

Important Design Differentiators

Product Development & Global Technology

Product Development & Global Technology

Used in ZF Designed cPower Shown @ 2010 Bauma

Product Development & Global Technology

Explaining the term Coupled

8000 IVT 2nd,4th

The Variator is Coupled to the Output

Dual Mode/AHSII/EP40 2nd

Product Development & Global Technology

Discrete Ratio Powertrain Schematic

Engine Speed vs Ground Speed

Two Engine Speeds

Engine Speed rpm

One Engine Speed

Ground Speed mph

Product Development & Global Technology

Hypothetical Engine Fuel Rate Contours

Engine Speed rpm

Product Development & Global Technology

Engine Gross Power kW

Continuously Variable Ratio Powertrain Schematic

Continuously Variable Transmission

Engine Speed vs Ground Speed

Any Engine Speed

Engine Speed rpm

Functional Definition of CVT:

Engine speed can be placed and maintained at the

Ground Speed mph

Product Development & Global Technology

Product Development & Global Technology

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