Hydro-Mechanical Continuously Variable

Transmission (HMCVT) for Off-Road

Applications

The people behind unique transmission design, development and manufacturing…

 Introduction

Motivation:
The following slides give a more detailed overview of hydro-mechanical CVT (HMCVT) for Off-Road Applications. Here
we first motivate the discussion with SMT’s research and opinions on current commercial position in the off-road
market:

• HMCVT technology is relatively old (see slides to follow) but has previously been limited to military applications
particularly as pump/motor technologies were not good enough for civilian noise/vibration levels.

• HMCVT are now widely used in and have become the state-of-the art agricultural applications. Fendt VARIO 260
1996 is an early example.

• BAUMA fair in Munich 2010 saw Caterpillar, ZF and Dana/Bosch showing HMCVT prototypes for construction
machines; wheel loaders etc; engine powers up to 120 kW.

• Oct 2011 Press Release: Joint Venture Dana Rexroth Transmission for “hydromechanical variable powersplit
transmission systems for global off-highway markets” .“Dana Rexroth Transmission Systems' HVT series are
targeted for the construction, … up to 360 horsepower (270 kW). Tests … with the new HVT powersplit systems
demonstrate fuel savings in the drivetrain of more than 20 % when compared .. with a conventional torque
converter transmission”

• Compare Alison HD4560 used in 35 T GVW 310 hp medium on-road truck & 60 T GVW 450 hp off-road wheel
loader

• Current position for off-road transmissions is that torque converters are widely used with electric drives tending to
be used for very heavy duty applications. Examples:
• Caterpillar 797F Mining Truck, 2.5 MW, 400 tons payload use 7 speed planetary AT with torque converter
• Nearly all other ultra heavy trucks are electric drive, e.g. Komatsu 930 E, 2.0MW, Hitachi EH5000, 2.0MW
 Contents

1. Performance Requirements
2. Typical design examples & their working principle
3. Advantages & disadvantages compared with conventional AT
4. What relevant key/core technologies can be provided by SMT?
5. Design validation & development tests
6. Consideration for product families & modularisation
 Performance Requirements

• Multiple Wheels / Tracked Vehicles

• Need to cope with large range of power

requests and operating conditions

• PTOs for working

power, e.g. dig, left,
and move things, etc.
 Performance Requirements

• Low noise for operating in areas where are crowded of people

• Both straight line travelling & small radium/neutral turning transmission

systems

• Be easy to use / fine driving control

• High efficiency

• Low cost Engine

直
驶
驱
动

Hydrostatic-Hydrodynamic
Superimposed Steering System
Steering
转向驱动 Geared Steering System
Differential Steering System
 Performance Requirements

• Multiple radius / neutral turning required

power can be as much as or higher than
travel at full speed

• Steering power come from engine and at

small radii turning the inside wheel/tracks
absorb power or called recycling power.

Turns will require energy to overcome ground frictions

Braking Steering Transmission
Neutral Turning Traces for Wheeled Vehicles
 Example Designs & Working Principles

HCVT I HMCVT II
k
nb

e
US Sundstrand DMT-25 Transmission (70s)
n
b

no

DMT-25 Operation Speeds,

Torques, Power & Efficiencies
DMT-25 Operation Power Flows
 Example Designs & Working Principles

MASTA model of DMT-25 – shows how MASTA can be used

to concept design different HMCVT concepts
 Example Designs & Working Principles

MASTA model of DMT-25 – MASTA calculates

powerflow for a given pump/motor speed ratio giving
power-splits and overall ratio. Results show:

• ‘Step-less’ change between two gear modes

• Re-circulating power if gear ratios not chosen carefully
 Example Designs & Working Principles

100% Hydrostatic power Mixed mechanical &

Hydraulic: High
Recirculating power
through hydrostatic path

Mixed mechanical & Hydraulic:

Power split: 57% Mechanical,
43% Hydrostatic
 Example Designs & Working Principles
Simple HMCVT Layout Concept Design:

Layout 1 e
P M
i2
i1
o b

Layout 2 e
P M

i1 i2
b
o

Layout 3
e
P M
i2
i1
o b

k = Teeth Ratio of Ring Gear/Sun Gear of Planetary Gear Train; Hydraulic P-M speed ratio:
 Example Designs & Working Principles

e
P M

i2
i1
o b

e nb (1  k )e Mb i
 k
Layout 5
Speed ratio:
no i1i2
Torque ratio:  2
P M M M 1 k
i2 Power ratio:
i1
o b

1  (1  k )e 
Layout 6 e Speed ratio:
nb
   1 Torque ratio:
Mb

ki2
no k  i1i2 
P M M M 1 k
i2
i1 Power ratio:
o b

k = Teeth Ratio of Ring Gear/Sun Gear of Planetary Gear Train; Hydraulic P-M speed ratio:
 Example Designs & Working Principles

US GE HMPT-100 Transmission Principle Layout & Operating Speeds (60s) – successful, widely
used in military applications
 Example Designs & Working Principles

West Germany Opel Car SHL-g Transmission Principle Layout

 Example Designs & Working Principles

Germany ZF LSG-3000 FSHL Transmission Principle Layout

(by Professor F. Jarehow in Bohn Uni., Germany)
 Example Designs & Working Principles
Relatively complex modern HMCVT developed for
agricultural industry, has:

• 4 different speed/drive gears

• 2 summation planetary gear-sets
• ‘Stepless’ changes between 4 gears allowing
smooth power shifts

Several transmission gear drives are available on the low- and high-speed coupler shafts. In the hydrostatic unit,
sophisticated synchronization ensures coordination of the gear drives on the high- and low-speed coupler shafts.
Power flow is transferred from one coupler shaft to the other without jerks or interruptions in power flow. The end of one
driving range represents the beginning of the next one, making it possible to travel continuously through the entire
transmission range. Shifting gears at identical speeds allows the use of the low-loss dog clutches employed in
conventional gearboxes—one of the reasons for the transmission's high efficiency.
 Example Designs & Working Principles

Concept MASTA model of CLAAS HMCVT – shows complex HMCVT layouts can be
modelled and analysed in MASTA
 Example Designs & Working Principles

MASTA Model of CLAAS HMCVT

Results show:
• ‘Step-less’ speed changes
between the four gear modes
• The power percentage split
between the mechanical and
hydrostatic paths.
 Example Designs & Working Principles

Forward Gear 1
4
3
2
 HMCVT Advantages & Disadvantages

Advantages

Compared to a conventional (torque converter) AT, with the HMCVT:

• No torque interruption occurs during gear change. Because the CVT has no explicit gears, it accelerates smoothly,
with no jerking motion.
• During slow-moving situations like stop-and-go urban traffic or in a traffic jam, the CVT perceived comfort is
good. Low engine rpm keeps noise levels inside the vehicle down.
• The CVT control unit automatically selects the best ratio between rpm, and the torque required for vehicle
performance. The engine thus operates within an optimum power range, lowering fuel consumption.
• When the driver steps on the gas pedal, the CVT lowers the transmission ratio and maintains a consistently high
engine rpm for optimal torque and acceleration.
• At a uniform driving speed it switches to the fuel-saving overdrive mode with the economic engine rpm.
• Non-slip traction among pump, motor & clutches enables the CVT to deliver high dynamics & power from
engine to road. Fits well with tracked vehicle steering mechanisms with recycling power.

Disadvantages
• High cost of hydraulic pump & motor units
• High cost of maintenances
• Volume & weight are mainly affected by hydraulic units & layout design
 HMCVT Advantages & Disadvantages

1.0
Steering Efficiency

0.8

0.6

20 40 60 80 100

Output Speed (%)

1. Hydrodynamic transmission 2. 2-gears planetary gear transmission
3. Hydro-static & dynamic hybrid transmission 4. (Pure) Hydro-static transmission
5. 2-mode hydro-mechanical transmission 6. 3-mode hydro-mechanical transmission
 Core Technologies for HMCVT

What relevant key/core technologies can be supplied by SMT?

Provided that clients take the following responsibility

• CAD & Engineering Drawings for Manufacture
• Outsource high efficient, high power hydraulic pump and motor, separated or back to back arrangement of
hydraulic pump & motor

SMT can provide the following technical services or supervision:

• Concept design of HMCVT gear/shaft/pump/motor layout/topology, e.g. for optimum powertrain efficiencies, gear
ratios for step less shifts – using MASTA modeling and power-flow calculations
• Vehicle performance simulation using SMT DRIVA L1 software
• Further concept design of mechanical layout – gear, bearing, pump-motor choices and packaging - MASTA
• Detailed mechanical design using GMES for gear geometries (including gear design for manufacture), bearing
choice, shafts, clutch and pump/motor capacities
• Whole system compatibility by advanced analyses: system deflection including casing, NVH, shift dynamics (Multi-
Body Dynamics simulation) – SMT DRIVA
• Controls for clutches, hydraulic pump – see SMT control capabilities presentation.
• Prototype Design Validation & Development Tests
 Design Validation & Development Tests

Product development tests (equipment, tests & procedures)

• HMCVT performance & endurance tests (Engine –HMCVT-Coupling – Dynamometer (EHMTCD) Test bed,
associated with torque, speed, hydraulic fluid pressure, temperature, etc. data acquisition hardware & software)

• Hydraulic & system control tests (EHMTCD Test bed as above)

• PGT performance tests (Motoring Rig, associated with torque, speed, torsional vibration, lubrication & control
fluid pressure, temperature, etc. data acquisition hardware & software)

• Gear mesh/vibration tests (Motoring Rig as above)

• NVH tests (EHMTCD Test bed in Noise Cell plus NVH data acquisition hardware & software)

• Proving tests (Machine based HMCVT application tests)

• Test procedures (TBD)

 Product Family Development

Target Small & Medium Machines

• One set of Hydraulic pump & motor (40kw to 55kw, to be decided on market availability) as basic HCVT mode

• Multi-mode HMCVTs with a series of gears and planetary gear trains (PGTs)to cover different power ranges

• Proposed ratings (kw): 0-80, 0-120, 0-160, 0-200, 0-240; or 0-110, 0-165, 0-225. (refer: CAT small & medium engine
ratings)

• Design Target: Typical HMCVT with validated / optimized layout

 Thanks for Your Attention !
谢 谢!

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Nottingham, NG1 6BB
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