Efficiency Improvement through Reduction in Friction and Wear in Powertrain Systems

The objective of this project is to improve the efficiency of truck drivelines through reduction of friction and parasitic losses in transmission and drive axles. Known efficiencies for these products exceeded 97 percent, so the task was not trivial. The project relied on a working relationship between modeling and hardware testing. Modeling was to shorten the development cycle by guiding the selection of materials, processes and strategies. Bench top and fixture tests were to validate the models. Modeling was performed at a world class, high academic level, but in the end, modeling did not impact the hardware development as much as intended. Insights leading to the most significant accomplishments came from bench top and fixture tests and full scale dynamometer tests. A key development in the project was the formulation of the implementation strategy. Five technical elements with potential to minimize friction and parasitic losses were identified. These elements included churning, lubrication, surface roughness, coatings and textures. An interesting fact is that both Caterpillar and Eaton independently converged on the same set of technical elements in formulating their implementation strategies. Exploiting technical elements of the implementation strategy had a positive impact on transmission and drive axle efficiencies. During one dynamometer test of an Eaton Best Tech 1 transmission, all three gear ranges tested: Under drive, direct drive and over drive, showed efficiencies greater than 99 percent. Technology boosts to efficiency for transmissions reached 1 percent, while efficiency improvements to drive axle pushed 2 percent. These advancements seem small, but the accomplishment is large considering that these products normally run at greater than 97 percent efficiency. Barriers and risks to implementing these technology elements are clear. Schemes using a low fill sump and spray tubes endanger the gears and bearings by lubricant starvation. Gear coatings have exhibited durability issues, stripping away under conditions less demanding than 750,000 miles in service on the road. Failed coatings compound the problem by contaminating the lubricant with hard particles. Under the most severe conditions, super finished surfaces may polish further, reaching a surface roughness unable to support the critical oil film thickness. Low viscosity and low friction lubricants may not protect the gears and bearings adequately leading to excessive pitting, wear and noise. Additives in low friction oils may not stay in solution or suspended thus settling to the bottom and unavailable when they are needed most. Technical barriers and risks can be overcome through engineering, but two barriers remain formidable: (1) cost of the technology and (2) convincing fleet owners that the technology provides a tangible benefit. Dry sumps lower lubricant operating temperatures so the removal of heat exchangers and hoses and reduced demand on engine cooling systems justify their use. The benefits of surface texturing are varied and remain unproven. Lubricant costs seem manageable, but the cost of super finishing and gear coating are high. These are issues of scale and processing technology. Going across the board with gear super finishing and coating will reduce costs. Pushing the envelope to applications with higher torque and higher power density should drive the adoption of these technologies. Fleet owners are an educated and seasoned lot. Only technology measureable in dollars returned is used on truck fleets. To convince fleet owners of the benefit of these technologies, new precision in measuring fuel efficiency must be introduced. Legislation for a minimum standard in truck miles per gallon would also enable the use of these technologies. Improving the efficiency of truck transmissions and axle will make a noticeable impact on the fuel consumption by heavy vehicles in the United States. However, the greatest benefit will come when all the individual efficiency technologies like hybrid power, aerodynamic fairings, auxiliary power units, super single aluminum wheels, single wide tires and reduced cross section radiators are combined synergistically in a single vehicle, the high efficiency truck