Development of a new high performance material to improve vehicle efficiency by reducing frictional and parasitic energy losses in transmission components.
||Richard G. Van Ryper
||David J. Ritchey
Emission regulations, fuel conservation and green-house gas reduction have made vehicle efficiency a driving force in driveline and transmission design. Literature and customer interviews have identified only 10% to 15% of the energy in a liter of fuel makes it to the driving wheels. A significant component (~10%) of this energy loss can be attributed directly to frictional losses from moving or rotating parts. The largest component of frictional losses, outside the engine itself, occurs in transmission and driveline components (1).
To respond to the market need for improved efficiency, the DuPont™ Vespel® Parts & Shapes business has investigated the role materials and design play in reducing frictional and parasitic losses within a transmission. This investigation led to the development of a new material and design practices which demonstrate a 50% improvement in measured torque loss on a transmission shaft. In addition, by careful design, the required oil flow rates can be reduced by 90%, significantly reducing the parasitic losses associated with the transmission oil pump.
This paper will discuss how the unique properties of a new composition provide opportunities in motion- and fluid-control devices to reduce weight, improve dimensional control and drive out cost.
(1) ‘Parasitic Energy Loss Mechanisms Impact on Vehicle System Efficiency, Project 15171’, Argonne National Laboratory, April 18-20-2006. Authors: G. Fenske, R. Erck, L. Ajayi, A. Erdemir, O.Eryilmaz.