05 - SMG Iii
05 - SMG Iii
05 - SMG Iii
SMG III
Subject
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SMG Getrag 247 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Powerflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Gearshift Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Gear Recognition Hall Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Input Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Drivelogic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Steering Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Gearshift Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Longitudinal Acceleration/Gradient Sensor . . . . . . . . . . . . . . . . . . . . . . .12
Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Wake-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Hood Contact Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Door Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Reverse Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SMG III Hydraulic System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Pressure Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Hydraulic Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Solenoid Valve for the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Hydraulic Pump with Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Hydraulic Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Pressure Limiter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Regulator Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Clutch Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PLCD Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Initial Print Date: 09/05
Revision Date:
Subject
Page
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Transmission Ratio of the SMG 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Drivelogic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
In Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
In Sequential Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Tow-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Hill Ascent Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Launch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Clutch Overload Protection (KS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Clutch Teach-In Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Teaching in the Axle Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Pressure Accumulator Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Adaptations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Shift Range Mid-Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Valve Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Transmission Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Longitudinal Acceleration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SMG III
Model: E60 M5
Production: from 9/2005
3
SMG III
Introduction
A new 7-speed sequential M gearbox (SMG) has been developed for the E60 M5. The
SMG 3 is designated SMG Getrag 247.
The SMG 3 is the first sequential M gearbox that has been specifically developed for
automated operation. Previous sequential gearboxes were conventional manual transmissions with an adapted hydraulic gearshift unit attached.
The central gearshift shaft has been replaced by individual selector rods. The hydraulic
gearshift unit is a part of the gearbox casing and is no longer designed as an add-on
part.
Compared to the SMG 2 the gearshift times have been shortened by 20%.
Essentially, these shorter gearshift times have been achieved by:
Individual selector rod operation
The use of carbon fibre friction cones in the synchronizer rings that facilitate
shorter synchronization times through their higher load bearing capacity
Redesign of the transmission pinion placement (first gear pinion is not next to
second gear pinion - they do not share the same synchronizer)
The power is transmitted from the engine to the gearbox by a dual-mass flywheel
supplied by LUK and a two-disc dry clutch supplied by Fichtel und Sachs.
In addition, the system also has the ability for the following special features:
Launch control
Hill ascent assistant
Drivelogic
Tire teach-in function,
Initialization procedures designed to ensure the system functions precisely may also be
necessary after performing work on the vehicle that is not directly related to the gearbox.
4
SMG III
NOTES
PAGE
5
SMG III
6
SMG III
Explanation
Light Module
Sequential M Transmission
Pump Relay
10
11
12
Drivelogic Switch
13
14
15
16
17
18
19
20
Instrument Cluster
21
Head-Up Display
7
SMG III
System Components
SMG Getrag 247 Gearbox
A special feature of this gearbox is that the main shaft is mounted in three bearing
assemblies. The third bearing assembly has been realized by an end shield bolted in the
gearbox casing.
Powerflow
The diagram below illustrates the powerflow of the gearbox.
8
SMG III
7 5
3 2
4R
Gearshift Pattern
Besides the gearbox being designed solely for a sequential shifting mechanism (making a
manual shift version impossible), the shift pattern would make it impractical for manual
shifting.
Shift Pattern
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SMG III
Clutch
The E60 M5 utilizes a two disc dry clutch setup to transfer power from the engine to the
gearbox.
10
SMG III
Index
Explanation
Drive Plate
Intermediate Plate
Drive Plate
Contact Plate
Formed Spring
Pressure Plate
Selector Lever
The tasks of the selector lever are:
To select the ranges D-N-R
To change the operating modes D <-> S
To activate launch control
To activate the tow start function.
Gearshift Lever
Eight Hall sensors determine the selector lever positions which are sent individually to the
transmission control.
All selector lever positions are based on a redundant design where a sensor switches to
ground and the corresponding redundant sensor switches in positive direction to ensure
reliable detection even in the case of failure.
Drivelogic Switch
The Drivelogic selector switch can be used to choose between six gearshift programs in
sequential mode and five shift programs in Drive mode.
The shift speed and therefore the shift hardness are preselected in sequential mode.
The shift points can be influenced by the setting in Drive mode.
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SMG III
Gearshift Paddles
The gearshift paddles can be used to perform the following functions:
Upshift and downshift (+/-)
Change of operating mode from "D" to "S"
Manual initiation of wheel circumference teach-in function (the hill ascent assistant
no longer needs to be activated manually).
Gearshift Lever
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SMG III
Wake-Up
The SGM control unit assumes standby mode as soon as the vehicle is unlocked. As
a result, the hydraulic unit generates sufficient pressure to disengage the clutch if
necessary.
Door Contact
Information on the door status is sent via the CAN to the SMG control unit. The gear is
automatically disengaged when the door is opened.
This signal should not be confused with the wake-up signal.
Engine Speed
For redundancy reasons, this signal is made available via the CAN-bus as well as a hardware signal. It is used to control the clutch and to establish whether the engine is running.
Within the safety concept, the engine speed signal is used to monitor the current status.
Reverse Light
The redundant sensor system of the 1/R selector rod detects reverse gear when engaged
and correspondingly informs the transmission control.The transmission control informs
the lights switching center that reverse gear is engaged.
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SMG III
Hydraulic System
A DC motor drives the hydrostatic pump. The pump conveys the hydraulic oil via a nonreturn valve into a pressure system while energy is stored in a hydraulic accumulator.
The operating pressure is 75 bar. The maximum pressure is 90 bar which is applied
only during initialization procedures.
The maximum shift force is approx. 2,500 N.
Inside the hydraulic unit are the following components:
Pressure Accumulator
Regulator Block
Expansion Tank
Check Valve
Filter
Explanation
Hydraulic Unit
14
SMG III
Index
Explanation
Index
Explanation
Clutch
14
Proportional Valve
Working Piston (R / 1)
15
Proportional Valve
16
Hydraulic Pump
17
Edge-Type Filter
Working Piston (3 / 5)
18
Electric Motor
19
Temperature Sensor
Working Piston (2 / 4)
20
Pressure Sensor
21
Pressure Accumulator
11
Working Piston (6 / 7)
22
12
23
PLCD Sensor
13
Proportional Valve
15
SMG III
16
SMG III
Explanation
Working Piston (R / 1)
Working Piston (3 / 5)
Working Piston (2 / 4)
10
11
Working Piston (6 / 7)
12
13
Proportional valve
14
Proportional valve
15
Proportional valve
16
17
Edge-type filter
18
19
Temperature sensor
20
Pressure sensor
21
Pressure accumulator
22
23
PLCD sensor
17
SMG III
Pressure Accumulator
The pressure accumulator is fitted on the bottom left of the transmission. The pressure
accumulator supplies enough hydraulic power for the gearshift.
Regulator Block
The regulator block is installed in the center of the transmission housing close to the
clutch housing.
The regulator block consists of the following components:
4 shift travel valves for actuating the hydraulic shift cylinders
2 pressure control valves for modulation of the shift force
4 hydraulic shift cylinders for moving the shift rods in the longitudinal axis
4 transmission position sensors for recording the selected gear (shift rod sensor
R/1 is designed as a double version.)
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SMG III
Explanation
Index
Explanation
PLCD Sensor
Pistons
PLCD Sensor
The PLCD sensor essentially consists of a special core made of soft magnetic material.
The entire length of the core is enclosed by a coil (primary coil) with a further, short evaluator coil at each end.
A permanent magnet approaching the sensor causes local magnetic saturation and
therefore virtual division of the core.
A voltage, depending on the position of the saturated area, is induced in the evaluator
coils when an appropriate alternating current is applied to the primary coil. Consequently,
the length of the virtual parts of the core and therefore the position of the saturated area
can be determined in this way.
The SMG control unit powers the sensor and
correspondingly processes, evaluates and converts
the signals.
The alternating voltage necessary for the measurement
is supplied by the ASIC (Application Specific Integrated
Circuit) integrated in the PLCD sensors.
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SMG III
Expansion Tank
The expansion tank ensures that there is always sufficient hydraulic fluid available for the
system.
Check Valve
The check valve at the outlet to the hydraulic pump prevents the hydraulic pressure from
reducing when the hydraulic pump is inactive.
Filter
A filter is installed at the inlet end of the hydraulic pump. The filter prevents impurities
from entering the solenoid valve (functional failure). It is not necessary to clean the filter.
20
SMG III
Features
Transmission Ratio of the SMG 3
The SMG 3 is designed as an overdrive gearbox as can be clearly seen in the overview
of gear ratios.
Gear
Ratio
Gear
Ratio
1st gear
3.985
5th gear
1.159
2nd gear
2.652
6th gear
1.00
3rd gear
1.806
7th gear
0.833
4th gear
1.392
Reverse
3.985
Drivelogic
Each time you change between the Sequential
mode and the Drive mode, the driving program
last selected in the respective mode is active.
The exception to this is after the first
change from the Sequential to the
Drive mode. In this case, driving
program 3 is active.
In Drive Mode
Five driving programs, from relaxed 1 to sporty/highly dynamic 5 are available for
selection.
In Sequential Mode
You can choose from six driving program from balanced/dynamic 1 to sporty/purist 6.
Each time the engine is started, driving program 3 is activated.
The sporty/purist driving program 6 is only available with the DSC Dynamic Stability
Control deactivated. When DSC is activated, the system switches from driving program
6 to 5.
Note: To maintain vehicle stability, always drive with the DSC switched on
when possible.
21
SMG III
Special Functions
Tow-Start
The following procedure must be implemented to activate this function:
With the brake pedal depressed, turn the ignition key to terminal 15
Select position "N"
Tow-start/push-start the vehicle
Shift selector lever to "S+" and hold in this position.
The transmission control engages the gear corresponding to the speed and activates
the clutch.
Hill Ascent Assistant
Compared to the SMG 2, the hill ascent assistant function has now been automated.
This means the hill ascent assistant no longer needs to be selected manually with
the minus shift paddle on the steering wheel and the brake depressed as was the
case with the SMG 2 but it is now activated automatically when the transmission
system recognizes any other position than "N".
The hill ascent assistant in the SMG 3 is now an active system that makes use of the
DSC to control the vehicle via the wheel brakes on uphill/downhill gradients (clutch
load reduction).
Note: Further information on the hill ascent assistant can be found in the
Chassis and Suspension Section under "DSC MK60E5".
22
SMG III
Launch Control
Launch control has been carried over from the E46 M3.
Clutch Overload Protection (KS)
The clutch overload protection function (KS) protects the clutch from thermal overload.
The clutch overload protection function makes use of an arithmetic logic in the SMG
control unit that can calculate the thermal load of the clutch based on the slip and
contact force.
In the first stage, the clutch overload protection function reduces the slip at the clutch.
The customer would refer to this as a "harsh gearshift".
The anti-jolt function is activated as a further protection measure. As a result, the
thermal input at the clutch discs is reduced and the driver's attention is drawn to the
overload situation.
If the temperature continues to increase, a warning is triggered in order to repeatedly
draw the driver's attention to the overload situation. Start-off in 2nd gear is automatically
inhibited when the gearbox warning is triggered in order to minimize the clutch slip.
23
SMG III
Service Information
Initialization
As on the SMG 2, the SMG control unit must newly adapt and store various parameters
after a component has been replaced in the area of the clutch or gearbox as well as after
programming.
Adaptations
It is necessary to check the gearbox mechanism after replacing a gearbox, components
of a gearbox or the SMG control unit. The following adaptations are provided in the
GT1/DISplus.
The most important adaptations in the gearbox are:
Shift range mid-points
Valve characteristics
Transmission characteristics
Longitudinal acceleration sensor offset.
Shift Range Mid-Points
This function ensures a gear can be disengaged without previous adaptation of the transmission characteristics.
Valve Characteristics
The shift range valves in the hydraulic system are designed as proportional valves. Due to
the tolerance scatter in series production, it is necessary to teach in the offset current of
these valves.
The current at which the corresponding selector rod begins to move is determined. This
value is stored as the offset current in the SMG control unit.
The current consumption of the proportional valves is determined in both switching
directions.
Transmission Characteristics
In this adaptation phase, the selector rods are moved to the end positions and the actual
values determined.
The measured values indicate whether a gear is engaged.
The selector rod for reverse gear is additionally monitored by a redundant sensor whose
values are also stored.
In addition, the hydraulic pressure is read off at this selector rod and the selector rod is
monitored to ensure it remains in the end position.
Longitudinal Acceleration Sensor
The measured value of the longitudinal acceleration sensor has a constant offset. This
value is determined when the vehicle is at rest in horizontal position and therefore the
longitudinal acceleration is zero.
The actual values are permanently sampled. As soon as a sample value deviates by
more than a reference value, external influences are assumed and the adaptation
procedure is terminated to ensure no falsified acceleration values are measured during
vehicle operation.
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SMG III