TraXon

The New Modular Transmission System

Internal © ZF Friedrichshafen AG
ZF Shapes the Future in Four Technology Domains

Vehicle Motion Control Integrated Safety

Automated Driving Electric Mobility

Internal © ZF Friedrichshafen AG 2
Financial Overview 2019

EUR 36.5 billion 147,797 EUR 2.7 billion

sales employees Research &
Development

EUR 1.5 billion 4.1% EUR 1.9 billion

adjusted investments in
adjusted EBIT
EBIT margin property, plant,
and equipment

Internal © ZF Friedrichshafen AG 3
Key Figures – Locations

North America Europe

Locations 48 Locations 121
Employees 34,785 Employees 88,304

241 locations in 41 countries

Asia-Pacific
production locations Locations 55
161
in 27 countries Employees 18,759

main development locations

16
in 9 countries South America
Locations 10
130 service locations Employees 5,322 Africa
Locations 7
Employees 627
Over 650 service partners worldwide

Worldwide Presence – Production, Development, Sales and Service

Internal © ZF Friedrichshafen AG 4
T Division
Commercial Vehicle Technology

TC
CV Chassis Technology Chassis Modules
Damper Technology

TE
CV Steering Systems
Steering Systems

TN
CV Powertrain Modules
Clutches & Systems

TT
Truck & Van Driveline
Technology Transmissions

TU
Axle & Transmission Systems
for Buses & Coaches Axles & Transmissions

Internal © ZF Friedrichshafen AG 5
ZF South America operations are spread in 8 plants

Sorocaba Iracemápolis São B. Campo Araraquara

• Transmissions • Chassis systems • Clutches Components • Clutches Assembly
• Axles for LV and HCV for LV and HCV
• Chassis
components for LV • Development Center • Clutches
and HCV for Facing Technology Remanufacturing
• Chassis systems for HCV

Limeira Eng. Coelho Itu San Francisco

• Braking systems • Foundry for braking • Integrated Logistic • Shock absorbers
• Steering systems systems Center for LV and HCV
• Restraints and safety (ZF Aftermarket)
electronics
Plants
Sales offices
ZF Technology in Buses

Main customers
(alphabetical order)
Passive safety* Advanced driving*
systems Safety* assistance systems
Electronics
Chassis
components
Steering
systems

Low floor axles*

Damping
systems

Tire pressure
monitoring Brakes*
Clutches

Transmissions

Status: April 2019

* Without local production
Highlights

TraXon • International benchmark

Nm/kg ratio 12.83 • Transmission spread 16.78 • Efficiency 99.7 %

Versions Quiet operation

12-speed DD/OD 35 % quieter than predecessor
16-speed DD/OD (- 6 dB)

Torque Extreme tractive force

OD up to 3,400 Nm i = 16.69 (DD)
DD up to 2,800 Nm
Safety
High reliability Intarder with up to 600 kW
66 % more gear changes, braking performance
50 % more clutch
operations than predecessor Lightweight
Up to 100 kg more payload
in comparison to competition
Functionality
PreVision GPS
Rolling function Service
Free the vehicle by rocking, etc. Datalogger

© ZF Friedrichshafen AG 8
TraXon – A Step into the Future
Customer Values
Long service life and excellent reliability

• Minimizes the peripheral interfaces

• Digital signal transmission only
• Low-maintenance ConAct clutch actuation system
• Longer clutch service life
• Extra long oil change intervals
• No external breather
• Longer service life of transmission and oil

Internal © ZF Friedrichshafen AG 9
The Highlights
(Software)
Most cutting-edge transmission functions

• PreVision GPS anticipatory driving strategy

• Driving programs from ECO to Power
• Special driving functions:
• Supports the engine's start-stop function
• Rolling function
• Fast gear changes
• Maneuvering function
• Hill holder
• Off-road function
• Rock-free function

Internal © ZF Friedrichshafen AG 10
TraXon – A Step into the Future
Customer Values
More payload

• Up to approx. 65 kg more payload

non-Intarder transmission in comparison to competition

At just 265 kg (dry) TraXon is a lightweight transmission that,

in return, delivers a higher payload.

For comparison:
Scania Opticruise (GRS 905/GRSO 905): 332 kg
Volvo I-Shift (AT 2812 E/ATO3112 E): 277 kg

Internal © ZF Friedrichshafen AG 11
TraXon – A Step into the Future
Customer Values
Quiet operation

• Virtually no transmission noise

• Significantly quieter shifting noises
• Anti-rattling shock absorber in reverse gear
• No exhaust noises
• No transmission casing required
• Extensive test bench and real tests in the vehicle

Internal © ZF Friedrichshafen AG 12
TraXon – A Step into the Future
Customer Values
Excellent starting behavior

• Extreme tractive force

• Optimum selection of starting gear

• Smooth clutch control

Internal © ZF Friedrichshafen AG 13
TraXon – A Step into the Future
Customer Values
Fuel-efficient

• Excellent smooth-running transmission

• Driving in ECO program mode

• Reduced engine speeds at cruising speed

• Fuel-efficient transmission control unit

Internal © ZF Friedrichshafen AG 14
TraXon – A Step into the Future
Customer Values
Fully-automatic safety

• Protection against incorrect operation

• Transmission functions increase driving safety

• ZF-Intarder (option)

Internal © ZF Friedrichshafen AG 15
The Transmission System

Additional Dry separating Mechatronics modules

modules clutch Control elements
(SAE 1) Power take-offs (PTOs) (option)

Concentric
clutch actuation system Integrated Intarder
ConAct bell housing (option)

Internal © ZF Friedrichshafen AG 16
TraXon
Basic Transmission (12-Speed)
Countershaft Splitter group Splitter group Range change group
Constant 1 Constant 2

Input shaft and

main shaft

Countershaft
Output shaft
Output flange

3 2 1 R
3-speed main
transmission section Deflection gear of R gear

Internal © ZF Friedrichshafen AG 17
TraXon
Mechatronics
Valve module Mechatronics
Sensor module • Module

"Select" actuation module • Exchangeable modules

• Vibration stability
• Temperature-resistant
• Internal wiring
• Digital signal transmission
• Designed for many gearshifts,
long service life

Internal © ZF Friedrichshafen AG 18
TraXon
Exhaust Air Chamber and Oil Filter
New

• Oil filter with collecting

magnet
Permanent oil cleaning
• ZF-Ecofluid M transmission oil
(initial fill)
• Internal exhaust air chamber
Low-noise
• One central air connection
Reliable

Central air
connection
Protected exhaust Oil filter with collecting
air chamber magnets

Internal © ZF Friedrichshafen AG 19
TraXon
Mechatronics • ConAct ® Clutch Actuation System
Plug-in termination to Features
electronic control unit
(TCU) • Concentric clutch actuation (on
input shaft)
• Push-type clutch
• Protected inside the bell housing
• Compressed air actuation

Travel sensor

Internal © ZF Friedrichshafen AG 20
TraXon
Mechatronics • Housing Cover
New integrated circuit packaging (AVT) Features

• Aluminum die castings

• High rigidity
• AVT connection technology with
plastic intermediate frame
• Fully installed transmission control
unit (TCU)
• Heat-insulated
• Mechanically protected
• Integrated connection technology
• Robust central connection
for vehicle electrical system
(32-pin plug)
• Self-aligning plug contacts to the
TCU fully integrated mechatronics modules
into the housing cover

Internal © ZF Friedrichshafen AG 21
TraXon
Electronic Control Unit
Electronic transmission control unit (TCU) Driving strategy

• PreVision GPS anticipatory driving strategy

• Fully automatic driving with automatic adaptation
of the driving programs (Eco to Power)

Software-based transmission functions

Safely hidden behind
the cladding of the
housing • Rolling function
cover – the TCU • Maneuvering function
• Fast gear changes
• Convenience shifts
• Start-stop assistance
Central connection • Hill holder
for vehicle electronics • Offroad mode
• Rock-free function

Internal © ZF Friedrichshafen AG 22
TraXon
Extension Modules
Individuality through diversity

Available auxiliary devices: In field testing:

• Single/twin plate dry clutch Hybrid module

• ZF-Intarder The starting module for the electric drive
• Clutch-dependent and driving-
dependent power take-offs (PTOs)
• Additional heat exchanger
H 10,5 x B 7,45 cm
for non-Intarder transmissions
Position
• WSK torqueHconverter
1,0 x 3,0 cm
clutch,
the starting module for heavy
goods vehicle traffic
(TraXon Torque)

Internal © ZF Friedrichshafen AG 23
TraXon with ZF-Intarder

• Increases safety

• Integration in
brake management

• PTOs
possible without any problems

Internal © ZF Friedrichshafen AG 24
TraXon with Intarder
Driveline

GPS- Engine control TraXon Intarder Brake control

module (EDC) (TCU) control ABS/EBS

Internal © ZF Friedrichshafen AG 25
TraXon with PreVision/GPS
Anticipatory Driving Strategy
TraXon with PreVision GPS

• Driving with the GPS module:

Detects the position and upcoming driving route
• Permanent determination of optimum gear and gear shifting point

Benefits:
• Increased comfort through a reduction in gear-change frequency
• Fuel savings thanks to increased rolling phases
• Increased driving quality and effectiveness

Internal © ZF Friedrichshafen AG 26
TraXon • PreVision/GPS
Anticipatory Driving Strategy
Early upshift
Ideal shifting points into the most economical gear PreVision GPS

• Reduces the shift frequency

Selects the right gear –
before the uphill gradient increases • Fuel consumption savings
• Increased comfort
thanks to fewer gearshifts
Consumption-optimized rolling • Increase of rolling phases
Optimally uses the omentum Identifies the upcoming
on downhill gradients uphill gradient • Optimized calculation of the
driving resistance and the vehicle
Rolling activated No rolling
mass to increase driving quality
and effectivity

Prevent unnecessary gear changes

Here, PreVision does not shift into the top gear:
no downshifting is required for the coming uphill gradients

No rolling

Internal © ZF Friedrichshafen AG 27
TraXon
Rolling Function
Features

• Calculates driving resistance for

track gradient
• Activates the rolling function:
transmission in neutral position

Benefits

• Reduces the drag losses

• Fuel economy

Internal © ZF Friedrichshafen AG 28
TraXon
Hill Holder
Features

• Setting off with optimum engine

torque
• Determines vehicle weight and
track gradient

Advantages

• Easy and safe setting off on

mountains and on difficult terrain

Internal © ZF Friedrichshafen AG 29
TraXon
Fast Gear Changes
Fast gear changes

• Improved shift sequence in case

of demanding topographies
• Minimum shifting time
• Adapted driving strategy

Advantages

• Fuel economy
(driving at lower engine speeds)

Internal © ZF Friedrichshafen AG 30
TraXon
Convenience Shifts
Characteristics

• Soft clutch actuation and gear

changes
• Precise speed recording due to
high-resolution sensors

Benefits

• Improved driving comfort

• Optimum acceleration when
setting off

Internal © ZF Friedrichshafen AG 31
TraXon
Start-Stop Assistance
Start/stop

• Transmission functions to support

the "Engine OFF" function during
longer stops (for example with
long traffic light phase)

Benefits

• Fuel economy
• Less emissions

Internal © ZF Friedrichshafen AG 32
TraXon
Offroad Mode
Features

• Adapts the driving functions to

difficult terrain / ground:
• Optimum calculation of driving
resistance
• Adapted shifting speed
• Special clutch functions
• Manual activation by the driver

Benefits

• Safer driving on difficult terrain,

also with high loads

Internal © ZF Friedrichshafen AG 33
TraXon
Maneuvering Function
Features

• Smooth closing of drive clutch

• Excellent adjustment control via
the accelerator pedal

Benefits

• Perfect control over the vehicle

• Even with difficult track conditions

Internal © ZF Friedrichshafen AG 35
Improvements
TraXon vs. AS Tronic
100 % 120 % 140 % 160 %
Hardware
DD / OD torque + 25 %

100 %
Gear spread (including R gear) + 20 %

Transmission efficiency +5%

=
= 100 %
Power-to-weight ratio +5%

TronicTronic
Noise -35 %
Sensor technology (inclination,
+ 65 %

ZF-AS
rotation direction, resolution)
Service life + 25 %

AS
Reliability + 25 %

Software
Functions (PreView, rolling function,
free the vehicle by rocking) + 65 %

Internal © ZF Friedrichshafen AG 36
Product Range

12-speed
Direct drive (TD) 12 TX 1410 1610 1810 2010 2210 2420 2620 2820

12-speed
Overdrive (TO) 12 TX 1610 1810 2010 2210 2410 2610 2820 3020 3220 3420

16-speed
Direct drive (TD) 16 TX 1640 1840 2040 2240 2440 2640 2840

16-speed
Overdrive (TO) 16 TX 1840 2040 2240 2440 2640 2840 3040 3240 3440

Nm 1,000 1,500 2,000 2,500 3,000 3,500

Internal © ZF Friedrichshafen AG 37
Technical Data TraXon – Europe

12-speed transmission (12 TX)

16.69 – 1.00
R 15.54 / 12.03
TD 1410 1610 1810 2010 2210 2420 2620 2820
12.92 – 0.77
R 12.03 / 9.29
TO 1610 1810 2010 2210 2410 2610 2820 3020 3220 3420
Nm
1,400 1,600 1,800 2,000 2,200 2,400 2,600 2,800 3,000 3,200 3,400

Non-Intarder kg
253 265

+ Intarder kg
335 347

Non-Intarder dm3
12.5 13.5

+ Intarder dm3
22.5 23.5

878 910
mm

SAE
1 1

Internal © ZF Friedrichshafen AG 38
Technical Data TraXon – Europe

16-Gang-Getriebe (16 TX)

17.94 – 1.00
R 17.27 / 14.14
TD 1640 1840 2040 2240 2440 2640 2840
14.68 – 0.82
R 14.14 / 11.60
TO 1840 2040 2240 2440 2640 2840 3040 3240 3440
Nm
1,400 1,600 1,800 2,000 2,200 2,400 2,600 2,800 3,000 3,200 3,400

Solo kg
290

+ Intarder kg
372

Solo dm3
14.5

+ Intarder dm3
24.5

965
mm

SAE
1

Internal © ZF Friedrichshafen AG 39
Main Dimensions
(mm)
289 289 Transmission length1)

1 2

SAE 1
1) 12 TX xx10 = 878
12 TX xx20 = 910
7 6 5 4 3 16 TX xx40 = 965

1 Transmission control unit 5 Oil filling and oil level monitor

2 Impulse sensor 6 Drive
3 Output 7 Connection point for PTO
4 Oil drain

Internal © ZF Friedrichshafen AG 40
Main Dimensions with ZF-Intarder
(mm)
300 289 1,1701) / 1,2022) / 1,2573)
8781) / 9102) / 9653)

SAE 1
1) Typen 12 TX xx10
2) Typen 12 TX xx20
1 2 3 4 3) Typen 16 TX xx40

1 Connection for PTO

2 ZF transmission TraXon
3 ZF-Intarder unit
4 Oil/water heat exchanger

Internal © ZF Friedrichshafen AG 41
TraXon:
Fuel Savings and CO2 Reduction
• Reducing fuel consumption • Reducing emissions
• Optimizing economy • Preserving resources

0
-4%
-6%
-5 -8%
- 12 %
Fuel consumption (%)

(with DD and long axle)

-10

(with extra long axle)

-15

TraXon Hybrid
TraXon Dual
-20

AS Tronic
Ecosplit

TraXon
-25

-30

5 % reduction in fuel consumption at 200,000 kilometers a year corresponds to savings

of approx. EUR 4,000 to 5,000 a year

Internal © ZF Friedrichshafen AG 42
Fuel Savings in Long-Distance Fleets
with Automatic Transmission Systems
Further fuel consumption reduction with new TraXon functions combined with long axle

Manual transmissions

AS Tronic
Number of drivers

TraXon AS Tronic Manual

80 110 120
92 % 96 % 100 %
Fuel consumption [%]

Internal © ZF Friedrichshafen AG 43