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The legislative and market pressure for CO2 reduction and fuel efficient powertrains lead to a variety of automatic transmission concepts in recent years. The CVT technology, the dual clutch technology (DCT) and optimized architectures of torque converter / planetary gear based automatic transmissions (AT), such as 6, 7, and 8 speed ATs entered the market in the last decade. Also different hybrid technologies have entered the market offering further improvement for fuel consumption especially in city driving. Helpful for OEMs and suppliers to flexibly meet market demands proofed the use of modular hybrid solutions. Clear demand to meet were packages of existing vehicles and powertrains with AT and hybrid transmission (HT), e.g. the modular transmission kit based on the ZF 8 speed AT. Hybrid technology is offering fuel efficiency benefits, but there are also reasons for a slow market penetration.

The slip-controlled converter lock-up clutch is an indispensable feature of modern automatic car transmissions and has been included in every ZF transmission since the start of production in 1994. In view of the development of their electro-hydraulic control system - including design, adjustment and testing -, computer based methods are needed to reduce the volume of work, costs and time to market. This paper focuses on computer-aided methods such as automatic control simulation and route and consumption simulation. Furthermore, the practical use of a slip-controlled converter lock-up clutch is described.

In a collaborative investigation of ZF Friedrichshafen AG and the Fraunhofer-Institut für Betriebsfestigkeit LBF [1], both constant and variable amplitude fatigue tests were performed on induction-hardened automatic transmission shafts made from Ck 35 mod. steel. The objectives of the project were to evaluate the safety reserves of the shafts and to apply several selected methods to assess fatigue life, to compare these methods and to gain insights for future component developments.