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ZF Says Production Ready Technology Can Cut Fuel-Consumption by 18%

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Old Aug 6, 2009 | 05:16 AM
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ZF Says Production Ready Technology Can Cut Fuel-Consumption by 18%

Auto parts maker and engineering firm ZF Friedrichshafen AG says that its new lineup of driveline modifications and transmissions, when combined, can deliver up to 18 percent better fuel-consumption on traditional gasoline powered cars. The results are even more impressive for hybrids, with total fuel-economy rising 30 percent.

Harald Naunheimer, VP of research at ZF delivered the news at the Center for Automotive Research’s Management Briefing Seminars in Traverse City, Michigan, earlier this week. Naunheimer said all of his company’s new initiatives will make their way into production cars starting next year.

Included in the list of fuel-saving technologies are lighter transmissions with more gears, as well as electric, rather than mechanical, features. Electrical power steering can account for a savings of 2 to 3 percent, while electric active roll stabilizers add another 1 to 2 percent.

A start-stop function, which shuts off the engine at stop lights or when stuck in traffic, can save up to 5 percent while a new, lighter transfer case for all-wheel drive cars can add an additional 1 to 1.5 percent.

The single largest way to boost fuel-economy, however, is with a transmission with more gears. ZF says its new 8-speed box can deliver a 6 percent boost in fuel economy over a six-speed unit. Lexus already uses an 8-speed transmission and BMW recently launched a new 8-speed box in the flagship 760Li (pictured above). This, however, raises the issue of cost.

With an 8-speed in a six-figure BMW, we’re unlikely to see the same technology make it into a Toyota Corolla any time soon. Still, the race is on for improved fuel-consumption as the Obama Administration’s new CAFE regulations will see fleet averages for passenger cars rise to 35.5 mpg for 2016, up significantly from 27.3 mpg for 2011.


[Source: Automotive News]
But how much extra weight does this technology add?
Old Aug 6, 2009 | 05:47 AM
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Not sure start stop feature is a good idea. Isn't most of the engine's wear come from starting the engine? Wouldn't this possibly shorten the motor's lifespan?
Old Aug 6, 2009 | 08:16 AM
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Honestly, considering how quickly people go through cars these days, most new car buyers don't come close to wearing out their engine. So they aren't very likely to care.

Used car buyers on the other hand...
Old Aug 6, 2009 | 08:18 AM
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Originally Posted by SSbaby
But how much extra weight does this technology add?
They say it is lighter, but that is also engineered in to save fuel.

Originally Posted by Kris93/95Z28
Not sure start stop feature is a good idea. Isn't most of the engine's wear come from starting the engine? Wouldn't this possibly shorten the motor's lifespan?
We will find out soon enough. European cars are going to start showing up with this soon, even BMWs.

http://www.autobloggreen.com/2008/07...odels-by-2010/
http://www.bmw.com/com/en/insights/t..._function.html

by 2012 they think half of all new cars will be sold with it.
http://reviews.cnet.com/8301-13746_7-10081298-48.html
Old Aug 6, 2009 | 08:44 AM
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Electric power steering blows.
Old Aug 6, 2009 | 09:01 AM
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Originally Posted by Sixer-Bird
Electric power steering blows.
While the result of failure compared to that of a hydraulic power steering system scares me, I can't feel the difference with my G6 that has it. Do you have anything more substantial to contribute rather than just saying it "blows"?
Old Aug 6, 2009 | 09:22 AM
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electrronic throttle control blows, and it only saves ~5 lbs.
Old Aug 6, 2009 | 09:25 AM
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Originally Posted by Kris93/95Z28
Isn't most of the engine's wear come from starting the engine?
I would think that refers to cold starts. The subject start/stop wouldn't even give the oil a chance to drain down.
Old Aug 6, 2009 | 10:01 AM
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Originally Posted by DAKMOR
electrronic throttle control blows, and it only saves ~5 lbs.
And didn't the challenger have some issues where the car would get stuck in wide open throttle? Wasn't there a chrysler mechanic/sales guy who wrecked one on a dealership lot?
Old Aug 6, 2009 | 11:08 AM
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Originally Posted by SSbaby
But how much extra weight does this technology add?
Weight isn't an issue.

1. Fuel economy is greatly increased, and far more than offsets any fuel economy loss from weight gain.

2. The weight gain is small enough that it won't even come close to adversely affecting performance and handling.

Originally Posted by AdioSS
Honestly, considering how quickly people go through cars these days, most new car buyers don't come close to wearing out their engine. So they aren't very likely to care.

Used car buyers on the other hand...
That is a very good point.

Originally Posted by Sixer-Bird
Electric power steering blows.
I've never driven a car with it, so I'll be open enough to reserve judgement (I'm old enough to have had a hydralic power steering system go out on me).

Originally Posted by DAKMOR
electrronic throttle control blows, and it only saves ~5 lbs.
This I agree with.

It still involves a wire, so why not a cable.


Originally Posted by Tokuzumi
And didn't the challenger have some issues where the car would get stuck in wide open throttle? Wasn't there a chrysler mechanic/sales guy who wrecked one on a dealership lot?
I'm sure he wasn't the only mechanic/sales guy who wreack a car on a dealership lot, and I can guarantee that scenario isn't limited to a Chrysler vehicle lot.

One internet story doesn't equal an issue since no one knows what really happened and anyone working at a dealer has a very high motive to blame the car and not themselves when wrecking a car at their dealership.

The "Throttle Stuck" excuse is as old as Audi's "sudden uncontroled acceleration panic from the 1970s that turned out being nothing more than people hitting the gas when the automatic was accidently put in gear.

That's why today you have to actually put your foot on the brake in order to shift out of drive.... true item.

There has been no issue of an electric throttle car being stuck open any more than a cable operated one.

In fact, it's far more likely a cable throttle gets stuck open than an electronic one.

Again, true item.
Old Aug 6, 2009 | 11:13 AM
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Originally Posted by JeremyNYR
While the result of failure compared to that of a hydraulic power steering system scares me, I can't feel the difference with my G6 that has it. Do you have anything more substantial to contribute rather than just saying it "blows"?
The Sigmas have an issue with their electric steering. My neighbour's Malibu Maxx had the boost quit working on her, and it was way to difficult for her to even back the car out of the parking lot. She had to call a tow truck. And it went back to dealer once or twice after that for the same thing. Now that wouldn't be catastophic on the highway, but it a huge dissastifier.

Having said that, I think most of the knocks against electric assist come from the artificial feel. I'm sure that over time, engineers will improve that along with the reliability.

Back to the article, I'm scratching my head trying to figure out how electric active roll stabilizers are going to improve fuel economy 1-2%
Old Aug 6, 2009 | 11:24 AM
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This isn't new news. I think most of us have been aware of all of the above technologies. It's just that most of them add extra cost to the production of the vehicle as well as other downsides like more expensive repairs.
I didn't realize that active roll stabilization made a 1-2% improvement in fuel economy... I thought that was just a cool way to improve handling without compromising ride quality. Right now many of the technologies listed in there are only found in cars in the 50k+ range... and usually on cars where fuel economy is not a primary concern of the buyer.

Originally Posted by Sixer-Bird
Electric power steering blows.
In some cars it does, and in some cars it's great. I think it's more tuning-dependent than ever. I drove the most recent generation of Audi TT with EPS and the steering was very impressive actually... I don't just mean acceptable, I mean very good.

My Aura XR-4 has EPS and it's nothing great but I actually prefer it to the hydraulic steering in my friend's Aura 3.5 V6. I've read at least two reviews that specifically mentioned the EPS had a better feel to the hydraulic steering.

Also to whoever said electronic throttle control sucked.. honestly I can't even feel a difference between mechanical and electronic. The only time it becomes apparent is when the stability control system kicks on, but to me that's a benefit, not a detractor.
Old Aug 6, 2009 | 11:26 AM
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I am wondering now, though... what DOES happen if EPS fails? Well first of all, how common should an EPS failure be in theory? Is EPS generally thought of as a system that will last the life of the car and is quite a bit more reliable than hydraulic steering? If it does fail are there mechanical backups?

I know on every car I've owned with electronic throttle control they all have had mechanical backup systems as far as I know.
Old Aug 6, 2009 | 11:32 AM
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Originally Posted by Kris93/95Z28
Not sure start stop feature is a good idea. Isn't most of the engine's wear come from starting the engine? Wouldn't this possibly shorten the motor's lifespan?
Most of the engine's wear comes from cold starts, when the oil has had time to drain back to the pain.

Warm starts are no problem. The car should just have a control mechanism that ensures that it fires the engine up once every couple minutes to maintain ideal operating temperature and keep everything oiled up.
Old Aug 6, 2009 | 11:36 AM
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WRT to the number of gears in transmissions today...aren't we kind of getting towards the point of diminishing returns? I think it was Top Gear's Jeremy Clarkson, who was doing a comparison between the M3 and the Lexus IS-F?...maybe, and said that the 8-speed transmission in the Lexus was always looking for gears. I would think this would be more of a problem/nuisance for typical drivers.



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