trends hd transmission oils key drivers, …
TRANSCRIPT
Shell Lubricants 1
TRENDS HD TRANSMISSION OILS KEY DRIVERS, CONSEQUENCES, FIELD EXPERIENCES
Frank Machatschek Product Application Specialist
2
Key Drivers For Transmission Oil Development
Total Cost of Ownership
Measures to improve TCO also affecting transmission oil
Transmission oil needs to be robust against mechanical and thermal load
over extended oil drain intervals and compatible with new materials
3
Longer drain intervals
Today: 400k-500k km
Mid-term: 750k km, Long-term: 1 Mio km... Fill-for-Life
Increased power density
High demand on cooling and wear protection capability at high load
Higher operating temperatures
Higher power density
Smaller oil volumes
Reduction by 30-50% for lower churning losses
New Developments
4
New Developments
Improved Fuel Economy
0,5 – 1,5% higher efficiency through less friction losses
Eg Gear box: 75W-9075W-80, Axle: 80W-9075W-85
Improved, durable and constant shifting quality
Special oils for special applications (operation, climate)
Mining, off-raod, hot climate: Volvo 97315 SAE 75W-90 Protection
Long haul: lower viscosities Efficiency
New materials
Plastic material compatibility
Carbon synchronizer
5
Carbon Synchronizer
Many EU OEMs moved to carbon in recent years
Benefits compared to Molybdenum:
Longer service life, higher loads higher temperatures
More shift cycles, improved shift comfort
Less vulnerable against faulty shifting
Carbon can be used to replace Mo synchro at
repair/maintenance refer to manuel instructions
New oil spec to prevent synchro failure due to oil
carbon: ZF TE-ML 01
Shell Spirax S6 GXME 75W-80 approved against ZF
TE-ML 01L
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New Developments Require Advanced Lubricant Solutions
Base oil
Improved thermal stability and oxidation/deposit control
More high quality synthetic base oils Gr III or Gr IV
OEMs: global availability and supply security
Additives
Higher shear stabililty advanced VI-Improver
Advanced EP/AW to compensate for lower viscosity
Anti-Foam: higher durability
Finished formulation
Improved compatibility ela/synchro
OEM tailored formulations
DRAIN INTERVAL
VOLUME EFFICIENCY
& DURABILITY
OIL
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OEM AXLE TRANSMISSION
ArvinMeritor O76 (SAE J2360, MIL-PRF-2105E)
O81
DANA/Eaton SHAES 254 SHAES 256 Rev C
PS-164 Rev 7
ZF TE-ML 05, 12 TE-ML 02
Volvo 97310 97312
97305 97307
Iveco SAE J 2360 (MIL-PRF-2105E) TE-ML 02 DAF (GL-5) TE-ML 02 MAN Typ 342/3343 Typ 341/3343 Scania STO 1:0
STO 2:0A STO 1:0
STO 2:0G Mercedes-Benz 235.0, 235.6
235.8, 235.9 , 235.20 235.1, 235.11 235.4, 235.5
Various OEM Requirements Cannot Be Met By One Product
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Additive Chemistry (EP/AW)
FUEL ECONOMY
GL-5
GL-4
75W-90 75W-80
THER
MA
L ST
ABI
LITY
SAE viscosity grade
STO 2:0G API GL-5
SAE 75W-90
STO 2:0G API GL-5
SAE 75W-80
STO MTF API GL-4
SAE 75W-80
commercially available under development
Various OEM Requirements: Scania Transmission Oil
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SPIRAX MB 90 SPIRAX S3 AD Transmission MB SPIRAX S5 ADE
85W-90 80W-90 75W-90 75W-85
FUEL ECONOMY
Various OEM Requirements: Mercedes-Benz Axle Oil
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5x Eaton gear box RTSO 1234..
Test duration: 500k km
Oil Drain Interval Gear Box: Spirax S6 GXME 75W-80
Fe
[ppm]
Cu
[ppm]
Oil Milage [km]
11
Some more examples: DAF, MAN, Volvo
Oil Drain Interval Gear Box: Spirax S6 GXME 75W-80
Shell Lubricants 12
?
?
Axle Oil Drain Intervals In EU Approach Fill-For-Life
???
Shell Lubricants 13
6 x MAN hypoid axle HY-1350
Test duration: 6 years
No oil drain!! No top up!!
Oil Drain Interval Axle: Spirax S6 AXME 75W-90
Shell Lubricants 14
2 axles inspected after 680k km
2 axles inspected after after 1,0 Mio km
4 axles inspected after 1,2 Mio km
Oil Drain Interval Axle: Spirax S6 AXME 75W-90
All oil parameters excellent
Normal wear pattern
No oil sludge
No oil leakages
No failures
Unique test facility at Shell R&D lab Germany
Each lubricant combination Engine-Gearbox-Axle can be tested
Each single FE contribution (engine-gearbox-axle oil) can be measured
Diff Ratio
1:1 / 1:4 / 1:8 /1:16
Power Brake
Generator
Pmax:470kw
Mmax:50.000Nm
Fuel Economy: Shell Driveline Test Rig Evaluation
Gear Box
Shell Lubricants 16
Driveline test with Mercedes-Benz G210-16 gearbox and HL-7 axle
FE improvement 1,5 - 1,7%
Oil temperatures are reduced for longer equipment endurance
Fuel Economy: Shell Driveline Test Rig Evaluation
Reference Shell FE Fluids Axle MTF Axle MTF
SAE 90 80W 75W-90 75W-80
API GL-5 GL-4 GL-5 GL-4
KV40
KV100
VI
184
16,9
97
87
9,9
92
115
15,2
140
56
9,1
143
Decrease in fuel
consumption per
hour
at 65 km/h
at 75 km/h
at 85 km/h average 1,5 ... 1,7%
Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz
Question:
What was the maximum oil drain interval in the MAN field
trial with Shell Spirax S6 AXME in the rear axle ?
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0 2 4 6 8 10
Wet Clutch Friction Stability
Oxidation Stability
Scuffing Protection
Pitting Protection Wear Protection
Synchroniser Performance
Low Temperature Properties
ATF MTF
Performance Requirements MTF vs ATF
Shell Lubricants 19
Technology Leader In Automatic Transmission Oils
Long history of cooperation with OEMs
Range of fully-synthetic ATFs
First Fill business eg ZF, Voith
Longest ODIs
Spirax S6 ATF ZM: 180.000 km
Spirax S6 ATF VM Plus: 180.000 km
Multiple long drain
Spirax S4 HDX: Voith, ZF, Allison
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Shell ATF Products Are Approved For Longest Oil Drains
Allison Spirax S6 ATF 295
300.000 mls
Voith Spirax S6 ATF VM
Plus
180.000 km
ZF Spirax S6 ATF ZM
180.000 km
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Capable for long drain intervals
Today: increase from 30.000 km up to 180.000 km over last 3 decades
Mid-term: Fill-for-life (500.000 km)
Cope with increased mechanical and thermal load
Provide constant friction behaviour over entire oil drain period
Extremely high shear stability
Provide corrosion protection
New Developments
22
oil s
ump
tem
pera
ture
[°C
]
time
80
90
100
110
120
Euro I
Euro II
Euro II &
articulated
bus
Euro III &
IV
Increasing Oil Sump And Peak Temperatures Drove Development
Euro VI
Oil sump peak: 120°C
Torque converter: 140-180°C
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Spirax S6 ATF ZM mineral ATF
change of viscosity @ 100°C
+ 0,8 mm 2 /s + 16,1 mm 2 /s
sludge No Yes
Oxidation Test @ 170°C and 384 h
Superior oxidation stability enables both longest
ODI and high durability of ATs
Oxidation Stability Mineral vs Synthetic ATF
Shell Lubricants 24
Spirax S6 ATF ZM
ZF First Fill Oil
Approved for highest specifications:
TE-ML 14E for Ecomat up to 150.000 km ODI
TE-ML 20 F for Ecolife up to 180.000 km ODI MAN 339 Z13
TE-ML 04D (marine) and 16N (rail)
Benefits compared to other ATFs:
Joint development with ZF
Designed to meet requirements of ZF transmissions
Esp high temperature and long ODI
Excellent low temperature performance
Better viscosity control through high shear stability
Ecolife
Ecomat
Shell Lubricants 25
Donax TZ
Spirax S6 ATF ZM: Excellent Viscosity Control
4,0
6,0
8,0
10,0
12,0
0 50.000 100.000 150.000 200.000 250.000 300.000 350.000
kin. viscosity [mm2/s]
Oil Milage [km]
Shell Lubricants 26
Spirax S6 ATF VM Plus
Voith First Fill Oil
Approved for highest spec: Voith H.55.6336 Section 3
Underwent severe field trials in coop with Voith with continuous oil
analysis and hardware inspections, up to 340.000 km ODI
Only Voith approved oil for max ODI of 180.000 km w/o restrictions
H.55.6336 Section 2: 180.000 km with restictions (eg GVW)
H.55.6336 Section 1: 120.000 km w/o restrictions
Benefits compared to other ATFs:
Joint development with Voith
Designed to meet requirements of Voith transmissions
Excellent low temperature performance
Improved oxidation stability
Better viscosity control through high shear stability
Shell Lubricants 27
Spirax S6 ATF 295
Approved for highest spec: TES 295
HD trucks and buses as well as MD and LD vehicles
Significantly extended ODI compared to TES 389
up to 300.000 ml (480.000 km) or 6.000 hrs
Benefits compared to TES 389 fluids:
Synthetic: better than previous spec (eg Allison C-4)
Improved low temperature performance
Improved oxidation stability
Better viscosity control through high shear stability
Meets GM Dexron-III for steering/hydraulics
Meets specs based on Allison TES 389/295 eg Cat
AT-1 Synthetic ATF
Shell Lubricants 28
TRANSMISSION OILS FOR MINING APPLICATIONS
Carlos Torres Indirect Lubricant Technical Coach
Shell Lubricants 29
Applications
Hydraulic Systems
Power Train
Wet Breaks
Shell Lubricants 30
Mining Sector Trends
Extended Service Intervals
High Loads
Low Environmental
Impact Fine Filtration
Energy Efficiency
Extended Component
Life
Shell Lubricants 31
Off Road Haul Truck – Mechanical
Brake & Hoist System
Torque Converter & Transmission
Differential & Final Drives
Steering System
Shell Lubricants 32
Off Road Haul Truck – Electric Drive
Traction Motor
Planetary Gears
Omala S4 Wheel
Shell Lubricants 33
Shovels
Omala S3 GP Omala S4 GX
Omala S4 Wheel
Omala S3 GP Omala S4 GX
Omala S4 Wheel
Omala S3 GP Omala S4 GX
Omala S4 Wheel
Shell Lubricants 34
Fuel Economy Transmission Fluids Trends
Load Capacity
Oxidation Resistance
Shear Stability
Viscosity
Friction Coefficient
Heat Dissipation Viscosity Index
Shell Lubricants 35
Shell Spirax Portfolio for Mining FZG Low Speed Wear Test
<35
10
0 10 20 30 40 50
CAT FD-1
S4 CX 50
S5 CFD M 50
Wear [mg]
Spirax S5 CFD M 50/60
36
1 2 3 CHALLENGE SOLUTION OUTCOME
VALUE 4
Albian Sands Energy in Fort McMurray – Canada operates 75 haul trucks Caterpillar 797F.
In 2008, Albian introduced a new fleet of haul trucks and started to experience failures in less than 5000 hrs of operation whereas the expected life was of 20.000 hrs.
Shell, through Shell LubeExpert, made a detailed analysis of the application and proposed the use of a high-performance lubricant for final drives (Shell Spirax S5 CFD M 50).
Together with the change of lubricant, a systematic monitoring of the final drives, a process of contamination control and training of all staff involved was implemented. All these actions delivered a life extension of the lubricant and increased the life of the final drives.
•Savings of over USD 160,000.00/year with productivity increasing and life extension of the lubricant •Life extension of the lubricant from 2000 hours to 4000 hours •Increased the life of the final drives from 5,000 hours to 20,000 hours (expressive values not accounted in this case) •Increased the life and reliability of the final drives
The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices.
Success Case 01 – Albian Sands Energy Shell Spirax S5 CFD M – Final Drives of CAT 797F