POWERTRAIN
ALEXANDER
CPOWER
TO THE PEOPLE
A TREND-SETTING PREMIUM TRANSMISSION TECHNOLOGY FOR OFF-
HIGHWAY MACHINERY IS STARTING A QUIET REVOLUTION WHEN IT
COMES TO DRIVELINE CHOICE. WHAT CAN IT OFFER YOU?
ABOVE: CVT-driven ZF believes it has set a milestone
wheeled loader at a
ZF test drive in transmission technology for off-
highway construction machinery with its
new cPower. This continuously variable
transmission reduces fuel consumption
by more than 25% while simultaneously
increasing productivity by more than 20%.
This fully powersplit, continuously
variable technology benefits from the
company’s long-term experience and offers
some notable consumer benefits. Due to
rising fuel prices and a growing awareness
ALEXAN
ALEXANDER
DER EISNER
EISNE
EISNER
SNER
of CO2 emissions, the market increasingly
demands more efficient drive systems. A
trend toward lower engine speeds and the
demand for engine stabilization through a
constant speed concept are some future
challenges in the construction machinery
market, while new emission guidelines
(US-EPA and EU directives) also create
technological restrictions and constraints
for diesel engines. But while searching
for the ideal transmission concept, ZF
realized that other technologies, combining
iVT International Off-Highway 2016 37
POWERTRAIN
hydrostatic and powersplit concepts, had
some considerable disadvantages including
losses in efficiency and performance.
Characteristics of torque converter
and hydrostatic transmissions
Over the years, hydrodynamic powershift
transmissions for construction machinery
have been continuously improved in the
attempt to increase overall efficiency.
With the introduction of more gears
and a lock-up clutch, the high efficiency of
a mechanical transmission can be expected
as early as the second gear. Torque converter
transmissions also have excellent torque
control behavior in low-speed, high-torque
operations such as bucket filling. However,
it is in this type of operation where the
converter shows its weakness in efficiency
– this weakness is compounded when some
applications require the spending of a high
percentage of time at these high-torque and
low-speed operations.
If rim pull is not controlled while in the
pile, the tires of a wheeled loader can slip,
damaging the ground in front of the pile,
and reducing the loading performance of
the vehicle in the ensuing operations.
As an alternative to torque converter
transmissions, hydrostatic transmissions
38 iVT International Off-Highway 2016
are increasing in popularity for small and
mid-size wheeled loaders. It is at these
lower driving speeds where hydrostatic
transmissions demonstrate their efficiency
advantages. A hydrostatic transmission also
offers an infinitely high gear ratio.
However, the mechanical hydraulic
efficiency can become a disadvantage in
hydrostatic transmissions when traveling
at higher speeds. The weaknesses of a
ABOVE: Wheeled loader driveline built around
ZF cPower
LEFT: ZF’s cPower – fully powersplit CVT in all
driving ranges
ABOVE RIGHT: Fuel efficiency can be enhanced
by up to 25% with ZF cPower
hydrostatic transmission can be seen in
applications where a wheeled loader must
travel longer distances at higher speeds.
The ever-growing importance of lower fuel
consumption has exposed weaknesses in
both types of transmission concepts.
Fast, smooth reversing performance is
yet another requirement in the construction
machinery market; a function that greatly
increases productivity in many construction
machines. Yet another prerequisite for a
construction machinery transmission is
durability. The level of robustness for
which ZF transmissions are known can
only be reached if the chosen concept
allows for simple mechanical structures,
easy manufacturability of all parts, low
internal speeds, and good serviceability.
To prevent any major changes being
required to existing customer vehicles, a
new transmission concept must also fit
within the existing installation envelope.
Achieving all of these design goals, while
maintaining the robustness of today’s
current transmissions, is a great challenge.
The powersplit hydrostatic-mechanical
cPower transmissions have therefore been
designed to combine the advantages of
both transmission concepts throughout
the entire vehicle speed range. This leads to

refuel
+
Fuel consumption
0 The transmission series also deploys
optimum performance in terms of fuel
economy in all operating conditions.
To cover a huge variety of off-highway
applications that require high loads at low
speed, in combination with high dynamics,
ZF is developing a whole family of
transmissions. These criteria are optimally
met by its CVT transmission technology.
refuel
Fuel savings
up to 25 %
Standard*
with ZF cPower
Distance / Time
The percentage of hydrostatic power is kept
low, resulting in an optimal degree of
efficiency, while the mechanical part of the
design covers most of the output. Even in
very short loading cycles, CVT technology
is fuel thrifty.
The ZF cPower offers full powersplit
ability and perfectly combines hydrostatic
POWERTRAIN
and mechanical advantages. The high-tech
CVT is completely assembly-compatible
with ZF Ergopower transmissions. The
application of an elaborate hydraulic
transmission-control unit and transmission-
integrated onboard electronic unit helps to
complete the driving functions.
In terms of forestry equipment, ZF is
already supplying the cPower transmission
design for skidder applications. In
addition, this transmission system is also
the ideal driveline solution for forwarder
applications as it enables maximum
traction, excellent driving comfort and
easy handling. The ideal application of
these units is concerned with reference to
sensitivity, driving comfort and achieving
an aligned power management.
well-known and well-proven construction
kit modules and greatly benefits from ZF’s
competence in transmission and vehicle
system engineering. iVT
Alexander Eisner is head of product communication at
ZF, where he is responsible for construction, agricultural
and material handling machinery marketing operations
FREE READER INQUIRY SERVICE
To learn more about this advertiser, visit
www.ukipme.com/info/ivo Ref: 509
Hall 5b Booth L038