Lepelletier gear mechanism
In 1992, Lepelletier proposed three degrees of freedom epicyclic gear mechanisms.[1] These are now called Lepelletier gear mechanisms.[2] The Lepelletier gearbox is constructed by connecting a planetary gear to a Ravigneaux gear.[3]
History
The transmission was the first of its kind to offer additional gear ratios by combining serial and parallel power flow without increasing the complexity of the design.
Due to these advantages, this gearset concept became widely used in automatic vehicle transmissions. ZF was the first to start series production in 2000. Aisin/Toyota, Ford, and GM followed in 2005. For the first time, the construction costs could be reduced compared to the respective predecessor models.
Gearset concept: combined parallel and serial power flow for more gears and improved cost-effectiveness
Main objectives
The main objective in replacing the predecessor model was to improve vehicle fuel economy with extra speeds and a wider gear span to allow the engine speed level to be lowered (downspeeding). The layout brings the ability to shift in a non-sequential manner – going from gear 6 to gear 2 in extreme situations simply by changing one shift element (actuating clutch E and releasing brake A).
Extent
In order to increase the number of ratios, all major manufacturers has abandoned the conventional design method of limiting themselves to pure in-line epicyclic gearing and extended it to a combination with parallel epicyclic gearing. The 6HP from ZF is the first transmission designed according to this new paradigm. After gaining additional gear ratios only with additional components, this time the number of components has to decrease while the number of ratios still increase. The progress is reflected in a much better ratio of the number of gears to the number of components used compared to existing layouts.
| With Assessment |
Output: Gear Ratios |
Innovation Elasticity[b] Δ Output : Δ Input |
Input: Main Components | |||
|---|---|---|---|---|---|---|
| Total | Gearsets | Brakes | Clutches | |||
| 6HP Ref. Object |
Topic[b] | |||||
| Δ Number | ||||||
| Relative Δ | Δ Output |
· |
Δ Input |
|||
| 6HP 5HP 24/30[c] |
6[d] 5[d] |
Progress[b] | 8 9 |
3[e] 3 |
2 3 |
3 3 |
| Δ Number | 1 | -1 | 0 | -1 | 0 | |
| Relative Δ | 0.200 |
−1.800[b] · |
−0.111 |
0.000 |
−0.333 |
0.000 |
| 6HP 5HP 18/19[c] |
6[d] 5[d] |
Progress[b] | 8 10 |
3[e] 3[e] |
2 3 |
3 4 |
| Δ Number | 1 | -2 | 0 | -1 | -1 | |
| Relative Δ | 0.200 |
−1.000[b] · |
−0.200 |
0.000 |
−0.333 |
−0.250 |
| 6HP 3-Speed[f] |
6[d] 3[d] |
Market Position[b] | 8 7 |
3[e] 2 |
2 3 |
3 2 |
| Δ Number | 3 | 1 | 1 | -1 | 1 | |
| Relative Δ | 1.000 |
7.000[b] · |
0.143 |
0.500 |
−0.333 |
0.500 |
| ||||||
No use of 5th gear from the original concept
The Lepelletier gearset concept actually provides 7 forward gears. However, the 5th gear, which is configured as a direct gear (ratio 1.00) in this configuration, requires a releaseable brake for S1 (sun gear of the first gearset, which is the simple one) and thus a 6th shifting element without any corresponding benefit: with ratios of approximately 1.15 and 0.85, the 4th and 6th gears are so close together that the 5th gear can easily be dispensed with. This means that all manufacturers can manage with 5 shifting elements and all transmissions built have 6 gear ratios instead of the possible 7.
Gearset concept: specifications
Illustration
In the illustrations, the Ravigneaux gearset is shown vertically mirrored, contrary to actual practice, for the sake of clarity.
-
Reverse gear
-
Neutral
-
1st gear
-
2nd gear
-
3rd gear
-
4th gear
-
5th gear: not used in actual existing gearboxes
-
6th gear: 5th gear in actual existing gearboxes
-
7th gear: 6th gear in actual existing gearboxes
Quality and technical specifications
The ratios of the 6 gears are nicely evenly distributed in all versions. Exceptions are the large step from 1st to 2nd gear and the almost geometric steps from 3rd to 4th to 5th gear. They cannot be eliminated without affecting all other gears. As the large step is shifted due to the large span to a lower speed range than with conventional gearboxes, it is less significant. As the gear steps are smaller overall due to the additional gear(s), the geometric gear steps are still smaller than the corresponding gear steps of conventional gearboxes. Overall, therefore, the weaknesses are not overly significant. As the selected gearset concept saves up to 2 components compared to 5-speed transmissions, the advantages clearly outweigh the disadvantages.
In combination with a torque converter lock-up clutch, the gearset largely closes the gap between vehicles with automatic and manual transmissions in terms of fuel efficiency.
| In-Depth Analysis[c] With Assessment And Torque Ratio[d] And Efficiency Calculation[e] |
Planetary Gearset: Teeth[f] Lepelletier Gear Mechanism |
Count | Nomi- nal[g] Effec- tive[h] |
Cen- ter[i] | |||
|---|---|---|---|---|---|---|---|
| Simple | Ravigneaux | Avg.[j] | |||||
| Make[k] Model |
Version First Delivery |
S1[l] R1[m] |
S2[n] R2[o] |
S3[p] R3[q] |
Brakes Clutches |
Ratio Span |
Gear Step[r] |
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
[c] | [c] | [c] | [c] | [c] | [c] | [c] |
| Step[r] | [s] | [t] | |||||
| Δ Step[u][v] | |||||||
| Shaft Speed |
|||||||
| Δ Shaft Speed[w] |
|||||||
| Torque Ratio[d] |
[d] | [d] | [d] | [d] | [d] | [d] | [d] |
| Efficiency [e] |
[e] | [e] | [e] | [e] | [e] | [e] | [e] |
| 2000: first manufacturer to use the Lepelletier gearset mechanism: ZF 6HP 1st generation | |||||||
| ZF 6HP 26[x] ZF 6HP 19[x] ZF 6HP 32[x] |
600 N⋅m (443 lb⋅ft) 400 N⋅m (295 lb⋅ft)[y] 750 N⋅m (553 lb⋅ft)[4] 2000 (all) |
37 71 |
31 38 |
38 85 |
2 3 |
6.0354 4.9236 [h][s] |
1.6977 |
| 1.4327[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.4025[s][h] |
4.1708 |
2.3397[t] |
1.5211 |
1.1428 [v][w] |
0.8672 |
0.6911 |
| Step | 0.8158[s] | 1.0000 | 1.7826[t] | 1.5382 | 1.3311 | 1.3178 | 1.2549 |
| Δ Step[u] | 1.1589 | 1.1559 | 1.0101[v] | 1.0502 | |||
| Speed | -1.2258 | 1.0000 | 1.7826 | 2.7419 | 3.6497 | 4.8096 | 6.0354 |
| Δ Speed | 1.2258 | 1.0000 | 0.7826 | 0.9593 | 0.9078[w] | 1.1599 | 1.2258 |
| Torque Ratio[d] |
–3.3116 –3.2665 |
4.0186 3.9436 |
2.2837 2.2559 |
1.5107 1.5055 |
1.1359 1.1325 |
0.8633 0.8613 |
0.6867 0.6845 |
| Efficiency [e] |
0.9733 0.9600 |
0.9635 0.9455 |
0.9761 0.9642 |
0.9931 0.9897 |
0.9939 0.9910 |
0.9955 0.9932 |
0.9937 0.9905 |
| 2007: ZF 6HP 2nd generation | |||||||
| ZF 6HP 28[x] ZF 6HP 21[x] ZF 6HP 34[x] |
600 N⋅m (443 lb⋅ft) 450 N⋅m (332 lb⋅ft)[z] 750 N⋅m (553 lb⋅ft)[aa] 2007 (all) |
37 71 |
31 38 |
38 85 |
2 3 |
6.0354 4.9236 [h][s] |
1.6977 |
| 1.4327[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.4025[s][h] | 4.1708 | 2.3397[t] | 1.5211 | 1.1428 [v][w] |
0.8672 | 0.6911 |
| Other manufacturer using the Lepelletier gear mechanism | |||||||
| Aisin AWTF-80 SC |
450 N⋅m (332 lb⋅ft)[7] 2005 |
50 90 |
36 44 |
44 96 |
2 3 |
6.0494 4.9495 [h][s] |
1.6865 |
| 1.4333[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.3939[s][h] |
4.1481 |
2.3704[t] |
1.5556 |
1.1546[v] |
0.8593 |
0.6857[w] |
| Step | 0.8182[s] | 1.0000 | 1.7500[t] | 1.5238 | 1.3472 | 1.3436 | 1.2532 |
| Δ Step[u] | 1.1484 | 1.1311 | 1.0027[v] | 1.0722 | |||
| Speed | -1.2222 | 1.0000 | 1.7500 | 2.6667 | 3.5926 | 4.8272 | 6.0494 |
| Δ Speed | 1.2222 | 1.0000 | 0.7500 | 0.9167 | 0.9259 | 1.2346 | 1.2222[w] |
| Torque Ratio[d] |
–3.3023 –3.2568 |
3.9956 3.9204 |
2.3127 2.2841 |
1.5444 1.5389 |
1.1471 1.1434 |
0.8553 0.8532 |
0.6813 0.6791 |
| Efficiency [e] |
0.9730 0.9596 |
0.9632 0.9451 |
0.9757 0.9636 |
0.9929 0.9893 |
0.9935 0.9903 |
0.9953 0.9928 |
0.9936 0.9904 |
| Ford 6R 60 6R 80 |
600 N⋅m (443 lb⋅ft) 800 N⋅m (590 lb⋅ft) 2005 (all) |
37 71 |
31 38 |
38 85 |
2 3 |
6.0354 4.9236 [h][s] |
1.6977 |
| 1.4327[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.4025[s][h] | 4.1708 | 2.3397[t] | 1.5211 | 1.1428 [v][w] |
0.8672 | 0.6911 |
| Ford 6R 140 |
1,400 N⋅m (1,033 lb⋅ft) 2005 |
49 95 |
37 47 |
47 97 |
2 3 |
5.8993 4.6441 [h][s] |
1.6361 |
| 1.4261[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.1283[s][h] |
3.9738 |
2.3181 [t][v] |
1.5158 |
1.1492 [v][w] |
0.8585 |
0.6736 |
| Step | 0.7872[s] | 1.0000 | 1.7143[t] | 1.5293 | 1.3190 | 1.3389 | 1.2744 |
| Δ Step[u] | 1.1210[v] | 1.1594 | 0.9854[v] | 1.0504 | |||
| Speed | -1.2703 | 1.0000 | 1.7143 | 2.6216 | 3.4580 | 4.6290 | 5.8993 |
| Δ Speed | 1.2703 | 1.0000 | 0.7143 | 0.9073 | 0.8364[w] | 1.1710 | 1.2703 |
| Torque Ratio[d] |
–3.0449 –3.0035 |
3.8290 3.7576 |
2.2615 2.2333 |
1.5055 1.5003 |
1.1419 1.1383 |
0.8543 0.8522 |
0.6692 0.6669 |
| Efficiency [e] |
0.9733 0.9601 |
0.9635 0.9456 |
0.9756 0.9635 |
0.9932 0.9898 |
0.9937 0.9906 |
0.9952 0.9927 |
0.9934 0.9900 |
| GM 6L 45 6L 50 |
500 N⋅m (369 lb⋅ft) 2006 |
49 89 |
37 47 |
47 97 |
2 3 |
6.0346 4.7507 [h][s] |
1.6548 |
| 1.4326[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.2001[s][h] |
4.0650 |
2.3712 [t][v] |
1.5506 |
1.1567 [v][w] |
0.8532 |
0.6736 |
| Step | 0.7872[s] | 1.0000 | 1.7143[t] | 1.5293 | 1.3406 | 1.3557 | 1.2662 |
| Δ Step[u] | 1.1210[v] | 1.1408 | 0.9889[v] | 1.0703 | |||
| Speed | -1.2703 | 1.0000 | 1.7143 | 2.6216 | 3.5144 | 4.7643 | 6.0346 |
| Δ Speed | 1.2703 | 1.0000 | 0.7143 | 0.9073 | 0.8928[w] | 1.2499 | 1.2703 |
| Torque Ratio[d] |
–3.1138 –3.0710 |
3.9156 3.8421 |
2.3127 2.2826 |
1.5396 1.5340 |
1.1490 1.1453 |
0.8490 0.8468 |
0.6692 0.6692 |
| Efficiency [e] |
0.9730 0.9597 |
0.9633 0.9452 |
0.9753 0.9630 |
0.9929 0.9893 |
0.9934 0.9902 |
0.9951 0.9925 |
0.9934 0.9900 |
| GM 6L 80 6L 90 |
800 N⋅m (590 lb⋅ft) 2005 |
50 94 |
35 46 |
46 92 |
2 3 |
6.0401 4.5957 [h][s] |
1.6384 |
| 1.4329[r] | |||||||
| Gear | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Gear Ratio[c] |
−3.0638[s][h] |
4.0267 |
2.3635 [t][v] |
1.5319 |
1.1522 [v][w] |
0.8521 |
0.6667 |
| Step | 0.7609[s] | 1.0000 | 1.7037[t] | 1.5429 | 1.3296 | 1.3522 | 1.2781 |
| Δ Step[u] | 1.1043[v] | 1.1604 | 0.9832[v] | 1.0580 | |||
| Speed | -1.3143 | 1.0000 | 1.7037 | 2.6286 | 3.4948 | 4.7258 | 6.0401 |
| Δ Speed | 1.3143 | 1.0000 | 0.7037 | 0.9249 | 0.8662[w] | 1.2310 | 1.3143 |
| Torque Ratio[d] |
–2.9817 –2.9410 |
3.8794 3.8068 |
2.3048 2.2756 |
1.5213 1.5160 |
1.1448 1.1412 |
0.8478 0.8456 |
0.6622 0.6599 |
| Efficiency [e] |
0.9732 0.9599 |
0.9634 0.9454 |
0.9751 0.9628 |
0.9931 0.9896 |
0.9936 0.9904 |
0.9950 0.9924 |
0.9932 0.9898 |
| Actuated Shift Elements[ab] | |||||||
| Brake A[ac] | ❶ | ❶ | ❶ | ❶ | |||
| Brake B[ad] | ❶ | ❶ | ❶ | ||||
| Clutch C[ae] | ❶ | ❶ | |||||
| Clutch D[af] | ❶ | ❶ | |||||
| Clutch E[ag] | ❶ | ❶ | ❶ | ||||
| Geometric Ratios: Speed Conversion | |||||||
| Gear Ratio[c] R & 3 & 6 Ordinary[ah] Elementary Noted[ai] |
|||||||
| Gear Ratio[c] 1 & 2 Ordinary[ah] Elementary Noted[ai] |
|||||||
| Gear Ratio[c] 4 & 5 Ordinary[ah] Elementary Noted[ai] |
|||||||
| Kinetic Ratios: Torque Conversion | |||||||
| Torque Ratio[d] R & 3 & 6 |
|||||||
| Torque Ratio[d] 1 & 2 |
|||||||
| Torque Ratio[d] 4 & 5 |
|||||||
| |||||||
Limitations
The limitations of the Lepelletier gearset lie in the number of gear ratios provided and in the efficiency issues that Ravigneaux gearsets always contend with. Therefore, starting in 2008 with the ZF 8HP, the Lepelletier gearset was replaced by gearset concepts with even more gears and largely dispensing with the use of Ravigneaux gearsets. This was followed later by the GM 8L, Aisin-Toyota 8-speed transmission, and the Ford-GM 10-speed transmission, for example.
References
- ^ P. A. G. Lepelletier, Multispeed automatic transmission for automobile vehicles, U. S. patent no. 5106352 (1992)
- ^ Essam L. Esmail (2016-01-13). "Configuration design of ten-speed automatic transmissions with twelve-link three-DOF Lepelletier gear mechanism". Journal of Mechanical Science and Technology. 30: 211–220. doi:10.1007/s12206-015-1225-4.
- ^ "Model seven-speed Lepelletier transmission based on planetary gear and Ravigneaux gear - MATLAB - MathWorks Australia". Au.mathworks.com. Retrieved 2016-03-08.
- ^ "ZF 6HP26 Transmission" (PDF). Retrieved 2017-02-02.
- ^ "Review: Ford FG X Falcon (2014–16)". AustralianCar.Reviews. Archived from the original on 18 October 2015. Retrieved 2 August 2016.
- ^ "ZF 6HP34" (PDF). ZF Friedrichshafen AG. Retrieved 18 September 2009.
- ^ Kasuya, Satoru; Taniguchi, Takao; Tsukamoto, Kazumasa; Hayabuchi, Masahiro; Nishida, Masaaki; Suzuki, Akitomo; Niki, Hiroshi (2005). "AISIN AW New High Torque Capacity Six-Speed Automatic Transmission for FWD vehicles". SAE Transactions. 114: 1193–1201. ISSN 0096-736X. JSTOR 44725152. Archived from the original on 2020-07-20. Retrieved 2020-07-09.