ZF cPOWER – continuously variable transmissions for industrial lift trucks

• Fuel savings up to 25%
• Technological leap in construction machinery by fully powersplit CVT from ZF

ZF will be presenting a continuously variable transmission for construction machinery and material handling vehicles – ZF cPOWER – at the Cemat from the 19th – 23st Mai 2014. “As technological leader, ZF is setting the trends”, states Hermann Beck, Head of Off-Highway Systems, ZF Friedrichshafen AG. cPOWER is the beginning of a new technological era in construction machinery. With this transmission range we will ensure and extend our market position for construction machinery.

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With the cPOWER ZF enhanced the fully hydrostatic-mechanic powersplit continuously variable technology used in agricultural machinery. It was adapted especially for applications where heavy and bulky loads must be moved with large vehicles. The cPower makes it possible to handle loads sensitively and with fine adjustment.

The benefits of the ERGOPOWER, very much appreciated in many business sectors, were combined with the new technology. In addition to the use in lead applications such as forestry and wheel loaders, the transmission also increases productivity with the fuel-saving continuously variable technology for material handling.

Because of rising fuel prices and a growing awareness of CO2-emissions, the market demands for more efficient drive systems. New emission guidelines (USA-EPA and EU directives) implicate technological restrictions and constraints with diesel engines that can hardly be achieved today or in the future.

High loads at low speeds in combination with high dynamic are the outstanding requirements for construction machinery. These criteria are met optimally by the new ZF CVT transmission technology with a degree of efficiency that was inconceivable up to now. While searching for the ideal transmission concept it became clear that other technologies and mixed hydrostatic and powersplit concepts had considerable disadvantages and were only compromises with constraints in performance and efficiency.

The rising demands for fuel reduction and productivity increase require new technologies in construction machines, such as the CVT.

A trend towards lower engine speeds and the demand for engine stabilization by a constant speed concept are the future challenges in the Diesel-engine-powered lift truck market. The continuously variable cPOWER from ZF meets both requirements. In wheel loader applications, hydrostatic-powersplit transmissions ensure significant consumption benefits compared to hydrodynamic transmissions and purely hydrostatic concepts. The continuously variable transmissions clearly demonstrate their benefits in all ranges of the typical wheel loader operating cycle, i.e. during bucket-filling, transporting and loading.

In this process, the percentage of hydrostatic power is kept low whereby an optimal degree of efficiency can be achieved. Already in the start-up process the bigger part of output comes from the mechanical part of the transmission. Even in very short loading cycles, the utility of the CVT technology becomes noticeable in reduced fuel consumption.

The application of an elaborate hydraulic transmission-control unit and transmission-integrated on-board electronic unit optimally completes driving functions. The application of these units is done with reference to sensitivity and driving comfort and realizes an aligned power management.

The cPower transmission series deploys well-known and -proven construction kit modules and benefits from ZF competence in transmission and vehicle system engineering.

Main features of the new ZF cPOWER:

•  Continuously variable drive over the whole range forward and reverse
•  Hydrostatic-mechanical powersplitting in all driving ranges, including the frequently used range up to 10 km/h
•  Reduction of diesel motor speed independent of driving speed
•  Up to 25 % less consumption
•  Up to 20 % higher efficiency
•  Installation-compatible with ZF-ERGOPOWER