With the implementation of BS6 standards, India's commercial vehicle sector is aligning with global benchmarks, creating a level playing field for OEMs. Emphasising driver comfort, fuel efficiency, and reduced Total Cost of Ownership (TCO), OEMs are exploring advanced technologies like Automated Manual Transmission (AMT), Air Disc Brakes (ADB), Electronic Stability Control (ESC), and connectivity solutions. ZF responds to this shift by introducing 'EcoTronic Mid,' India's first electronically controlled intelligent nine-speed AMT tailored for commercial vehicles. Notably, it secures ISO 26262 certification, a safety standard for electrical and electronic systems in road vehicles.
This lightweight transmission supports low-speed maneuvering, hill assist, and off-road driving, featuring intelligent shift logic for improved clutch life. Operating in both manual and automatic modes, EcoTronic Mid provides a 9-gear ratio for a broad commercial vehicle range, including goods transportation, mining (tippers), long-haul, and fuel carriers. Its integrated Power Take Off (PTO) mechanism excels in demanding tipper truck applications.
Noteworthy features include throttle, acceleration, and gear-based shift strategies that enhance fuel efficiency and drivability. The transmission control unit, equipped with an inclination sensor, accurately measures gradients to optimise gear selection, effectively doubling clutch life. P Kaniappan, Managing Director of ZF Commercial Vehicle Control Systems India, states, 'Setting the pace for intelligent transmission systems in India’s CV industry, ZF's EcoTronic Mid advanced solution will support vehicle efficiency in various applications, from long-distance journeys to construction sites or municipal operations.'
Driving Forces Behind EcoTronic Mid's Introduction
According to V Ramanthan, Head of OE Business at ZF Group's Commercial Vehicle Solutions Division, the development of EcoTronic Mid for the Indian market is anchored in three pivotal factors: safety, reliability, and efficiency. Ramanthan emphasises that this transmission can play a significant role in mitigating the shortage of skilled drivers by automating the system, thereby desensitising the driver's skill requirement.
One of the notable advantages of EcoTronic Mid is the significant extension of clutch life by 2x, coupled with an improvement of up to 5% in fuel efficiency. This not only enhances the reliability of the system but also ensures hassle-free driving on challenging terrains, preventing rollbacks, and offering a rock-free mode. These features specifically cater to long-haul applications, enhancing overall uptime and gearbox longevity. Additionally, the transmission seamlessly integrates with electronically controlled Power Take Off (PTO) operations.
Versatile Driving Modes
EcoTronic Mid is adaptable to diverse customer needs, available in both direct drive and over-drive options. It offers various driving modes, including Eco, Power, and Auto/Manual modes, providing flexibility and customisation.
The transmission boasts industry-first functions such as shift-free low-speed manoeuvring, hill assist, rock-free, crawler, and off-road modes, making it suitable for a wide range of applications. This results in a smooth driving experience, eliminating the need for a clutch pedal and enhancing driver productivity for quicker turnarounds.
Featuring a best-in-class fully automated system with a deep crawler ratio for improved gradeability and performance, EcoTronic Mid incorporates a sensitive starting mechanism. Continuously monitoring and automatically adjusting torque and engine speed in response to changes in loads and gradients, it ensures smooth starts on challenging inclines.
Ramanathan assures that the power-to-weight ratio remains unaffected. However, the Intelligent Algorithm system autonomously determines the appropriate gearshift, significantly enhancing the overall drivability of the vehicle.
Understanding EcoTronic Mid's Operation
EcoTronic Mid, ZF's innovative transmission system, operates on advanced principles aimed at enhancing both performance and longevity.
Intelligent Clutch Heat Mapping Algorithm: The system incorporates a smart clutch heat mapping algorithm that minimises unnecessary wear on the clutch mechanism. This not only extends the life of the clutch but also ensures the durability of the entire driveline. As a result, customers can expect trouble-free operation while meeting stringent functional safety standards.
Fully Automated System with Crawler Ratio: Offering a best-in-class fully automated system, EcoTronic Mid includes a deep crawler ratio for better gradeability and performance. The sensitive starting mechanism continuously monitors changes in loads and gradients, automatically adjusting torque and engine speed for smoother starts on challenging inclines.
Integrated Power Take Off (PTO) Mechanism:The transmission seamlessly integrates with ZF's PTO mechanism, particularly beneficial for demanding tipper truck applications. This integration contributes to easy operation, a doubled clutch life, and extended gearbox life, minimising vehicle downtime.
Versatile Applications: The company strategically focuses on various segments such as mining, off-road, e-commerce, and long-haul transportation, where driving conditions are demanding. EcoTronic Mid facilitates smooth and seamless operations, allowing drivers to manoeuvre vehicles effortlessly and concentrate on their tasks. The system is designed to enhance driver productivity and efficiency, especially for less-experienced drivers compared to manual transmissions.
Limitations Of Driving Modes
While EcoTronic Mid comes with auto and manual modes, offering a range of driving functions, including low-speed manoeuvring, hill assist, and off-road modes, there are limitations. For instance, the auto mode may face challenges in gear toggling on changing gradients, but an inclination sensor in the ECU addresses this by predicting gradients accurately. The manual mode allows dynamic toggling between auto and manual without stopping the vehicle, improving fuel efficiency, says Ramanathan.
Unlike conventional accelerator pedal-based shifting, EcoTronic Mid employs a special shift algorithm that dynamically considers mass, slope, curve, and drive resistance to calculate shift RPMs for the selected gear. This optimised approach improves overall drivability and efficiency.
The intelligent clutch heat mapping algorithm simulates real-time driving patterns, optimising clutch usage and resulting in extended clutch life for end-users.
Localisation & Legacy
Assembled and supplied by ZF's Pune facility, this indigenous solution is currently available as original equipment fitment. Compatible with ZF's connectivity solutions, the system provides valuable vehicle insights to enhance fleet operational efficiency.
ZF's EcoTronic Mid carries forward a strong legacy, building on the pioneering efforts of WABCO, now part of ZF Group's Commercial Vehicle Solutions division. ZF's collaboration with WABCO in 1995 led to the introduction of the AS Tronic automated manual transmission, supporting the evolving requirements of CVs. The subsequent development of EcoTronic Mid showcases ZF's prowess in software-driven transmission engineering, delivering advanced features to support efficiency, comfort, and safety requirements.
Also Read:
With WABCO In, ZF Will Deliver Products To Customers At A Much Competitive Price
ZF Showcases AxTrax 2 LF Low-Floor Electric Axle For City Buses