Updated Design Delivers Substantial Output Gains and Increased Efficiency for Spicer® TE-15HX Hybrid Transmission

MUNICH, GERMANY.  Apr. 19, 2010 – At Bauma 2010 today, Dana Holding Corporation revealed the results of simulations that show a substantial increase in the output of the concept demonstrator Spicer® TE-15HX electric parallel hybrid transmission specifically designed for off-highway vehicles.

Since Dana first announced the development of the Spicer TE-15HX transmission at INTERMAT 2009, testing has advanced on an optimized configuration featuring a high-output, permanent magnet synchronous motor (PMSM) that produces up to 47 kW (63 horsepower) at peak—a three-fold increase in output over earlier configurations.  The new patent-pending design will improve the performance of the Spicer TE-15HX transmission when the PMSM is operational and allow the use of stored electric power during more of the duty cycle. 

Also, by positioning the electric device at the rear of the transmission to interact with drum speed, Dana can use a smaller unit that operates at a higher RPM and provides better performance, lower system costs, and a better fit within the increasingly tight design envelopes of today’s off-highway vehicles.  All told, engineers predict that the Spicer TE-15HX transmission will provide fuel savings of up to 20 percent over conventional transmission designs, depending on duty cycle.

“Throughout the development of our hybrid transmission, we have worked to increase fuel efficiency while supplying the high productivity users demand from their off-highway equipment,” said Pietro Franzosi, vice president of sales and marketing for the Dana Off-Highway Products Group.  “Our latest design will allow us to offer these benefits at a system cost with a short payback period.”

A concept transmission in the evaluation phase, the Spicer TE-15HX is an electric parallel hybrid featuring a dual power path transmission control system.  Targeted for use in shuttling applications such as construction and material handling vehicles, this system continuously monitors operating conditions and selects the proper combination of diesel and electric power to optimize productivity while reducing fuel consumption, emissions, noise, and engine idling. 

Dana has adopted a neutral stance toward energy-storage chemistry in the development of the Spicer TE-15HX transmission, allowing it to integrate with many different energy-storage solutions.  At Bauma 2010, Dana will present a system configured with super capacitors for highly cyclic applications such as front-end loaders and forklift trucks, while other applications that permit longer duration charging under a light load can be outfitted to work with lead-acid storage and other conventional battery technologies.

Whenever possible, the TE-15HX control system disengages the diesel engine and supplies power from the energy storage system for inching and other vehicle operations that require low energy consumption.  During idling, the control system uses stored power for lights, climate control systems, and other electrical accessories.

To carry light loads, the diesel engine works alone to power the vehicle while the electric device serves as a generator to efficiently charge the solution chosen for energy storage.  Vehicle braking is also an important source of regenerative energy for recharging the energy storage system.

When additional tractive effort is required, the controller directs the electric device to draw power from the energy storage system and function as a motor for added torque boost and faster take-off.

The addition of torque converter lockup to the transmission will allow the system to use stored electrical energy to support load lifting, while appropriate system changes will enable energy recuperation during load lowering.

The Spicer TE-15HX transmission capitalizes on the flexible modular design of the popular Spicer TE-15 electronically modulated transmission to coordinate the operation of the diesel engine and electric device. 

Dana is evaluating three- and four-speed versions of the TE-15HX transmission in long- and short-drop configurations—all based on the Spicer TE-15 transmission rated at 120 kW to 190 kW (160 to 255 horsepower).

About the Dana Off-Highway Products Group
The Dana Off-Highway Products Group includes research and development and manufacturing operations in Belgium, Brazil, China, Hungary, India, Italy, Mexico, the United Kingdom, and the United States.  It designs, manufactures, assembles, and markets Spicer axles and transaxles, driveshafts and end-fittings, transmissions, torque converters, electronic controls, and brakes. 

The Dana Off-Highway Products Group serves more than 1,000 vehicle assembly and manufacturing facilities in 30 countries.  Dana also supports off-highway customers in more than 100 countries by supplying genuine Spicer service parts, operating two global service parts distribution centers, and certifying 66 Authorized Spicer Service Centers.  Construction, agriculture, forestry, underground mining, material handling, outdoor power, leisure/utility vehicles, and industrial equipment are just some of the markets that demand the quality found in Spicer products and genuine service parts.  For more information, visit www.dana.com/offhighway.

About Dana Holding Corporation
Dana is a world leader in the supply of axles; driveshafts; sealing and thermal-management products; and genuine service parts. The company's customer base includes virtually every major vehicle manufacturer in the global automotive, commercial vehicle, and off-highway markets. Based in Maumee, Ohio, the company employs approximately 21,000 people in 26 countries and reported 2009 sales of $5.2 billion. For more information, please visit: www.dana.com.

DANA CONTACT:
Jeff Cole
Director, Marketing Communication
Dana Holding Corporation
P: +1.419.887.3535
E: jeff.cole@dana.com