Voith Retarder

for Mercedes-Benz Trucks

01.12.2011 – São Bernardo do Campo

1
Voith, one of Europe’s large family-owned
companies

• Founded in 1867
• 40 000 employees
• Locations in around 50 countries
worldwide
• Euro 5.2 billion in sales

Dec 2010 figures

2
Voith
group structure

PaperPaperVoith Siemens
VoithVoith Voith Hydro Voith Turbo Voith Industrial
Hydro Services

3
Voith Turbo
How we see ourselves
We are an independent enterprise within the Voith Group of Companies striving for
internal and external growth.
What we offer
We offer customers from all over the world technically challenging components,
systems and services.
Torque conversion
Speed conversion
Pump systems

Driving machine Voith Turbo Driven machine

• Torque Connect • In industry

• Speed Couple • On the roads
• Tractive power Transmit • On the rails
Control • On the water

4
Voith Turbo – Road Division
position in the organization

Voith GmbH

Voith Paper Voith Hydro Voith Turbo Voith Industrial

Services

Division Division Division Division

Industry Rail Road Marine

Product Group Product Group Product Group

Bus Drive Systems Drive Line Engine
Components

5
Voith Turbo – Road Division
Group Products
• Automatic transmission
• hybrid systems - parallel
Bus Drive Systems • hybrid systems - serie
Road Division

• axles

• Retarders
Drive Line • Dampers
• VIAB

• Turbochargers
• Turbo Compound
Engine Components
• Air Compressors
• Energy recover systems

6
Voith Turbo – operational structure SA
road

Division A Division B Division C

transmission retarder compressors

product product product
group A1 group A2 group A3

Product R&D
Market Service & Application
South America
Hub Hub Hub
company A company B company C

Brazil Chile Colombia

marketing marketing marketing
company A1 company A2 company A3

7
Voith Turbo – operational structure SA
road

Division A

OEM
transmission retarder compressors global
product product product
group A1 group A2 group A3

Product
Market
South America
OEM regional
Hub
company A

Brazil Chile Colombia

marketing marketing marketing
OEM dealers
company A1 company A2 company A3
local
Fleet Operators
8
Units Retarder
1994 – 2011 (million Euro)
Units*

70 000

60 000 58,200 57,400

50,700
50 000 44,100
40,200
40 000 35,600
30 000 26,800

20 000 13,700
10 000
0
94/95 … 04/05 05/06 06/07 07/08 08/09 09/10 10/11

*sales quantity without spare parts

9
Top Customer Retarder

Units 2010/2011
Total 57,400 Units Andere
3,500
1,500 5%
3%

7,200
12%
29,700
52%

15,500
27%

10
Why Retarder ?

11
Why Retarder ?

Because engine Requirements of today: The Solution:

powers have
Higher comp. pressure Higher braking
been adapted to
Higher loads power with the
today’s
Higher transport volume wear-free conti-
requirements
Higher mileage nuous brake that
but braking Higher speeds operates without
powers have not. Higher safety fading.

12
Continuos Braking Systems

Primary Secundary
before transmission after transmission

Pneumatic Hydrodinamic Magnetic Hydrodinamic

exhaust In the engine Eletromagnetic in Line
compression in the transmission Magnet-Permanent off line

Combinated

The continuos action brakes should

take 90 % of the total braking process
13
Why Retarder ?

Because today‘s
higher engine
powers allow 4
higher average Today
speeds and require > 500 HP
E = 1/2 • m • v2
higher braking powers > 70 t

E
which put too much
strain on the friction
brakes.
1
1960
177 HP
38 t 40 v 80

14
Why Retarder ?

Because double
the speed
means a 4
fourfold in-
crease in the 3 E = 1/2 • m • v2
kinetic energy
to be converted
E [%]
2
into heat.

40 2 = 1600 1
80 2 = 6400

v [km/h] 40 60 80

15
Why Retarder ?

Because with
increasing
temperature of 0,5
the brake linings,
the friction value

(Brake drum/-linings)
0,4

Friction coefficient µ
of the service
0,3
brake system
Wear factor
falls drastically
0,2
(fading!)
whereas wear rises 0,1
rapidly.
Temp. of the brake drum [°C]

16
Why Retarder ?
Brakes Retarder 80 km/h 10 km/h
73,8 m
hot no
drum: 284°C 247°C service brake pressure: 4,3 bar

no 68,1 m
cold
drum: 80°C 60°C service brake pressure: 4,3 bar -7,7 %

- 9,9 m -14,5 %
58,2 m
hot
drum: 290°C 231°C service brake pressure: 4,8 bar -15,6 m -21,1 %

cold 49,8 m active safety

drum: 109°C 85°C service brake pressure: 4,4 bar - 24 m -32,5 %

braking distances much shorter when foundation brakes are cold

17
Myths and Truths about Retarder

Typical customer question :

ABS X R
Shall I invest on ABS or retarder ?

The systems have completely different function !

ABS for brakes anti blocking

retarder for additional brake capacity

ABS and retarder should work together !

This “dilemma” is to be extinguished after 2014

when ABS will be obligatory

18
Myths and Truths about Retarder

Typical customer question :

R X
brakes linings replacement are not that
expensive !

The main aspect is not the cost of the repair

but the downtime of the vehicle and safety

retarder can increase more than 5 times the

brakes life !

This factor can be even higher with

disc brakes

19
Myths and Truths about Retarder

Typical customer question :

R X !
Shall I invest on engine brake or retarder ?

The systems are complementary

engine brake has better performance at low speed

retarder has better performance at high speed

The combination is additional value for the fleet operator !

20
Myths and Truths about Retarder

combinated

retarder

engine brake

21
Myths and Truths about Retarder

Typical customer question :

R X !
There are engine brake systems that
replaces the retarder function

Engine brakes are always dependent of

the driver`s skill and the transmission
gear ratios

High performance engine brakes

increases the air intake of the engine what
can generate troubles in off road application

22
Engine Brake performance analysis

Announced engine brake peformance is normally achieved

at maximum engine speed
!
[kW]
10% 8% 6%
500

400

4%
ENGINE BRAKE (2300rpm)
300
G5 G6 G7 G8 G9 G10 G11

G12
200

2%
100

30 40 50 60 70 80 90 [km/h]
Vehicle data: iHA = 3,44; tyres= 315/80R22,5; weight = 40.000 kg; retardation = 1%; 12 gears transmission

23
Engine Brake performance analysis

Announced engine brake peformance is normally achieved

at maximum engine speed
!
[kW]
10% 8% 6%
500

400

4%
ENGINE BRAKE (2300rpm)
300 G7 G11
G5 G6 G8 G9 G10
ENGINE BRAKE (1500rpm)
G12
200 ENGINE BRAKE (1000rpm)

2%
100

30 40 50 60 70 80 90 [km/h]
Vehicle data: iHA = 3,44; tyres= 315/80R22,5; weight = 40.000 kg; retardation = 1%; 12 gears transmission

24
VR 115 HV for Mercedes-Benz
ACTROS / AXOR

25
Positioning of Voith Retarder
in Mercedes-Benz trucks

Sales ACTROS
Manual Speed transmission:
Code BA1
G 210-16, i = 2,13
G 211-16, i = 2,13
G 231-16, i = 2,13
G 240-16, i = 1,68
VR 115 HV with three G 260-16, i = 1,68
AXOR
step-up gear ratios: Speed transmission:
i = 2,13 PowerShift:
i = 1,97 G 210-16, i = 2,13
G 211-16, i = 2,13 G 211-12, i = 1,97
i = 1,68 G 230-12, i = 2,13
G 221-9, i = 2,13
G 240-16 i = 1,68 G 241-16, i = 2,13
G 280-16, i = 1,68
PowerShift: G 281-12, i = 2,13
G211-12, i = 1,97 G 300-16, i = 1,68
G 330-12, i = 2,13 26
Mercedes-Benz Actros and Axor

Optional-Packages with VR 115 HV (Code BA1):

• P01 - Economy Pack Classic

for truck-tractor and rigids

• P02 - Economy Pack Top

for truck-tractor and rigids

• PR3 - Safety Pack Classic

for rigids

• P26 - Safety Pack Classic

for truck-tractor

27
Mercedes-Benz Actros only

Optional-Packages with VR 115 HV (Code BA1):

• PA4 - ADR Package with Retarder for the

German market only

• PR4 - Safety Pack Top

for rigids

• PQ4 - Configuration Packages, logging

transportation

• P27 - Safety Pack Top

for truck-tractor

28
VR 115 HV - Voith step-up-retarder
Integrated into Mercedes-Benz transmission

Transm. oil Engine oil

Lubri- Energy
cation carrier

Transmission-independent retarder oil supply

29
VR 115 HV
Sectional view of transmission integration and retarder
Mercedes-Benz
Retarder Step-up
transmission
shaft gear

Bearing bell

Rotor Transmission main shaft

Stator
Transm. -independent Animation
oil supply

Stainless steel
Heat exchanger

Diaphragm

Oil sump
Control air
30
VR 115 HV - Heat transfer
integration into vehicle cooling circuit

1
The operating medium (oil)
6
in the heat exchanger
3 transfers the braking energy
produced to the cooling
Transm. water.
Engine
Retarder 4
For protection of engine and
2
Retarder, the Retarder oil
5
temperature and the cooling
1 Thermostat water temperature are
2 Radiator
3 Fan
monitored continuously.
4 Heat exchanger
5 Temperature sensor Retarder oil
6 Temperatur sensor water

31
 VR 115HV – Main Components
Oil separation element 2/2 Way valve

Temperature
sensor oil

Bearing bell
Oil filling plug

Proportional
valve

Service
measuring
point
Water outlet
Pinion

Temperature Inlet valve

sensor water
Water inlet
Outlet valve Oil/water draining plug
Stainless steel heat exchanger
32
 Diaphragm technology and rotor shifting
Rotor

Twist gearing
on pinion shaft

Housing wall

Oil volume

Diaphragm to separate
retarder oil and control air
Pinion shaft

Stop
Spring
Control air side
Rotor shifting

Stator

Animation
33
Ventilating power reduction
by rotor shifting

Braking operation

Stator
Rotor

Idle

Rotor
Stator

34
VR 115 HV – control system VERA
Integration into Telligent® vehicle management
Abbreviations:
HS-CAN Bus = High-Speed-CAN Bus
LS-CAN Bus = Low-Speed-CAN Bus
FR = Fahrregelung
FMR = Fahrzeug Motor Regelung
FTCO = Flachtachograph
HHT = Hand Held Tester
DAS = Diagnose Assistenz System
RS = Retardersystem
Networking of components:
2 Retarder control unit (Voith)
3 HS-CAN Bus
3/1 LS-CAN Bus (Engine)
3/2 LS-CAN Bus (Clutch)
3/3 LS-CAN Bus (Brake)
29 Instrument
70 Control unit FR (FMR)
72 Control unit FTCO
73 Diagnosis port
(Can only be read with Daimler
Chrysler diagnosis systems HHT or
DAS)
76 K-line Voith VERA
77 Other control units
78 Basic module
35
VR 115 HV Operation and Driving Mode

Integration of endurance brakes into Telligent® braking system

In order to protect the wheel brakes, the Telligent® braking system, can activate
the vehicle's built-in endurance braking systems (engine brake, retarder),
depending on the load condition of the vehicle and the weather conditions.

Vehicles with Telligent® automated transmission

If the endurance brake is switched on and the service brake is activated, the
Telligent® gear automatically selects a lower gear range in line with the prevailing
driving situation.

36
VR 115 HV Operation and Driving Mode

Multi-function combination switch

to activate:
• Limiter
(limitation of driving speed)
• Tempomat
(pre-setting of driving speed)
• Telligent® proximity control
(determination of nominal distance)

37
VR 115 HV Operation and Driving Mode

Operation of endurance brakes

Leverpostion 0:
Endurance brakes (constant throttle- /exhaust
brake / VR 115 HV) switched off
Stage 1: 20 % of overall braking force
Stage 2: 40 % of overall braking force Deceleration of
Stage 3: 60 % of overall braking force vehicle
Stage 4: 80 % of overall braking force
Stage 5: 100 % of overall braking force
Operating lever of
permanent brake Display on instrument panel

Leverposition 6:
Function as braking cruise
Memory of current speed and increase by 0.5
control
km/h each on tapping
(Steps 1 to 5 need to be
Leverposition 7. switched on!
Memory of current speed and reduction by 0.5
km/h each on tapping

Pilot light of
permanent brake

38
VR 115 HV Operation and Driving Mode

Operation of combined driving/braking cruise control (limiter)

Combined driving/braking control (Tempomat):

Tempomat and endurance brake interact (Tempomat operates on upward
gradients/level road, endurance brakes operate on downward gradients).

Limiter:
limitation of driving speeds above 15 km/h.

39
VR 115 HV Operation and Driving Mode

Operation of combined driving/braking cruise control

(limiter):

Combination switch is in position 0:

• Button 4: Limiter is selected (shown on multifunction
Multi-function combination
switch display) and activated with stage 1
• Stage 1: pre-set and/or increase driven speed
• Stage 2: resume pre-set speed and decrease it
• Stage 3: Tempomat/Limiter “Off”

The pre-set maximum speed is shown in the multifunction

display.

40
VR 115 HV Operation and Driving Mode

Telligent® proximity control (Code ET5):

Installation in ACTROS flatbed trucks and trailer-tractors
only in combination with Voith Retarder VR 115 HV
(Code BA1).

Benefits for the customer:

• Driving in single-line traffic is much more comfortable.
• Reduced risk of rear-end collisions.
• Increased transport safety, reduced downtimes and
lower general costs

The Telligent® proximity control is a comfort system that

supplements the function of the cruise control by an
additional distance control facility.
41
VR 115 HV Operation and Driving Mode
Driving Mode at temperature limitation
Note:
For protection of engine, engine cooling system and Retarder, the
Retarder oil temperature and the cooling agent temperature are
monitored by the Retarder ECU!
During endurance braking high engine speeds (2300 rpm) are
required:

• The PowerShift shifts automatically into the ideal gear.

• The manual gear has to be shifted in a lower gear.

Goal: High delivery of water pump and high fan speed.

Result: The Retarder efficiency can fully be used.

The fuel consumption is not influenced by the high engine speed

since the injection system does not supply in overrun condition.

42
Braking Power VR 115 HV + Engine brake

ake
Actros 1851LS
ine br
de r + eng
Retar
Actros 1848LS
brake power [kW]

80 % of
brakings
are in
rake
engine b
this Actros 1851LS

range
Actros 1848LS rear axle:
2,929 (Acros 1851LS)
2,846 (Actros 1848LS)
Tire: 315/70R22,5
engine speed 1.100...2.300 rpm
Display of curves in simplified mode

engine speed [rpm]

43
VR 115 HV Customer Benefits
Economy (1)
Active retarder utilization saves fuel
and time
• Motivation to drive with foresight
• Payback of retarder usually within
1 – 2 years

Reduction of vehicle operating costs

• Service life of service brakes is
considerably extended
• Experience value in long-distance traffic
factor 4 an higher
• Fewer workshop stops
• Protection of drive line

44
VR 115 HV Customer Benefits
Economy (2)
Advantages for vehicle resale
• Retained value of retarder up to 2,000 €
• Increased demand for retarder-fitted
vehicles in the used vehicle market

Highest product quality

• Series-fitted stainless steel heat
exchanger
• Standard PTOs and emergency steering
pump can be integrated
• Maximum in innovative hydrodynamics
with rotor shifting
• Diaphragm technology optimises control
air consumption
45
VR 115 HV Customer Benefits
Safety
High braking power across entire speed
range
• Effective adaptation braking at maximum
speed without gearchange
• Winner of braking power comparison
(3,500 Nm)

Safety reserves thanks to cold service

brakes

Can be linked with proximity control

(Code ET5)

46
VR 115 HV Customer Benefits
Comfort
Reduced activation of brake foot pedal

Noticeably fewer gear-shifting operations

Stress-free driving

Smooth braking operations

Combined drive / braking tempomat

• Tempomat function on level road, ascends
and descends
• “VERA“ retarder control is part of Telligent®
system

47
VR 115 HV
Economy, Safety, Comfort
E = 1/2mv2 means: When doubling the speed,
high

VR 115 HV plus
engine brake E = 1/2 mv2 four times the kinetic energy must be
dissipated into heat.
Retardation [%]

VR 115 HV

Optimum: Addition of braking forces of

engine brake and Voith Retarder.
low

Engine brake
low high
Speed [km/h]

High braking force at high speeds.

high

0,5
Friction coefficient µ

• Permanent braking
0,4 • Adaptation braking
Brake linings
Wear factor

0,2
Possibility of increased average speeds with
0,1
more safety-reduced transport times.
Low

Low high
Temp. of brake linings [°C]
48
VR 115 HV – Customer Benefits
Practical Test

Applications Ø v km/h
Results:
1800
90 • 70 % reduced
- 70% - 36% + 5,9%
service brake
operations
1200 60

1890
1839 • 36 % fewer gear
70,4
74,5 shifting operations
600 1196 30

627 • 5,9 % increase of

0 0 average speed
Service brake Gear change Average speed
without with without with without with
VR 115 H VR 115 H VR 115 H

49
Mercedes-Benz Actros 1844 with PowerShift
Constant Throttle
Performance [kW]
278 kW at 2,300 rpm

Vehicle data:
iHA =2,84;
tyres=315/80R22.5
cross vehicle weight=40,000 kg
retardation=1%
transmission=12-Gear

Vehicle speed [km/h] Display of characteristic curve partly in simplified linear mode.
50
Mercedes-Benz Actros 1844 with PowerShift
Constant Throttle
Performance [kW]
207 kW at 1,900 rpm

Vehicle data:
iHA =2,84;
tyres=315/80R22.5
cross vehicle weight=40,000 kg
retardation=1%
transmission=12-Gear

Vehicle speed [km/h] Display of characteristic curve partly in simplified linear mode.
51
Mercedes-Benz Actros 1844 with PowerShift
Constant Throttle and Retarder VR 115 HV
Performance [kW]
207 kW at 1,900 rpm

660 kW
100 %

150 kW
33%
Vehicle data:
iHA =2,84;
tyres=315/80R22.5
cross vehicle weight=40,000 kg
retardation=1%
transmission=12-Gear

Vehicle speed [km/h] Display of characteristic curve partly in simplified linear mode.
52
Mercedes-Benz Actros 1852 with PowerShift
Constant Throttle and Retarder VR 115 HV
Performance [kW]
222 kW at 1.900 rpm

700 kW
100 %

175 kW
25%

Vehicle data:
iHA =2,84;
tyres=315/80R22.5
cross vehicle weight=40,000 kg
retardation=1%
transmission=12-Gear

Vehicle speed [km/h] Display of characteristic curve partly in simplified linear mode.
53
VR 115 HV + Top Brake
a perfect combination for productivity gain

vehicles – “on road “ vehicles – “off road “

54
 6%

possibility to go
downhill with a higher
ramp

Top Brake only

6 % ramp
speed
30 km/h possibility to increase speed
average in the same ramp

GVW 50.000 kg 55
 6%

6 % - 70 km/h
Top Brake + Retarder

effective increase int he

speed average driving
downhill
6 % - 30 km/h
Top Brake only

GVW 50.000 kg 56
VR 115 HV Eco-friendly
Up to 80 % less brake dust emissions

Saving dust from brake pads:

24 kg per service brake replacement

Dust produced over a lifetime of

1,500,000 km:

• without Retarder: 180 – 360 kg

• with Retarder: 36 – 72 kg
(depending on application and topography)

57
Joint activities – MBBras / Voith

to reproduce the succesful joint activities in

Europe ( Mercedes-Benz and Voith )
to generate proper argumentation to the
sales & service personal about the
advantages of the safety package which
includes Voith Retarder
to generate real added value for our common
customers with the best use of this kind of
technology ( best vehicle peformance )
to offer lowest total cost of ownership for our
common customer ( operation costs and
vehicle downtime reduction)
to generate additional business opportunities
based on differentiation package
58
Possible activities

sales training – MBBras personal and

dealership ( road show )
integration of Voith retarders in the
MBBras demo trucks
communication material ( flyers,
technical information via MB
communication means )
drivers training integration
joint press activites
to participate on MBBras special sales
actions ( Actros on tour,etc )
new business opportunities development
on Atego family

59
Big challenges...
a lot of fun !!

Thank you !

60
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