PROBLEM: The transmission in any motorised vehicle is a system of gears, located between the engine and the wheels, that literally “transmits” the power generated by the engine to drive the vehicle. The world is dominated by two forms of transmission, the manual transmission (MT) and the Automatic Transmission (AT). MT has a manually operated single dry clutch whilst the AT uses wet clutches that are automatically controlled. MT offers the advantages of simple manufacturing design, reliability, ease of maintenance, direct vehicle control, good fuel economy and an efficiency of ~97% for a representative drive cycle . On the down side, studies which monitor stress by measuring human heartbeat have shown that drivers of manual-transmission vehicles do experience significantly more stress than those in automatics . It also takes skill and practice to proficiently master a MT. Furthermore, gear shifts are sometimes not smooth, which causes discomfort for motorcyclist/car driver and/or passengers who will notice an interruption of engine torque to the wheels when the transmission is between gears. In severe situations the interruption of torque can cause dynamic instability of the vehicle resulting in loss of control. On the other hand, AT provides the ease of driving, smoother shift quality while the transmission picks the right gear for you. The downsides of AT are their manufacturing complexity, reduced performance and lower fuel economy because of the lower efficiency of the transmission. Not only are there parasitic losses to account for to operate the hydraulic pump, but large amounts of slip in the torque converter generates heat loss which warms the transmission fluid rather than provide torque to the wheels. Over a representative drive cycle the efficiency of an AT can be as low as 86%2. In the recent past, several attempts have been made to deliver a torque transmission system which resolves the weaknesses of both AT and MT systems. The rise of Automated Manual Transmissions (AMTs), Dual Clutch Transmissions (DCTs), and Continuously Variable Transmissions (CVTs) are examples of these recent developments. An unmet challenge for AMTs, however, is the reduction of torque interrupt to improve shift comfort for the driver/rider. It is possible to increase the complexity of the shift system to reduce shift time, but this does not solve the problem. The reduction in shift time is constrained by torque roll-off and roll-on from the engine and therefore the limit is comfort and not actuator performance or engine response.
IMPRTANCE FOR SOCIETY: The global need for an efficient & sustainable mobility has become more urgent for cities as traffic, congestion, parking space availability are becoming ever greater concerns for citizens. These challenges are accompanied by issues of increasing costs for transportation in terms of money as well as time. Use of motorcycles as an alternative mode of transport contributing to optimising urban mobility is on the rise & the reported increase in number of motorcycles on the road in the last 5 years is the direct evidence of that. Some of the global challenges associated with the motorcycles revolve around increasing riding comfort, fuel efficiency and reducing emissions. Our prposed technology 'Z-Tech' through its unique features and benefits to the motorcycle manufacturers and riders will help global uptake of comfortable and fuel efficient motorcycles. More seamless linear acceleration availability using Z-Tech means smaller engines can be fitted to the large vehicles which further improves fuel efficacy.
OVERALL OBJECTIVES: The overall objective of this innovation project is to develop a seamless, efficient, continuous torque multispeed Automated Manual Transmission with an increased efficiency of ~8% over MT gearbox, power efficiency of ~98% and a manufacturing cost of ~€700. Within this broader picture, as a first step we undetook Phase 1 project, the overarching objective of which is to conduct a techno-economic feasibility study to determine the commercial viability of Z-Tech for our target markets. Key objectives, which were successfully acheived, are
1 - Market Evaluation, to gain an up to date understanding of the market opportunities within the motorcycles, electric vehicles & performance car markets with specific details: VoC based validation of specification requirements; market dynamics; end user willingness to pay & most appropriate licensing models; and identifying challenges & opportunities in global markets over the next 5 years
2 - Technical Analysis, to address any conceptual or design challenges identified through VoC in Market Analysis to progress to final production stage. Assess any potential impacts and improvements using life cycle analysis, and highlight any potential technical and/or commercial risks with correlating mitigations
3 - Confirm any Intellectual Property impediments, through a patent search and Freedom to Operate (FTO) analysis, targeted to specific Markets (UK, EU or Third Country, etc.) and opportunities to extend the existing patents portfolio for additional IP protection through further patent applications and other methods of IPR
4 - Supply-chain development (to manufacture and test beta scale prototypes during Phase 2 ) to identify and/or recruit:
• commercial partners with relevant accreditations to build a scalable supply chain with sufficient capacity to deliver commercial volumes of Z-Tech prototypes for motorcycles to be tested and validated at test houses and by Harley Davidson whilst ensuring compliance with the regulations and standards
• technical partners to plug the skills gaps identified to complete the development to commercial readiness; end users and independent test houses to provide assistance with environment trialling and validation
5 - Develop a future Phase 2 project plan to clarify activity required to create a commercial manufacturing process
6 - Create a project-specific Business plan with a strong sales and marketing plan that overcomes the challenges of reaching key markets; Sales forecast; market opportunity, competition, risks, commercialisation strategy, IP strategy and financial projections; a strong financial and investor plan Carry out regulatory review by engaging with the relevant authorities.
