Press information

April 5, 2006

Mercedes Power-Shift: new generation of gear changes with

advantages for the driver and the entrepreneur

New generation of completely claw changes

automated
New standard for industrial vehicles: powerful engines
turbocharged and 12-speed changes
The standard for long distances: efficient gear changes
direct
Manual and semi-automatic synchronized changes as an option
Additional programs: driver assistance at the push of a button
20 years of experience in the development of automated changes
Base ideal: changes of claws with multiplicative-divisor group
• Control network: the claws require a processor
• Resumen: pequeño glosario de cambios

The new Mercedes Power-Shift system will successively replace the transmission.
automated Telligent in all Actros trucks for road. Mercedes Power-
Shift is the name of a package formed by unsynchronized manual changes.
completely automated with 12 or 16 speeds (for applications
special), along with an electronic management system that controls the functions
mainly - gear shifting and clutch operation - and includes new
actuation functions. The goal pursued with this new development was
increase the utility for customers by enhancing profitability and
achieve faster and more comfortable relationship changes.

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In this way, Mercedes Power-Shift helps to increase payload and reduce
fuel consumption. Furthermore, the new technique of shifting and control allows for
change relationships more smoothly and at the same time more quickly than before
now and offers the driver new driving programs, optimized for the
practice. In this way, the driver and the businessman benefit equally from the
Advantages of Mercedes Power-Shift.

Another basic feature of Mercedes-Benz automated manual transmissions

since its introduction to the market over 20 years ago and that is still preserved
fully in the new team is the reduction of the risk of handling errors and, therefore,
therefore, an increase in the availability of vehicles in the fleet.

Twelve speeds as standard

The mechanical base of the new family of Mercedes Power-Shift transmissions is

non-synchronized manual gearboxes with 12 speeds. This transmission
basic allows for configuring an ideal powertrain for circulation through
road combined with the enormous pulling power provided by modern
turbocharged six and eight cylinder engines from Mercedes-Benz.

The new twelve-speed changes are available in 2100 versions,

2800 y, later on, up to 3300 Nm of torque; the two shifts G 211-12 K G 281 K
they are groups of direct marches. The Mercedes Power-Shift range also includes two
16-speed unsynchronized changes for especially tough applications
on the road.

Mercedes Power-Shift is based on the philosophy of multi-step shifts.

Mercedes-Benz, systematically perfected: twelve precise gears for the
majority of the fields of application, both in suburban traffic and in the
long distances, and 16 speeds whenever the truck has to face
especially harsh working conditions on the road.

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Power-Shift benefits from the experience of Mercedes-Benz

The new Power-Shift change is backed by more than 20 years of experience.

Mercedes-Benz in the development of partial and fully manual transmissions
automated. The first step was the electropneumatic control EPS from 1985, followed by
in 1996 by the 'Telligent change' as standard equipment and the 'change
automated Telligent" as an optional team.

It is a known fact that the road infrastructure in Europe will not be able to increase in the
future at the same pace as traffic volume. For this reason, the engineers
The divisions of industrial vehicles of Mercedes-Benz will continue to develop.
automation and driver assistance systems for trucks. These
Equipment increases the comfort of shifting and clearly speeds up gear changes.
With the introduction of Mercedes Power-Shift, automated manual shifts
they will become the standard in the market for industrial vehicles in the medium term.

It is necessary to make the driver's task easier in traffic.

The constant increase in traffic density makes the measures and the
concepts to alleviate the driver's task should be an obligation for everyone
manufacturers of industrial vehicles, with the same priority as the optimization of
truck to increase its profitability in daily use. The new shifting system
Power-Shift can help reduce fuel consumption and increase
payload.

At the same time, it improves the comfort of the change and noticeably reduces the
duration of the gear changes. This last fact may seem surprising,
until the explanation from the specialists is heard: the suppression of the heavy ones
synchronization packages and their replacement by the so-called shaft brake
the intermediary clearly decreases the masses in motion. This fact, above all
in combination with the modern command equipment to ensure the synchronization of the
transmission elements are the key to faster and more efficient ratio changes.
soft.

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Unsynchronized changes require an intelligent control.

Without the help of a high-performance command team, the drive of a

Light and quick gear change requires skill from the driver and above all strength.
double clutching with perfectly dosed intermediate acceleration and the
Continuous operation of the gear lever implies a buildup of tasks
which increases the fatigue of the truck driver.

That is to say, just the opposite of what is required today: to ease the driver's task.
The continuous increase in traffic density, often coupled with the allocation
additional tasks for the driver make it necessary to develop concepts and equipment that
systematically facilitate the operation of the truck's equipment.

An unsynchronized change without electronic control poses very demanding requirements.

raised to the driver and, therefore, it is unthinkable in the world of transport of
future.

As is known, unsynchronized changes are smaller and lighter than

the synchronized changes, as long as the range of torque does not need to be increased
motor. In contrast, this modern interpretation of the classical change allows for an increase
clearly the torque ratings while conserving the dimensions and weight of a
synchronized change comparable. In order to fully benefit from your
Properties, the development of a claw change requires a high level of know-how.
both in the mechanical field and in relation to the electronic control.

The basic principle of operation does not change.

From the perspective of the drive system, the driver of the Actros does not find
no difference when taking a seat in a vehicle with Mercedes Power-Shift. On
all if you have already enjoyed the benefits of the automated Telligent transition. But
even in the case that the driver uses a truck with a transmission for the first time
completely automated: the Actros with Mercedes Power-Shift makes it easier for you
Introduction to this technique, as is reasonably expected of a vehicle with technique
advanced.

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Just like in trucks with automated Telligent transmission, in the cabin
Only two pedals are installed: the brake and the accelerator. To the left of both
There is plenty of space to place the foot on the pedals. The driver doesn't have to step on the
clutch pedal as before: that's handled by the electronic control.

The transmitter, which has a shape similar to a joystick, is also known on the right.
conductor, mounted on a folding arm to facilitate passage from one side to the other
inside the cabin. The driver can select the gears with a light
wrist movement, but only if desired.

Possibilities for manual operation

In vehicles with the well-known Telligent transmission, the driver's intervention is

necessary very rarely; with Mercedes Power-Shift it decreases once again the
need to manually trigger the change. As before, to manually change a
or several marches at once, the push-button control is used: both the Switch
tilting like the gear selector switch. To select manual mode
you need to press a button. No matter how reliable the automated functions are
from Mercedes Power-Shift, its programmers have preserved for good reasons the
basic principle: the driver maintains control over the changes in relationship of their
vehicle.

The selected mode is permanently displayed on the information display.

located between the speedometer and the tachometer. When starting the engine, it
automatically select mode 'A' (automatic): this was not possible in the
models with the fixed position switch for 'A' and 'M'.

A panel of indicators shows new possibilities

A reasonable and easy-to-understand novelty regarding the introduction of

Mercedes Power-Shift refers to the indicator of the engaged gear at any moment.
Instead of viewing the complete marches and the halves separately
marches, all available relationships are numbered alphanumerically starting from the
shortest to longest.

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But this is not the only novelty in the driver's environment. In order to assist with
Actros driver with more intensity than ever in the different
situations that may arise during daily driving, Mercedes Power-
Shift provides, in addition to its basic attributes, a wide range of new functions:

Power Mode: maximum power at the push of a button

Eco-Roll: an intelligent freewheel
Cruise control for propulsion and braking: flexible window for Eco-Roll
Maneuvering mode: advance and reverse with precision
• Modo para liberar al vehículo: salir airoso de situaciones comprometidas
Four reverse gears: with agility in the opposite direction

As is natural, the connection and disconnection of the driving functions and

assistance is displayed on the multifunction indicator in the instrument panel.

The new features are controlled through their own control panel in the
generous driving position of the Actros. The three double switches are
they find it logical and reasonable near the service center of
driver: this is next to the steering wheel.

Power Mode: maximum power at the push of a button

Two functions that are already part of the standard equipment of this range of
changes are 'Power' and 'Eco-Roll'. In Power mode, the driver can claim
for a limited period of time the maximum engine power up to the regime
nominal without needing to activate the overgas (kickdown). Just press a button.
for the change software to activate in Power mode a characteristic diagram
special. With this diagram, the gear shift control tends to hold the current gear or
even to reducing it, and at the same time it resists changing to a higher gear. From
This way, the vehicle's agility is increased in the short term: a condition
important for overcoming mountain passes or for merging into traffic on a
highway

In order not to lose the economic advantages of an automated manual change by

driver oversight, the Power mode disconnects by itself after 10

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minutes. This special program of the processor is always inactive when turning on
the engine is running. Furthermore, logically, it cannot be activated if you are driving with
the "M" change program, and the driver can deactivate it at any time
pressing a button.

Eco-Roll: a smart freewheel

Otherwise, the high-speed driving program cannot be activated if

the 'Eco-Roll' mode is activated. This smart feature, which is always active when
start the vehicle, take advantage of the energy under defined service conditions
inertia of the road train. Cyclists know this principle that helps to save.
forces: recover at least part of the energy invested to accelerate or to climb
a slope.

The freewheel function automatically deactivates whenever the

Braking cruise control: whether it is done by the driver or it is a
electronic intervention. From a mechanical point of view, the Eco-Roll function
realizes changing to neutral. This function only operates in automatic mode "A",
and at a minimum speed of 55 km/h.

These two additional programs of the Mercedes Power-Shift are also part
since 2005 with the automated Telligent system incorporated in the trucks
Actros with BlueTec 4 and 5 certification.

Cruise control for propulsion and braking: flexible window for Eco-Roll

In combination with the use of inertial force to save

fuel in Eco-Roll mode, another device that helps improve profitability
the trucks with Mercedes Power-Shift transmission is the automatic regulator of
speed.

The Tempomat program used until now braked the road train when going downhill.
pendents with a fixed hysteresis: that is, the continuous action brake was activated
whenever the vehicle's speed exceeded the limit by 4 km/h

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adjusted. Now, on the contrary, the driver can determine their 'inertia window'
own.

Using a button, the driver can choose the desired margin between 2 and 15
km/h and program the Tempomat that way. This freedom has limits, such as
if the driver has set a basic speed of 90 km/h and a margin of
15 km/h, the electronic control device does not allow the road train
the theoretical value reached is 90 + 15 = 105 km/h; in this case, the unappealable limit is 94
km/h.

Maneuvering mode: advance and retreat with precision

The exact coupling of the semi-trailer, the safe approach to an obstacle, the
precise parking next to a loading and unloading ramp: there are many
situations in which a truck with automated clutch requires the driver
a special sensitivity in the throttle operation. The new shift
Mercedes Power-Shift significantly facilitates the driver's work. Once
activated maneuvering mode, the accelerator pedal takes on the tasks assigned in a
conventional truck between the clutch pedal and the accelerator.

In other words: when the accelerator is activated, the opening and the priority are regulated.
clutch engagement; in this mode, the engine does not exceed in any case a
1000 revolutions per minute regime.

The maneuvering mode is activated by pressing a button. In combination with the possibility
to shift directly from first gear to reverse - another particularity of
new Mercedes Power-Shift change - the maneuverability capacity is optimized.
Actros to a level that, until now, only a very skilled driver could achieve.
experienced in perfect interaction with a manual shift or a Telligent shift.

Way to free the vehicle: to emerge successfully from compromised situations

Un camión para carretera no está exento del peligro de que las ruedas se queden
stuck: even more often than the stressed driver would like. The
The pavement of the loading and unloading ramps does not always meet the ideal of a

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road engineer. The Mercedes Power-Shift helps the driver to start smoothly
of these situations. Activating the special mode to release the vehicle, the driver
automatically enjoy the expertise of an experienced driver in a truck
with a conventional clutch: move forward slightly, modulating the force, disengage
suddenly, move forward again slightly, disengage, etc. until out of the muddy area or
of the snow.

The most important difference: in a truck with Mercedes Power-Shift you do not have to
press the clutch, release it, press it again, etc. Just operate and release
gently the accelerator. In most cases, after a few cycles the
proceso de balanceo longitudinal ha alcanzado un dinamismo suficiente para sacar
the wheels of the quagmire. This quick opening of the clutch when lifting the foot off the
the accelerator is precisely what the Mercedes Power-Shift change does if the
the driver has activated the program for the vehicle's release. This abruptness,
unwanted in normal exchange programs, helps to smoothly exit a
situation of this type.

Four backward marches: with agility in the opposite direction

The introduction of the new generation of Mercedes Power-Shift claw changes

it is accompanied by an increase in the number of reverse gears: four instead of two as before
Now. A quick reverse has many advantages: for example, if the vehicle
You have to cover a long stretch due to lack of space to maneuver.

A typical application is the semi-trailers with tilt bridge used in the

road construction. These vehicles have to transport a very large amount
elevation of aggregates to the paver, circulating over a layer of freshly laid asphalt
placed, where it is absolutely prohibited to maneuver to change direction.

More than 20 years of experience

From the historical development point of view, the introduction of manual changes
partially or completely automated 16-speed in the world of
12-speed changes Mercedes Power-Shift represents a logical evolution.
the first important step in this process, in the 1960s of the last century, was the

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Mercedes-Benz's decision to supply only synchronized transmissions, which
significantly facilitate the work of the truck driver. The next step of
This evolution was the electronic-pneumatic change (EPS) in 1985: the first system.
of change for heavy-duty vehicles fully powered by force
foreign (except for the clutch).

EPS quickly became the standard in this segment: an argument

important in favor of the specialists who develop the kinematic chain of the
Mercedes vehicles that are at the beginning of an irreversible process:
replace self-powered systems with externally powered systems, with the
following objectives: to facilitate the driver's work through automation of the
routine tasks that require strength and attention, reduce wear and protect the
equipment against drive errors. All of this increases the utility of the vehicle
for the businessman.

The Actros drives evolution: the beginning of manual changes

completely automated

About ten years later, the launch of the 1996 Actros by Mercedes took place.
Benz. This model marked the debut of the second generation of electronic transmission.
tire.

The 'Telligent change' (TS) developed at the same time has a greater
electronic intelligence" and therefore offers the driver a higher level of comfort. The
Telligent change has a processor that manages relationship changes in
function of the situation in which the vehicle is located. The driver is limited in
in all cases gently operate a control with the hand and step on the pedal of the
clutch.

Business owners and fleets have shown their agreement with the strategy of
Mercedes: the Telligent gear shift included as standard in all Actros models has
achieved a 70% equipment quota. To put it in absolute figures:
since its introduction to the market, the Telligent change has been installed in more than
325,000 Actros trucks.

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The popularity of Telligent change systems

This figure needs to be increased by another 40,000 units if we take into account the
automated change Telligent, the most advanced equipment available up to
introduction to the series of the Mercedes Power-Shift. If the market shares are added up
Europe of both devices reaches a percentage of 86%. The competitors
The most important in this market have an automation rate of 35%:
less than half of the Actros.

The automated change Telligent (TSA) is the next stage of development, and
convert to Telligent semi-automatic transmission in a functioning system
completely automatic for the management of the kinematic chain. The TSA, which
was introduced and put on sale as an optional equipment in the year 1996/97, included
still a folding pedal to be able to operate the clutch in special cases. Low
under normal conditions, the coupling between the engine and the gearbox was available from the
start of an external force actuator: of the electrohydraulic type until the year 2002
and exclusively pneumatic from that date. The "pedal of" has now been removed.
emergency" foldable. For good reasons: it has been practically proven that
it is absolutely unnecessary.

Currently, the automated Telligent change is a two-pedal system: one

configuration that recalls the 'authentic' automatic changes with converter of
par.

The reason: the team's performance has been decisively improved.

electronic, so that the driver hardly ever has to resort to
manual mode to move your vehicle with agility and economically, not even
in especially difficult terrains.

Less mass for faster changes

In the Mercedes Power-Shift transmission, this construction principle is especially

important, as it includes the weight savings due to the removal of the elements
synchronization mechanics and the greater inherent speed of the principle is added
constructive of a non-synchronized change. The reduction of mass is a requirement.

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basic: the rest is taken care of by the electronic management team, connected to the network with the
other components of the vehicle. Shifting to a shorter gear increases the
number of revolutions of the engine and, therefore, of the input shaft of the gearbox; to the
quickly switching to a higher gear precisely reduces the
regime at the entrance of the gearbox: a particularly important adaptation
when accelerating a heavy road train at the end of a slope.

Synchronization Assistant: the electronic management of the engine

As we have seen, the electronic management of the engine assumes an essential function in the
automation of the Mercedes Power-Shift change. As happens in other fields,
también aquí se aprecia la experiencia acumulada a lo largo de los años por el mayor
world's truck manufacturer. It should not be forgotten that the company from Stuttgart
it was the first manufacturer that met the increasingly stringent demands of each one
from the environmental protection directives, from Euro 1 to Euro 5, through a
systematic optimization of engine management and increasingly efficient combustion
efficient and therefore cleaner.

To make an unsynchronized change automatically change its relationship.

Gently and through external force, a control technology is required.
advanced, like that incorporated in modern engines for industrial vehicles.

The processor that controls the engine and the transmission achieves this effortlessly.
synchronization between the gears of the transmission that, in the early years of the
history of the automobile and even today in part in the United States, it had to be achieved
with strength and skill.

By the way: it is not about adjusting exactly the same number of revolutions in the
slidable crown and in the gear wheel that must couple, but to maintain
there is always a small difference between the regime of both components. The reason:
between two fully synchronized wheels there can be a correspondence.
exactly "from tooth to tooth", which would hinder or make a quick change impossible
relationship.

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Based on this knowledge, it is possible to develop a command team that
establish a previously defined exact difference in the number of revolutions
of both components, in order that changes in relationships are always
fast and smooth in any vehicle situation.

Modern gears with a robust base

The mechanical base of Mercedes Power-Shift is backed by the competition of the

brand, that develops and manufactures gears and shafts of all kinds for several years
decades. From this forging comes the mechanical base of the new gearboxes of
wide dissemination G 211-12 K and G 281-12 K, derived from current changes
synchronized 16-speed. Just like these transmissions, the new
claw change generation is equally based on the constructive principle of
multiplier and divisor groups placed before and after the main change. This
means the following: in the main change, three pairs of gears do not
synchronized with geometric scaling establish the three gear reductions
basics.

The synchronized multiplier group located below is a gear.

planetarium; at the exit of this group there are six gears. This duplication of
The number of speeds is due to the relatively small gear ratio.
raised in the multiplier group 4.40 : 1. In this way, the first gear with a
the demultiplication of 14.93 :1 is converted to the output of the multiplier group in the
fourth gear with an effective reduction of 3.39 : 1.

The preceding divisor group, prior to the main change, divides each of the six.
march in two: a fast march and a slow march. This way, a
twelve-speed change. The gears of the dividing group
dividend only in a ratio of 1.28:1; therefore, they are found in a way
alternated between the main 'long' gears. Truck drivers with
manual change and multiplier or divider groups know this very well
procedure. The most important difference is the automatic operation, which
it ensures that all processes are carried out with the reliability of an automaton.

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Direct shift changes for most applications

Depending on the intended use, the new changes from Mercedes-Benz

they are available in different versions. The direct shift with shaft
direct transmission (1:1) in the longest gear increases performance of the
transmission. A version with 'super direct' is also offered. The gear change
Directly used primarily for the transportation of goods in general:
both for short distances as well as for medium and long distances. It represents, so to speak, a
universal solution tailored to any field of application.

In order to optimize fuel savings, direct gear changes with

a "1" in the third position of the execution number combines with the axes of
hypoid gears HL 6 and HL 8. In this case, the kinematic chain is formed by
individually optimized components to reduce power loss. The
versions with super direct drive (with a '0' at the end) are used instead in
combination with HL 7 reducer cube shafts if it involves powering trains
road with a particularly high mass.

However, within the range of Mercedes-Benz Actros trucks, the predominance will be
direct shift gear combination with lightweight construction axles
reduction gears made with formed sheet metal. The family of gears
Mercedes compact Power-Shift with hypoid gear axles and transmission
directly will also be used in the Lowliner.

A perfect interaction of mechanical and electronic systems

The pneumatic actuators are partially integrated into the gearbox casing.
for the coupling of the three main gears, the multiplier group and the
divisor group, as well as the high-precision pneumatic actuators for opening and over
everything to close the standard incorporated friction clutch. Naturally, the
new claw changes are ready for equipment with power take-offs
and for the integration of the Voith secondary retarder.

If the mechanical design of the Mercedes Power-Shift transmission is supported by the

experience of Mercedes-Benz engineers in the construction of gearboxes and

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gears of all kinds, the technology used for electronic change management
also benefits from the know-how gathered over many years of
automation of systems for the automobile. The electronic pneumatic shift of
Mercedes, the first of its kind in the world, has been produced in series since the year
1985. The other milestones of this development, both the Telligent change and the change
automated Telligent, also constitutes a solid foundation for Mercedes
Power-Shift.

Sensors attentive to the vehicle's situation

The new control system is based on the well-known change control parameters.
automated Telligent. In addition to managing the clutch and engaging the gears, the
The electronic brain receives information from the sensors that assess the situation.
current vehicle data, process this information and choose a viable change strategy and
suitable for the situation. The change processor needs to know the current mass.
of the vehicle, the topography of the terrain in which it moves and the features it demands
The driver needs it.

Once the accredited electronic control circuit is well calibrated, it

they use characteristic variable diagrams to adapt the change program. The
specialists refer to this configuration as 'relative strategies', and they refer to
Hello to the quick reaction of the command team to external influences. This type of
Influences are, for example, the interventions of ABS or ESP and skidding.
due to the use of the secondary retarder with reduced dynamic loads
about the driven axle. The management of the powertrain must take into account
also the processes of regulating the cruise control with distance regulation
Telligent distance regulation.

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Small glossary of changes

Change The term 'change' generally refers to the box.

of changes or manual change. This component is
integrated into the force transmission line in the
kinematic chain, and adapts the power P [kW/CV]
variable or the pair M (Nm) delivered by the motor (of
combustion) to the different resistances, also
variables that the vehicle must overcome: the weight,
the resistance to acceleration and ascent, the
rolling resistance and resistance
aerodynamics. In general, gearboxes are
gear wheels
Types of • Manual change (with interruption of the force of
changes traction
• Partial or complete manual change
automated
• Gearbox under load
Change of In a change of claws, there are no elements of
claws synchronization between the gear cogs and
the movable crowns (rings or packages of
synchronization). In order to establish a union in
force drag (= coupled march) between the
pine nuts with claws on the side walls and the
movable crowns with claws are essential
that both components are stopped, or that
they enter at the same speed. In the past it was the
the conductor who had to ensure this synchronization
(double clutch, with intermediate acceleration between
the two clutch actuators). In the
Current affairs are taken care of by the engine control or
the control of change

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Change Just like in a change of claws, in order to
synchronized establish a drag force union (= change
of gear) between the pinions and the crowns
it is essential that both
components are stopped, or that they rotate to the
same speed. The synchronization mechanism is
in charge of ensuring it

Gear Power coupling change with branch low

planetarium load with input and output trees in the same
e.g. The branching of power is carried out by
through at least three satellites. The different
demultiplications are achieved through activation
alternating the pieces in motion.
Main components: planetarium, satellites (with
satellite doors), crown (with interior serration)
Execution of • from a single stage: all the marches are generated
change in the main change; in the case of a truck
it usually involves a 6-speed change
• of two stages: the 'main marches' of
basic change (generally 3 or 4) doubles
through a postponed gear (group
multiplier) a gear that is preceded (group
divisor)
• of three stages: the 'main marches' of
basic change (usually 3 or 4) are doubled
through a delayed gear (group
multiplier) a pregeared gear (group
divisor)
Escalation• geometric: uniform jumps of the number of
of the marches revolutions between one march and the next
• progressive: as the numbering increases
from the march decrease the jumps in number of
revolutions between one march and the next

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Change with Also called direct shift.
marches of The demultiplication in the longest march is 1 : 1.
mountain In this relationship, the torque from the engine
it is transmitted without conversion and therefore without losses
to the differential of the driven axle through the transmission

Change of The change with 'superdirect'. The motor pair is reduced.

fast march from the engine and the number is increased
revolutions in one or several stages
Margin of Also called scaling. It expresses the
demultiplication relationship between the shortest gear and the longest gear
n long
Tree brake Device for braking on the intermediate tree of the
intermediary main change. Your task is to stop the mass of
inertia of the clutch at the input of the gearbox, in order
to achieve synchronization between the input and the
output when shifting to a higher gear
Brake of Act on the primary tree of change. Your task is
clutch similar to that of the intermediate tree brake
Sistemas de Direct change: the gear lever is mounted
change directly on the change cover;
mechanical transmission of the force of change
(exercised by the driver)
Indirect change: the change and the lever are
found in different places; transmission
mechanics of the force of change (exerted by the
conductor) through rods or control cables or
hydrostatic/pneumatic transmission (generally
the force of the driver with power steering) or
by external force ("Shift by wire")

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