The mCVT transmission uses a toroidal architecture that offers smooth, seamless shifting with no steps through an infinite number of speeds. The infinite number of ratio enables the engine to operate at or close to its “sweet spot,” therefore driving significant fuel economy. The CVT also makes construction equipment easier to drive, safer, more productive and, due to its high efficiency, provides OEMs with the opportunity to downsize engines. Using a smaller engine and potentially cheaper emission after-treatment results in major system cost reduction for the OEMs.
The mCVT efficiency compares very favorably to other types of transmissions:
When compared to a powershift with a torque converter, the efficiency is better AND enables using the engine at its most efficient point, increasing fuel economy.
Compared to hydrostatic CVTs, the efficiency is 15-20% better while being on par or better than the typical hydromechanical CVTs used on large equipment and agricultural tractors all at a fraction of the cost.
CVTCORP’s mechanical CVT not only offers the best peak efficiency (up to 94%) available on the market but it also maintains industry-leading efficiencies, regardless of input power. Unlike other types of transmissions that are optimized to work in specific narrow power ranges, the traction drive design maintains its efficiency over the complete power and speed range.
When the rollers are high on the center disc, the output speed is reduced, multiplying the torque.
When the rollers are low on the center disc, the output speed is maximized.
The full ratio span is 6:1.
The traction drive CVT is both powerful and fuel-efficient by design. With a very low parts count, power is not wasted through parasitic losses due to excessive gearing, hydraulics and numerous clutch packs.
Efficiency is achieved by transferring torque and power from the input (end) discs to the output (center) disc through 6 actuated rollers. No metal to metal contact occurs as the specially formulated traction oil used in the transmission is trapped at each contact point between rolling element surfaces. The pressure at contact points induces a phase change in the oil which then momentarily becomes viscoelastic, allowing torque to be transferred without slippage.
The unique cam system continuously adjusts the compression force on the rolling elements throughout the entire speed and torque range, further optimizing transmission efficiency. The cam system was also designed to handle any torque spikes that may occur during equipment operation, avoiding any possible slippage.
The heart and soul of the mechanical CVT is the positioning of the 6 rollers between the input and output discs. The tilt angle of the rollers determines the transmission ratio and ultimately its output speed. This positioning is controlled by rotating the outer control rings by way of a simple, low power actuator. This movement steers the 6 rollers to the desired position. Force on the control system is minimal and only required during a ratio adjustment.
Over 500,000 hours of testing in laboratories and real-life applications by OEMs (Original Equipment Manufacturers) and CVTCORP.
– Over 200 units tested in the field
– 25,000 hours accelerated life test
Internal testing and in-field experience have led to the development of today’s transmission and achieving the level of reliability demanded from the industry. The facilities available on location can also perform accelerated testing in harsh environments that exceed industry standards and performance criteria. CVTCORP is constantly researching new designs to improve it’s software, efficiency and configurations.
The same cartridge can be on a tractor, a backhoe loader, a telehandler and a harvester.
Different software & different gearing
The CVTCORP transmission has an open architecture controller for each application that allows maximum flexibility on many vehicle types.
The Transmission Control Unit (TCU) allows seamless communication between the user, the engine and the transmission to achieve better fuel economy, reduced emissions and improved user interface, ensuring overall system optimization.
Inputs and outputs for user controls can be customized for maximum productivity and ease of use.
Special operating modes can be developed for specific applications.
Hybridization and full-electrified drivelines for construction machinery and agricultural applications are the new reality.
With the torque multiplication of the CVT then, there is a great opportunity to optimize the full powertrain and properly size motors, generators, inverters, batteries and battery management systems, resulting in smaller packages, enhanced range and reduced cost.
In fact, the use of an mCVT inside an all-electric driveline, contributes to downsize the engine, to increases torque at low speeds and to limits current peaks.
In a hybrid configuration including the mCVT, it’s possible to downsize the e-motor while perfectly combining electric and diesel power to maximize efficiency.
CVTCORP transmissions are well suited for various construction equipment. The superior performance of the mCVT in terms of fuel savings, engine downsizing, productivity improvement, improved safety and competitive cost makes it an attractive opportunity to replace hydrostatic and powershift transmissions.
The ECGenius, powered by CVTCORP, is the outcome of an agreement between CVTCORP and Bonfiglioli. Bonfiglioli is exclusively licensed to develop and sell the patented mCVT technology developed by CVTCORP, specifically for five vehicles usually ranging from 50 to 100 kW:
For more details, click here.
The rugged, simple design of the continuously variable transmission leads to long operating life with minimal maintenance. Compare the design to other CVTs and powershifts and you will quickly see that CVTCORP’s simple and elegant design adds up to significant design and cost savings.
CVTCORP’s Implement Drive is a revolutionary transmission that will serve multiple applications with one design. The truly flexible CVT can help attain higher levels of performance for a wide range of functions such as Feed Mixers.
Almost any vehicle that requires precision control, simplicity of operation and high-power input will benefit from CVTCORPs mechanical CVT. This is due to the rugged mechanical composition and the easy integration design of the transmission.
CVTCORP is a one-stop-shop with full-service capabilities ranging from product design engineering, software and controls development, validation testing, prototyping and manufacturing.
CVTCORP engineering department includes all required expertise to design complex transmission systems, including mechanical, hydraulic controls, lubrification, electronics and software and controls engineering. The engineering activities are supported by state-of-the-art CAE, simulation tools and in-house developed software.
Design validation, durability testing, life assessment
CVTCORP has 5 transmission test bays using diesel and electric motors and 8 various load configurations suitable for both performance and reliability testing. This is complemented by custom-made test equipment to assess the rolling elements durability and traction performance, various environmental testing and 2 test track set up to allow in-vehicle tests.
CVTCORP develops, tests and validates for its customers the Transmission Control Unit (TCU), including hardware design, firmware and software.
CVTCORP provides complete prototypes to its customers via in-house component manufacturing or external procurement. All prototypes go through an agreed-upon level of validation prior to customer shipment.
CVTCORP has developed extensive assembly capabilities not only for the CVT cartridge but also for full transmission systems. Assembly operations use lean manufacturing methods to optimize product flow and inventory while ensuring built-in quality using poka-yoke techniques and a cleanroom environment..
With its extensive machining capabilities, CVTCORP has the capability to make all kinds of jigs and fixtures in-house.
CVTCORP is committed to ensuring the highest quality standards in its products. CVTCORP uses industry standards in creating its Quality Management Systems. CVTCORP is working to become ISO9001 certified in 2021.
CVTCORP has developed extensive assembly capabilities not only for the CVT cartridge but also for full transmission systems. Assembly operations use lean manufacturing methods to optimize product flow and inventory while ensuring built-in quality using poka-yoke techniques and a cleanroom environment.
CVTCORP has the ability to manufacture many different components using state-of-the-art CNC turning, milling, 5 axis machining and gear machining equipment.
5 axis Mill Turn.
5 axis milling machine.
Twin spindle lathe with live tooling.
CNC Gear Shaper.
High-end CMM inspection machine.
Faro Arm + all standard tooling for part inspection.
CNC Drill Tap.