Active on-demand AWD systemIntelligent Torque-controlled Coupling
CAT.NO.D1002E-1
01 02
Stable, Smooth and Highly Efficient Transmission of Power Expanding the possibilities of AWDWeather conditions, vehicle use, driver's intentions… Calculating every element to ensure that all four tires are firmly hugging the road under ever-changing conditions.Expanding the ability of more and more vehicles to give the driver that true feeling of confidence and driving pleasure. Our goal is to deliver that experience to everyone! With this in mind, JTEKT has reduced size and weight while simultaneously improving reliability in the production of ITCC*: electronically controlled coupling for AWD vehicles.
Continuing the Evolution of JTEKT ITCCExcellent response and powerful torque drawing the maximum potential of all four wheels
From differential sensitive on-demand coupling (RBC) to the recently developed active on-demand AWD system (ITCC), automotive manufacturers around the world are using JTEKT AWD systems
ITCC…
ITCC History
Continuously evolving since beginning of mass-production, the third-generation system (Gen 3) introduces epoch-making improve-ments in performance and durability.
ITCC Evolution
Intelligent Torque Controlled Coupling
1985 1995 2000 2005 2010 2015 20201990
19901985
1980
1980 1995 20001998 2005 2010 2015 2020
AWD for daily use
Part-time Full-time
Developmentstarted Generation1
Generation 2
Performance
AWD mark
et tre
nds
ITCC ev
olutio
n
AWD market trends
The continuous evolution of active on-demand AWD is based on a quest with a single theme: consider-ation of every aspect to deliver optimum torque to each of the four wheels, front and back, left and right. At the core of this torque management is JTEKT's electronically controlled AWD coupling, ITCC.※1 Capable of responding instantaneously, safe and controllable, ITCC offers continuous control of the driving force delivered to the front and rear wheels, from 100:0 (front:rear) to 50:50 (front:rear). As a result of the unparalleled results achieved for both high fuel efficiency and traction performance, ITCC is now installed in many AWD vehicles, and holds No. 1 market share in the world.※2 Its superior installation ease, drive force transfer efficiency and wide-ranging load capacity are key factors supporting the development of AWD systems.
※1) ITCC:Intelligent Torque Controlled Coupling . ITCC is a registered trademark of JTEKT Corporation.※2) As of Jan. 2014, in-house study
Generation 3Reliability further enhanced through longer services life
Torque precision further improved
・DLC-coated control clutch introduced・Special high-performance ITCC fluid
introduced
・Newly developed control clutch introduced
Active on-demand
Improved fuel efficiency
Active on-demand (lightweight driveline)
Generation1
Generation 3
Improvements in AWD operation
Differential-speed sensitive on-demand
Generation 2
Safety Factors
03 04
Structure Operating principle
Transfer case
Transmisson
Rear differential
Propeller shaft
Front differential
・Electromagnetic clutch adopted, realizing reductions in size and weight.・Components broadly divided into five sections: Input case, main clutch, electromagnetic clutch, cam mechanism and output shaft.
ITCC structure
In vehicles with a FWD configuration, the ITCC is installed in front of the rear differential; the active on-demand (active torque split) AWD system providing optimum torque distribution to the front and rear wheels. This contributes to ensur-ing both high fuel efficiency and superior driving performance.
Rear differential
Main clutch section
Input case
Fluid
Main cam
Armature
Control clutch
Rear housing
Control cam
Output shaft
Electromagnetic coil
Cam mechanism
Electromagnetic clutch sectionITCC cross-section
Input case
Main clutch section
Electromagnetic clutch section
Cam mechanism
Output shaft
Based on signals from each sensor in the vehicle, such as wheel speed sensors, etc., the ECU analyzes driver operation and road surface conditions, and then ITCC transfers the appropriate torque to the output shaft according to the electrical current from the ECU.
ITCC Operating PrincipleITCC Installation Layout
●Electrical current to torque (I-T) characteristics
ECU
Control current=OFF
Control current=ON
1
2
3
4
Current applied to coil Generate magnetic flux Armature suction
Generate control torque
Cam actuated Pressure on main clutch
5
6
Torque transmitted from input case to output shaft
●Torque transmission flow
Output torque acquired is approximately proportional to the electrical current.
When in 2WD (normal driving)
Sensors for four wheel speeds, throttle position, etc.
ECU automatically analyzes signals from wheel speeds and other sensors, and continuously adjusts the driving force (e.g., 100:0~50:50) to the front and rear wheels according to driver operation and road surface conditions.
ECU
ITCC
Main camControl cam
Ball
Main clutchArmature
Control clutch
ECU
ECU
4 Control torque(generation of frictional torque on control clutch)
6 Main clutch pressure
5 Cam sectionTorque
1 Control current
2 Magnetic flux3 Armature suction force
When in AWD (front wheels slip)
Example of on-demand AWD mounted in FWD configurationIn this mounting example, the ITCC is located in front of the rear differential and the vehicle normally runs with the front-wheel-drive. The ECU receives signals from each sensor, analyzes driving and road surface conditions, and controls the electrical current sent to the ITCC, which then transfers the optimal torque to the rear wheels based on various conditions.
Out
put t
orqu
eElectrical current
Engine
ITCC
ITCC
Transfer case
Transmisson
05 06
Features Driving Performance
Driving Performance with ITCC
Lightweight/Compact size contributes to higher fuel efficiency
Superior durability and quietness have been realized, contributing to a confident, comfortable drive.
ITCC can be used in large-sized vehicles where the clutch is subjected to large load, and the amorphous carbon film contributes to both reducing size and increasing service life.
Newly developed control clutch, further improved torque precision and lighter driveline contribute to higher fuel efficiency.
Aiming to improve durability, a special fluid has been introduced that makes it possible to reduce the number of clutch plates to lighten the weight. Additionally, compared to conventional automatic transmission fluid (ATF), AWD coupling performance has been improved, thereby contributing to quietness of eco-cars.
■Special high-performance ITCC fluid introduced
ITCC AWDDesired driving line Neutral steer
Rigid AWDOversteer
2WD( FF )Understeer
Standing-start full-throttle acceleration on ice floe
Vehicles equipped with ITCC exhibit a standing-start acceleration performance equivalent tothat of rigid AWD.
Vehicles equipped with ITCC exhibit brilliant handling stability even on a slippery surface.
Traction performance Handling performance/Stability
FWD base electronically controlled
AWD coupling world share
No.1※1
Superior traction and maneuverability
Lighter driveline and improved fuel efficiency
Excellent compatibility with ABS and stability control systems
● Optimum driving force distributed based on road surface and driving conditions ● Compact, lightweight system
ITCCAWD
Rigid AWD
2WD( FF )
※1)As of Jan. 2014, in-house study
Lon
gitu
dina
l ac
cele
ratio
n(m
/s2 )
Yaw
rate
(rad
/s)
0
1
2
3
4
・ Ice surface・ Acceleration: Stop→WOT(wide open throttle)
・Ice surface・Accelerate from 30km/h
Time (s) Time (s)
2WD( FF )
2WD( FF )
Neutral steer
Rigid AWD
0 1 2 3 4 5 00
0.05
0.1
0.15
0.2
0.25
1 2 3 4 5
ITCC: Equivalent to rigid AWD
Direct-coupled AWD
ITCC: Ideal neutral steer
■Launch performance
ITCC Features
Introduction of an electromagnetic clutch enabled reductions in weight, size and electricity consumption, contributing to improved fuel efficiency.
Remarkable anti-shudder performance contributes further to quietness.
●Newly developed control clutch
■Control clutch coated with diamond-like carbon (DLC) introduced
■Newly developed control clutch introduced
ECU
■Cornering performance
●Durability results using special high-performance ITCC fluid
Gen1 Gen2Serv
ice lif
e du
rabi
lity (h
) Improved 1.4-fold
●DLC-coated control clutch
DLC coating
Oil groove shape optimized Oil groove shape optimized
Based on extensive experience, ITCC control contributes to reducing abnormal noises (e.g., driveline torsional vibration, driveline chattering, etc.) generated by the vehicle.
07 08
Control System Development Bases
Driveline component manufacturing
Steering manufacturing
Bearing manufacturing
Technical centers
Sales
Machine tool sales & service
Regional headquarters 1
4
2
9
3
3
1
Machine tool sales & service 1
NORTH AMERICA
Driveline component manufacturing
Steering manufacturing
Bearing manufacturing
Technical centers
Sales
Machine tool sales & service
Regional headquarters 1
7
1
6
4
8
2
EUROPE
Machine tool manufacturing
Steering manufacturing
Technical centers
Sales
2
1
1
2
SOUTH AMERICA
Driveline component manufacturing
Steering manufacturing
Bearing manufacturing
Machine tool manufacturing
Technical centers
Sales
3
3
5
1
3
24
JAPAN
Nagoya Osaka
Head Office
名古屋 大 阪
ITCC Control System Features
Optional control including driveline lightening and improving vehicle vibration/noise performance is available
AWD basic control
Coordinate with other electronicallycontrolled devices・ABS and stability
control systems
Driving mode judgment
Drivetrain systemInput torque control
Highly accurate control
Road surface condition judgment
DrivelineVibration/
noise reduction
The ITCC electromagnetic clutch is highly responsive, making it easy to coordinate control with various vehicle control systems (ABS and stability control systems), etc.
■Rear differential
ECU automatically analyzes sensor signals such as wheel speed, etc., and the driving force to the front and rear wheels can be varied continuously from 100:00 to 50:50 depending on driver operation and road surface conditions
■Intelligent Torque Controlled Coupling
■Wheel Speed Sensor
■Wheel Speed Sensor
■Throttle Position Sensor
■AWD Mode Select Switch
■Wheel Speed Sensor
■Wheel Speed Sensor
■ECU for Controlling ITCC
ITCC system layout
In situations such as driving in the city and on snowy roads, the simple ITCC system improves vehicle controllability and contributes to safe, confident driving.
Torque vectoring unit installation example
In addition to the function that distributes optimum torque to the rear wheels depending on vehicle operation and driving conditions, the system can also freely distribute torque to the right and left rear wheels. When cornering, large torque can be distributed to the outer rear wheel to produce yaw moment that suppresses understeer, thereby enabling the vehicle to hold the desired cornering line. Quick response to steering operation realizes sporty handling performance.
Torque Vectoring Unit Adaptation
Extended Use Example Based on ITCC
Ensuring the delivery of safer, more secure electronically controlled AWD couplings to customers around the world
Using wheel speed signal, throttle position signal, etc. that come as standard equipment in the vehicle, ITCC basic control logic compatible with traction performance and tight corner binding avoidance is developed
ITCC basic control
logic
■Easily coordinate control with other control systems
Sales 1
OCEANIA
Driveline component manufacturing
Steering manufacturing
Bearing manufacturing
Technical centers
Sales
Machine tool sales & service
Regional headquarters 2
11
4
11
2
12
Machine tool manufacturing 1
9
ASIA
Ensuring the Delivery of Safer,
More Reliable
Power Steering Systems
JTEKT has been conducting activities to ensure compliance with functional safety standards in accordance with ISO26262 Road Vehicles – Functional Safety since 2005.
Japan
・Projectmanagement・Labor
management
・Requirementsmanagement・Specifications
management
Activities started(2005)
Global organizationestablished
(2009)
Developmentprocess
introduced(2011)
Activities streamlinedusing management tool
(2013)
America
Europe
・Processmanagement・Structure
management
Transfer case
Transmisson
Rear differential(Torque Vectoring Unit)
Front differential
Control current
ECUITCC
Engine Propeller shaft
B
C
D
E
FA
F Noise Evaluation CourseFording CourseD Administration / Maintenance BuildingE Dynamics Pad
Straight-line CourseA Winding CourseB
C
Fully utilizing our knowledge as a world-leading systems supplier, JTEKT conducts driving evaluations and analyses of products installed in vehicles. We exhaustively pursue the highest standards in product safety and operation on a test course capable of simulating various road and weather conditions around the world. As a total systems supplier, our highest value is to provide our customers with products that deliver outstanding performance and the best quality that help to make automobiles that are more than just fun to drive.
Advanced R&D producing next-generation electronically controlled AWD couplings
JTEKT R&D centers exchange information around the world, enabling the company to accurately understand market demand and provide the newest/best/optimal systems to meet the diversified needs of our customers.
ITCC performance tester (equipped with gradient function)
ITCC durability tester
ITCC performance tester
Low-friction grade
Driving simulator
OFFICES
■JTEKT CORPORATION NAGOYA HEAD OFFICENo.7-1, Meieki 4-chome, Nakamura-ku, Nagoya, Aichi 450-8515, JAPAN TEL:81-52-527-1900 FAX:81-52-527-1911
■JTEKT CORPORATION OSAKA HEAD OFFICENo.5-8, Minamisemba 3-chome, Chuo-ku, Osaka 542-8502, JAPAN TEL:81-6-6271-8451 FAX:81-6-6245-3712
■Sales & Marketing HeadquartersNo.5-8, Minamisemba 3-chome, Chuo-ku, Osaka 542-8502, JAPAN TEL:81-6-6245-6087 FAX:81-6-6244-9007
PUBLISHER
www.jtekt.co.jp
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・Course area: 170,000m2
・Combined circuit length: 2,200m・Dynamics Pad area: 54,000m2
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■JTEKT (CHINA) CO., LTD. Shanghai BranchRoom 25A2, V-CAPITAL Building, 333 Xianxia Road, Changning District, Shanghai 200336, CHINATEL : 86-21-5178-1000FAX : 86-21-5178-1008
■JTEKT (CHINA) CO., LTD. Beijing BranchRoom 1012, Fortune Building, No.5 Dong SanHuan North Road, Chaoyang-District, Beijing, CHINATEL : 86-10-6538-8070FAX : 86-10-6538-8077
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Energieweg 10a, 2964 LE, Groot-Ammers, THE NETHERLANDSTEL : 31-184-606800FAX : 31-184-606857
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Electromagnetic Anechoic Chamber
Vehicle evaluation in cold regions
Iga Proving Ground Enables Testing / Evaluations Simulating Roads Worldwide
09 10
Research Facilities Contact
CAT.NO.D1002E-1Printed in Japan '15.08-12BCH(’14.04)