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GETRAG DCT New Modular Platform from 100Nm to 500 Nm

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GETRAG DCT New Modular Platform from 100Nm to 500 Nm GETRAG DCT New Modular Platform From 100Nm to 500 Nm Ernest DeVincent, VP Engineering and Global Platform Director DCT300 7th7th InternationalInternational CTI CTI Symposium, Symposium May 2013, May Detroit 2013, Detroit 1 Ernest DeVincent, GETRAG Corporate Group Agenda . Current GETRAG Front Wheel Drive DCT Portfolio . Creating the Next Generation FWD DCT Based on Customer and Market Requirements . 7DCT300 – The Anchor of the Next Gen DCT Plan . GETRAG Future FWD DCT Technology Roadmap . GETRAG Next Gen DCT Family – Family Modularity Approach . Summary . Q & A 7th International CTI Symposium, May 2013, Detroit 2 Ernest DeVincent, GETRAG Corporate Group Current GETRAG FWD DCT Portfolio 7th International CTI Symposium, May 2013, Detroit 3 Ernest DeVincent, GETRAG Corporate Group FWD DCT Current Product Portfolio Marketplace Inputs • Increase gear counts to be available in mid and high torque segments • Improve launch performance and refinement mid torque 6DCT470 • Need for low torque low cost 6DCT450 DCT • Need for modular application capability among products Torque segments 6DCT250 Small Mid High 2012 20132014 2015 2016 2017 2018 2019 2020 2021 2022 7th International CTI Symposium, May 2013, Detroit 4 Ernest DeVincent, GETRAG Corporate Group Creating the Next Generation FWD DCT Based on Customer and Market Requirements 7th International CTI Symposium, May 2013, Detroit 5 Ernest DeVincent, GETRAG Corporate Group Customer and Market Requirements CO2 IMPROVEMENTS FUN 2 DRIVE COSTS CUSTOMER/OEM NEEDS FUNCTIONALITY 7th International CTI Symposium, May 2013, Detroit 6 Ernest DeVincent, GETRAG Corporate Group Translating Customer and Market Requirements CO2 IMPROVEMENTS FUN 2 DRIVE . Highly efficient gearset . Increased launch performance . Ratio flexibility . Increased input speed . Intelligent gear ratio span . Improved low speed refinement . Power on demand actuation . Lower inertia . Weight reduction COSTS . Extended sailing functionality . Volume of Scale . Active thermal management . Global footprint CUSTOMER/OEM NEEDS . 7-speed needs for mid-segment FEATURES / FUNCTIONS . Upscale brand also need hybrid . Shift-by-Wire . Some require wet clutch . Park-by-Wire . Drive for Best-in-Class quality . Hybridization . Modularity across platforms . Start/Stop capability 7th International CTI Symposium, May 2013, Detroit 7 Ernest DeVincent, GETRAG Corporate Group Market Requirements Next Gen 7DCT300 . Improved Launch Performance and Fun to Drive: - Clutch primary inertia reduction of up to 70% - Thermal capacity increase by 300% - Higher input speed 7,000 rpm 7,500 rpm . Higher Fuel Economy Overall improvement of 4% over 6DCT250 - Gear ratio count 6 7 - Intelligent gear ratio span 7.2 > 8.5 - Low viscosity oil . Weight improvement: - 71 kg 65 kg (dry, with TCU) . Improved Driveability & NVH Refinement: - Higher torque control accuracy of wet double clutch . Features that Customers want and demand of next gen product: - Hybrid…AWD….Park By Wire…Integrated cooling….Reduced vehicle level cost Result = NEXT Generation Benchmark Transmission 7th International CTI Symposium, May 2013, Detroit 8 Ernest DeVincent, GETRAG Corporate Group 7DCT300 Technical Overview 7th International CTI Symposium, May 2013, Detroit 9 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Overview Key Features . Next generation of 6DCT250 with global footprint (B to D-segment) . Input torque 300 Nm . target dry weight 65kg (w/o DMF) . Wet nested dual clutch . 7-speed + R with a possible gear ratio span of ~ 8.5 . Mechanical park lock . Electro mechanical gear actuation . Electro hydraulic clutch actuation . Electrical on-demand cooling . Start/Stop functionality (no hardware modification) Optional Features . HEV (Mild- to Plug-In) . AWD . Integrated Park-by-Wire . Integrated transmission cooling 7th International CTI Symposium, May 2013, Detroit 10 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Overview TCU Motor for clutch cooling pump CONFIDENTIAL / All rights reserved / Patent pending 7th International CTI Symposium, May 2013, Detroit 11 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Overview Motor for shift actuator 2 Motor for shift actuator 1 Motor for pump actuator 2 CONFIDENTIAL / All rights reserved / Patent pending 7th International CTI Symposium, May 2013, Detroit 12 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Transmission length 10,8 215,1 165 380,1 7th International CTI Symposium, May 2013, Detroit 13 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Gear Layout 3 5 4 R Key Features . Centerdistance: - 183 mm - 188 mm available for AWD - 197 mm dedicated for AWD . Gear ratio span of > 8.5 possible - Shortest 1st gear: ~18 - Longest 7th gear: 1.87 . Max. output torque: 7 6 - 4,500 Nm 1 2 7th International CTI Symposium, May 2013, Detroit 14 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Gear Layout R 4 5 3 2 6 7 1 7th International CTI Symposium, May 2013, Detroit 15 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Shift Actuation General E-motors Shift drum . Electro mechanical shifting with even gears intermediate -2 E-motors gears - 2 independent shift drums - 4 shift forks - 2 linkages - 4 push rods / 2 shift rods . Many c/o parts of 6DCT250 Shift forks and linkages Shift drum with push odd gears rods and shift rods 7th International CTI Symposium, May 2013, Detroit 16 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Clutch Hardware General . Wet nested clutch designed for DMF . Oil-cooling . Fill-for-life (~4.0 liter) . Low-viscosity oil PICTURE . Low interia Dedicated for downsized LIMITED TO . Engines ON-SCREEN Technical Data VERSION . Maximum engine speed 7,500 rpm . Friction surfaces C1=6 / C2=8 . Torque capacity 300 Nm @ ~10bar . Similar clutch gain of 34 Nm/bar for both clutches . Stroke point of 1,5 bar . Weight 7 kg incl. support 7th International CTI Symposium, May 2013, Detroit 17 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Electro Hydraulic Actuation General . Robust design concept with development history . Robust manufacturing concept not requiring clean rooms . Independent control of each clutch - One electric motor drives one gerotor pump - Fast filling with low pressure and high volume - Excellent controllability enables comfortable and sporty shifting - Significantly improved off idle and creep control Clutch Cooling . Electrical on-demand oil-pump (low pressure) . Dedicated for extended sailing functionality . Optional integrated transmission cooler for severe applications 7th International CTI Symposium, May 2013, Detroit 18 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Hydraulic Schematic Clutch cooling system Actuation system for clutch 1 E-Cooling pump Actuation system for clutch 2 PICTURE LIMITED TO ON-SCREEN Pressure sensor VERSION Electric pump Orifice Temperature sensor Suction filter 7th International CTI Symposium, May 2013, Detroit 19 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Design of Clutch Actuator Pump . Gerotor pump placed on motor shaft . Stand alone pump housing to ensure high quality of pressure control . Separated pressure and suction line from the sump to the clutch to avoid interactions in-between pumps during operation PICTURE LIMITED TO ON-SCREEN VERSION 7th International CTI Symposium, May 2013, Detroit 20 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Clutch Software Controls . Base functionality is running in several series programs - 7DCI700 (BMW) - 7DCL750 (Ferrari) - 6DCT450/470 (Ford, Volvo, Mitsubishi, …) . Pump low level control has SOP 12/2012 7th International CTI Symposium, May 2013, Detroit 21 Ernest DeVincent, GETRAG Corporate Group 7DCT300 – Electronics incl. TCU General . Stand-alone TCU mounted to transmission housing . External wiring harness mounted on transmission . Interfaces comparable to existing 6DCT250 Transmission control unit . Power electronics - 5 power stages for BLDC motors (shift/clutch/cooling) . Processor - ~160 MHz - ~ 2.5 MB flash Sensors . 2 pressure . 1 oil temperature . 2 input speed (1 with direction) + 1 optional output speed . Transmission range sensor 7th International CTI Symposium, May 2013, Detroit 22 Ernest DeVincent, GETRAG Corporate Group 7DCT300 Optional Integrated Park by Wire General . Usage of shift-drum 2 to engage/disengage park lock . Normally-stay park lock Gear wheel actuation of parking lock via shift drum PICTURE LIMITED TO ON-SCREEN VERSION Parking lock system based on 6DCT250 Shift drum 2 design w/o external park E-motor R/2/4/6 gear for shift drum 2 lock lever and rooster comb 7th International CTI Symposium, May 2013, Detroit 23 Ernest DeVincent, GETRAG Corporate Group 7DCT300 Optional Integrated Cooling General . The integrated cooler is a water to housing cooler . Engine cooling fluid is used within clutch housing . Transmission cooling behaviour can be controlled by clutch cooling Options . Active thermal management of the transmission Water Inlet PICTURE water LIMITED TO ON-SCREEN oil VERSION Water Outlet 7th International CTI Symposium, May 2013, Detroit 24 Ernest DeVincent, GETRAG Corporate Group Next Gen 7DCT300 Results CO2 IMPROVEMENTS FUN 2 DRIVE . Highly efficient gearset . Increased launch performance . Ratio flexibility . Increased input speed . Intelligent gear ratio span . Improved low speed refinement . Power on demand actuation . Lower inertia . Weight reduction . Extended sailing functionality COSTS . Active thermal management . Volume of Scale . Global footprint CUSTOMER/OEM NEEDS . 7-speed needs for mid-segment FEATURES / FUNCTIONS . Upscale brand also need hybrid
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