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

Motor for shift actuator 2

Motor for shift actuator 1

Motor for pump actuator 2

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 . 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 25 Ernest DeVincent, GETRAG Corporate Group GETRAG Future FWD DCT Technology Roadmap

7th International CTI Symposium, May 2013, Detroit 26 Ernest DeVincent, GETRAG Corporate Group FWD DCT Product Roadmap

Marketplace Inputs

Torque segments 6DCT250 Small Mid High

2012 20132014 2015 2016 2017 2018 2019 2020 2021 2022

7th International CTI Symposium, May 2013, Detroit 27 Ernest DeVincent, GETRAG Corporate Group FWD DCT Product Roadmap

6DCT470 6DCT450 NEW 7DCT500 §

NEW 7DCT300 Torque segments 6DCT250

NEW 6DCT150 § Small Mid High

2012 20132014 2015 2016 2017 2018 2019 2020 2021 2022

§ Not Intended to Indicate Introduction Timing 7th International CTI Symposium, May 2013, Detroit 28 Ernest DeVincent, GETRAG Corporate Group GETRAG Next Gen FWD DCT Family Modularity Approach

7th International CTI Symposium, May 2013, Detroit 29 Ernest DeVincent, GETRAG Corporate Group FWD DCT Family - Modularity

Subsystem DCT300

Gear set 7 speed

Shift System Dual EM shift drum

Clutch DC300

Clutch Actuator Pump actuator

Park Lock Mechanical Actuator

Cooling/Lube E-motor driven pump Oil Fuel economy and cost optimized lubricant Hybridization, Full E-motor in transm. housing or axle-split hynrid Hybridization, E-motor in transm. Housing Mild

TCU Standalone TCU

Park By Wire Gear driven shift drum

Software SW features common

7th International CTI Symposium, May 2013, Detroit 30 Ernest DeVincent, GETRAG Corporate Group FWD DCT Family - Modularity

Subsystem DCT300 DCT150

Gear set 7 speed 6 speed

Shift System Dual EM shift drum Single EM Dual shift drum

Clutch DC300 DC300

Clutch Actuator Pump actuator Pump actuator

Park Lock Mechanical Mechanical Actuator

Cooling/Lube E-motor driven pump E-motor driven pump Fuel economy and cost Oil Common with DCT300 optimized lubricant E-motor in transm. housing or Hybridization, Full N/A axle-split hynrid Hybridization, E-motor in transm. Housing N/A Mild

TCU Standalone TCU Standalone TCU

Park By Wire Gear driven shift drum Shift Drum Actuated

Software SW features common SW features common

7th International CTI Symposium, May 2013, Detroit 31 Ernest DeVincent, GETRAG Corporate Group FWD DCT Family - Modularity Subsystem DCT300 DCT150 DCT500 Gear set 7 speed 6 speed 7 speed Shift System Dual shift drum (note: Dual EM shift drum Single EM Dual shift drum common motors, different drums and linkage) Clutch DC300 DC300 DC500 Pump actuator (higher Clutch Actuator Pump actuator Pump actuator current vs DCT300) Park Lock Mechanical Mechanical Mechanical Actuator Cooling/Lube E-motor driven pump E-motor driven pump E-motor driven pump Fuel economy and cost Oil Common with DCT300 Common with DCT300 optimized lubricant Hybridization, E-motor in transm. housing E-motor in transm. housing N/A Full or axle-split hynrid or axle-split hybrid Hybridization, E-motor in Trans Housing N/A E-motor in Trans Housing Mild Standalone TCU (common TCU Standalone TCU Standalone TCU motherboard) Park By Wire Gear driven shift drum Shift Drum Actuated Shift Drum Actuated Software SW features common SW features common SW features common

7th International CTI Symposium, May 2013, Detroit 32 Ernest DeVincent, GETRAG Corporate Group 6DCT150 Technical Data

Transmission 6DCT150 Maximum speed: 7,000 rpm Maximum torque: 170 Nm Weight (dry): approx. 56 kg Installation length: 350 - 355 mm Input shaft - 170 mm or higher differential: Overall ratio 1st gear: 13 – 18.5 Gear ratio spread: 4.5 – 8.0 Electro-mechanical gear actuation and Actuators: electro-hydraulic clutch actuation Transmission oil: 4 liters Dual clutch Nested wet dual clutch Other details: 3-shaft gear set layout all-wheel application possible mechanically actuated parking lock start/stop- and sailing capable without hardware change

7th International CTI Symposium, May 2013, Detroit 33 Ernest DeVincent, GETRAG Corporate Group 7DCT500 Technical Data

Transmission 7DCT500 Maximum speed: 7,500 rpm Maximum torque: 560 Nm Weight (dry): approx. 87 kg Installation length: approx. 380 mm Input shaft - 197 mm or higher differential: Overall ratio 1st gear: 13.8 - 17.5 Gear ratio spread: 6.7 - 8.5 Electro-mechanical gear actuation and Actuators: electro-hydraulic clutch actuation Transmission oil: approx. 6 liters Dual clutch Nested wet dual clutch Other details: 4-shaft gear set layout all-wheel application possible mechanically actuated parking lock shift and park by wire optional start/stop- and sailing capable without hardware change

7th International CTI Symposium, May 2013, Detroit 34 Ernest DeVincent, GETRAG Corporate Group Summary

7th International CTI Symposium, May 2013, Detroit 35 Ernest DeVincent, GETRAG Corporate Group Summary

. GETRAG expands its FWD DCT portfolio with new mainstream products in all three torque ranges, produced on three continents. . 7DCT300 to be launched as the first of the next generation of GETRAG FWD DCT products. It has been designed to be a new industry benchmark, achieving the most important OEM and final customer requirements . 6DCT150 and 7DCT500 achieve high degrees of commonality and modularity of key subsystems from 7DCT300  Common customer interfaces for clutch actuation, shift actuation and park by wire. TCU interface commonality under development . Full line of derivative hybrid offerings in mid and high torque segments

GETRAG WILL HAVE THE MOST COMPLETE LINE OF DCT PRODUCTS AVAILABLE IN THE GLOBAL AUTO INDUSTRY

7th International CTI Symposium, May 2013, Detroit 36 Ernest DeVincent, GETRAG Corporate Group Q & A

7th International CTI Symposium, May 2013, Detroit 37 Ernest DeVincent, GETRAG Corporate Group