New GETRAG FWD DCT Family Based on 7DCT300 GETRAG FWD DCT Family Based on 7DCT300 Ernest DeVincent,...

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne

New GETRAG FWD DCT Family Based on 7DCT300Ernest DeVincent, Vice President Product DevelopmentGETRAG


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 – Modularity Strategy Summary Q & A

Agenda

New GETRAG FWD DCT Family based on 7DCT300

2


Current GETRAG FWD DCT Portfolio


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014

Sm

all

Mid

Hig

h

2020 2021 2022

6DCT470

6DCT450

6DCT250

Marketplace Inputs

• Increase gear counts to be availablein mid and high torque segments

• Improve launch performance andrefinement mid torque

• Need for low torque low cost DCT• Need for modular application

capability among products


FWD DCT Current Product Portfolio

Legend:

in productionin developmentto be developed

4


Creating the Next Generation FWD DCT Based on Customer and Market Requirements


CUSTOMER/OEM NEEDS

FUNCTIONALITY

FUN 2 DRIVE

COSTS

CO2 IMPROVEMENTS


Customer and Market Requirements

6


CO2 IMPROVEMENTS

Highly efficient gearset

Ratio flexibility

Intelligent gear ratio span

Power on demand actuation

Weight reduction

Extended sailing functionality

Active thermal management

7-speed needs for mid-segment

Upscale brand also need hybrid

Some require wet clutch

Drive for Best-in-Class quality

Modularity across platforms

CUSTOMER/OEM NEEDS

Shift-by-Wire

Park-by-Wire

Hybridization

Start/Stop capability

FEATURES / FUNCTIONS

Increased launch performance

Increased input speed

Improved low speed refinement

Lower inertia

FUN 2 DRIVE

COSTS

Volume of Scale

Global footprint


Customer and Market Requirements

7


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


Market Requirements GETRAG Next Generation 7DCT300 Response

8


7DCT300 Technical Overview


Key Features Next generation of 6DCT250 with global footprint (dedicated for B up 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

7DCT300 – Overview7DCT300 - Overview


10


CONFIDENTIAL / All rights reserved / Patent pending

Motor for clutch cooling pump

TCU

7DCT300 – Main ViewNew GETRAG FWD DCT Family based on 7DCT300

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CONFIDENTIAL / All rights reserved / Patent pending

Motor for pump actuator 2

Motor for shift actuator 2

Motor for shift actuator 1

7DCT300 – Side ViewNew GETRAG FWD DCT Family based on 7DCT300

12


Shift forks and linkages with push rods and shift rods

Shift drumeven gearsE-motors with

intermediate gears

Shift drumodd gears

General Electro mechanical shifting

- 2 E-motors- 2 independent shift drums- 4 shift forks- 2 linkages- 4 push rods / 2 shift rods

Many c/o parts of 6DCT250


7DCT300 – Shift Actuation

13


General Wet nested clutch designed for DMF Oil-cooling Fill-for-life (~4.0 liter) Low-viscosity oil Low interia Dedicated for downsized

engines

Technical Data 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


7DCT300 – Clutch Hardware

14


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


7DCT300 – Electro Hydraulic Actuation

15


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

des. clutchtorque

ClutchTrq transfer behavior

des. pressure

Pressure-control

- Pedal position

- Clutch temp.

- Trailer, Hill,…

act. pressure

Launch characteristic map

Base Functionality


7DCT300 – Clutch Software Controls

16


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


7DCT300 – Electronics incl. TCU

17


GETRAG Next Gen DCT ResponseCO2 IMPROVEMENTS

Highly efficient gearset

Ratio flexibility

Intelligent gear ratio span

Power on demand actuation

Weight reduction

Extended sailing functionality

Active thermal management

CUSTOMER/OEM NEEDS 7-speed needs for mid-segment

Upscale brand also need hybrid

Some require wet clutch

Drive for Best-in-Class quality

Modularity across platforms

FEATURES / FUNCTIONS Shift-by-Wire

Park-by-Wire

Hybridization

Start/Stop capability

FUN 2 DRIVE

Increased launch performance

Increased input speed

Improved low speed refinement

Lower inertia

COSTS

Volume of Scale

Global footprint


18


GETRAG Future FWD DCT Technology Roadmap


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014

Sm

all

Mid

Hig

h

2020 2021 2022

6DCT470

6DCT450

6DCT250

Marketplace Inputs

• Increase gear counts to beavailable in mid and high torquesegments

• Improve launch performanceand refinement mid torque

• Need for low torque low costDCT

• Need for modular applicationcapability among products

Legend:



FWD DCT Product Roadmap

20


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 2019

6DCT470

2014

Sm

all

Mid

Hig

h

2020 2021 2022

6DCT451

6DCT250

6DCT450

Productfreshening –updated clutch

Legend:




21


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014

Sm

all

2020 2021 2022

7DCT300

6DCT250

Mid

Hig

h 6DCT470

6DCT451

6DCT450

Market request for 7 speeds, improved refinement and launch performance

Legend:




22


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 2019

6DCT150

2014

Sm

all

2020 2021 2022

Mid

Hig

h

6DCT250

6DCT470

6DCT451

6DCT450

7DCT300

Market request forlow torque / lowcost DCT

Legend:




23


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014

Sm

all

2020 2021 2022

7DCT500

7DCT300

Mid

Hig

h

6DCT250

6DCT470

6DCT451

6DCT450

Further efficiency increase, higher torque capacity, and higher no. of gears to fulfill market requirements

6DCT150

Legend:




24


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014

Sm

all

2020 2021 2022

7DCT500

7DCT300

7HDT300

Mid

Hig

h

6DCT250

6DCT470

6DCT451

6DCT450

6DCT451

Market also requires hybrid versions

XDCT150

Legend:




25


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014

Sm

all

2020 2021 2022

7DCT500

7DCT300

7HDT300

7HDT500

Mid

Hig

h

6DCT250

6DCT470

6DCT451

6DCT450

6DCT451

Market also requireshybrid versions

XDCT150

Legend:




26


Torq

ue s

egm

ents

2012 2013 2015 2016 2017 2018 20192014 2020 2021 2022

Legend:


7DCT500

7DCT300

7HDT300

7HDT500

Mid

Hig

h

6DCT451

6DCT250

6DCT470

6DCT450

6DCT451

Sm

all

XDCT150



27


GETRAG Next Gen FWD DCT Modularity Strategy

GETRAG Drivetrain Forum, September 25, 2012, Cologne

Subsystem DCT300

Gear set 7 speed

Shift System Dual EM shift drum

Clutch DC300

Clutch Actuator Pump actuator

Park Lock Actuator Mechanical

Cooling/Lube E-motor driven pump

Oil Fuel economy and costoptimized lubricant

Hybridization, Full E-motor in transm. housing oraxle-split hynrid

Hybridization, Mild E-motor in transm. Housing

TCU Standalone TCU

Park By Wire Gear driven shift drum

Software SW features common


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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 Actuator Mechanical Mechanical

Cooling/Lube E-motor driven pump E-motor driven pump

Oil Fuel economy and costoptimized lubricant Common with DCT300

Hybridization, Full E-motor in transm. housing oraxle-split hynrid N/A

Hybridization, Mild E-motor in transm. Housing N/A

TCU Standalone TCU Standalone TCU

Park By Wire Gear driven shift drum N/A

Software SW features common SW features common


30


Subsystem DCT300 DCT150 DCT500

Gear set 7 speed 6 speed 7 speed

Shift SystemDual EM shift drum Single EM Dual shift drum

Dual shift drum (note: common drums and motors,

different linkage)

Clutch DC300 DC300 DC500

Clutch Actuator Pump actuator Pump actuator Pump actuator (higher current vs DCT300)

Park Lock Actuator Mechanical Mechanical Mechanical

Cooling/Lube E-motor driven pump E-motor driven pump E-motor driven pump

Oil Fuel economy and costoptimized lubricant Common with DCT300 Common with DCT300

Hybridization, Full E-motor in transm. housing oraxle-split hynrid N/A E-motor in transm. housing or

axle-split hybrid

Hybridization, Mild E-motor in transm. Housing N/A E-motor coaxial to clutch

TCU Standalone TCU Standalone TCU Standalone TCU (commonmotherboard)

Park By Wire Gear driven shift drum N/A Gear driven shift drum

Software SW features common SW features common SW features common


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Subsystem DCT300

Gear set 7 speed

Shift System Dual EM shift drum

Clutch DC300

Clutch Actuator Pump actuator

Park Lock Actuator Mechanical

Cooling/Lube E-motor driven pump

Oil Fuel economy and costoptimized lubricant

Hybridization, Full E-motor in transm. housing oraxle-split hynrid

Hybridization, Mild E-motor in transm. Housing

TCU Standalone TCU

Park By Wire Gear driven shift drum

Software SW features common


32


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 Actuator Mechanical Mechanical

Cooling/Lube E-motor driven pump E-motor driven pump

Oil Fuel economy and costoptimized lubricant Common with DCT300

Hybridization, Full E-motor in transm. housing oraxle-split hynrid N/A

Hybridization, Mild E-motor in transm. Housing N/A

TCU Standalone TCU Standalone TCU

Park By Wire Gear driven shift drum N/A

Software SW features common SW features common


33


Subsystem DCT300 DCT150 DCT500

Gear set 7 speed 6 speed 7 speed

Shift SystemDual EM shift drum Single EM Dual shift drum

Dual shift drum (note: common drums and motors,

different linkage)

Clutch DC300 DC300 DC500

Clutch Actuator Pump actuator Pump actuator Pump actuator (higher current vs DCT300)

Park Lock Actuator Mechanical Mechanical Mechanical

Cooling/Lube E-motor driven pump E-motor driven pump E-motor driven pump

Oil Fuel economy and costoptimized lubricant Common with DCT300 Common with DCT300

Hybridization, Full E-motor in transm. housing oraxle-split hynrid N/A E-motor in transm. housing or

axle-split hybrid

Hybridization, Mild E-motor in transm. Housing N/A E-motor coaxial to clutch

TCU Standalone TCU Standalone TCU Standalone TCU (commonmotherboard)

Park By Wire Gear driven shift drum N/A Gear driven shift drum

Software SW features common SW features common SW features common


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Transmission 6DCT150Maximum speed: 7,000 rpmMaximum torque: 170 Nm*Weight (dry): approx. 56 kg**Installation length: 350 - 355 mmInput shaft - differential: 170 mm or higherOverall ratio 1st gear: 13 – 18.5Gear ratio spread: 4.5 – 8.0

Actuators: Electro-mechanical gear actuation and electro-hydraulic clutch actuation

Transmission oil: 4 litersDual clutch Nested wet dual clutch, with interface to dual mass flywheelOther details: 3-shaft gear set layout

all-wheel application possiblemechanically actuated parking lockstart/stop- and sailing capable without hardware change


6DCT150 Technical Data

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Summary


GETRAG expands its FWD DCT portfolio to industry leadership with newmainstream products in all three torque ranges produced on threecontinents.

7DCT300 to be launched as the first of the next generation of GETRAG FWD DCT products. It has been designed to be a new industrybenchmark, achieving the most important OEM and final customerrequirements

6DCT150 and 7DCT500 achieve high degrees of commonality andmodularity 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 AUTOMOTIVE INDUSTRY


Summary

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New GETRAG FWD DCT Family Based on 7DCT300 GETRAG FWD DCT Family Based on 7DCT300 Ernest DeVincent,...

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