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8/6/2019 China Autoshow 2004 - Guenter
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Powertrain New Technologies and Solutions
The Key Systems for Dual Clutch Transmissions
June 12, 2004
BorgWarner Transmission Systems GmbH, Germany
Powertrain Trends
Higher Environmental Requirements
Better Fuel Efficiency Demand
Increasing Engine Torque / Power and NarrowingUsable RPM Range for Gas DI Engines and DIDiesels (=> More Gears)
Higher Gas Engine Speeds
Higher Comfort Expectations
AWD Systems as Safety and Vehicle DynamicsFeature
More and Different Transmission / PowertrainConcepts
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Transmission Comfort vs. Fuel Efficiency Comparison
5
6
7
8
9
10
0 5 10 15Fuel Savings %
ComfortRating
CVTAT 6 speed
Wet DCT
AT 5 speed
AMT6 speed
Goal
Dry DCT
MT
6 speed
6 Speed AMT
6 Speed Dry DCT
6/7 Speed Wet DCT
6 Speed Step AT
CVT
SUV
CommercialVans
Fullsize(C)
High
EndPerformance(DP)
H
ighEndTraditional(D)
SportsCars
Micro-Cars(A00)
SubCompact(A0)
Compact(A)
Midsize(B)
Preferred Transmission Application by Market Segment
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CVT 1.5%AMT 4.6%
MT 68.7%
Step AT24.3%
2004
MT 62.4%
2009
DCT 0.9%
MT 59.2% Step AT22.3%
CVT 1.8%
AMT 7.1%
DCT 9.6%
MT 45%
AMT 18%
DCT 16%
2013
MT 52%
Step AT20%
DCT 16%
CVT 2%
AMT 10%
Transmission Technology Shift in Europe
13
5R
2
6
42
6
4
Differential
Damper Clutch
Inner Shaft
Dual
Hollow Shaft
Dual
Hollow ShaftHollow Shaft
EngineEngineTorqueEngineTorque
DCT Schematic
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6. Gear 5. Gear
4. Gear 3. Gear 1. Gear(active)
2. Gear(Preselected)
Engine
Input Shaft 1
Input Shaft 2
Differential
Clutch 2
Clutch 1
Output toDifferential
Output toDifferential
Reverse Gear
DCT Layout
Very Good Fuel Efficiency
Are Fun to Drive (Responsiveness /Accelaration, Engineand Drivetrain Decoupling Possible)
Good Shift and Launch Quality (Programmable / AdjustableControl Strategy)
Offers Large Variety of Gear Ratios and Ratio Spread forPerfect Adaptation to Engines and Vehicles at MinimalOncost
The Only AT Addressing all New Engine Trends (HighTorque TDI and High Power / High Speed Gas Engines)
Compact Design and Packaging and Low Weight
DCT Drivers
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Existing (OEM) Investment in MT Technology
Competitive Pricing (MT
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VW / Audi DSG (DCT) Transmission
Transmission Efficiency & Performance
0
20
4060
80
100
120
140
160
180
200
0 30
0,0 5,0 10,0 15,0 20,0 25,0
DCT
MTDCT: 10.3 l/100 km
Manual: 11.5 l/100 km
Top Speed:Manual 247 km/h / 154 mphDCT 247 km/h / 154 mph
Time
Speed Manual
DCT
Source: VW
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BW DualTronic Systems Solutions
DualTronic
BorgWarner DCT Sub-Modules
Dual Clutch and Damper
Synchronizer Systems
Mechatronic Transmission Control Module
Hydraulic Pump
DualTronic Clutch Module
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55 kW 750 kW
DualTronic Clutch System Application Range
External Dry Damper Integrated BW-Damper
Oil VapourGrease
EngineEngine
Torsional Vibration Damper
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DualTronic Torsional Vibration Damper
Stable Damper Characteristics overLifetime
Minimal Temperature Impact onPerformance
Excellent Vehicle Response andEngine Agility through Low Inertia
Simplified System Tuning inCombination with DualTronicClutch Module
Space Efficient Packaging whenIntegrated with DualTronic ClutchModule
Engine Vibration Damping without Damper
Higher Clutch Slip:
Slip Loss ~ 4.5 kW
Lower Clutch Slip
Slip Loss ~ 3.5 kW
Conclusion:
Torsional vibration damping through clutch slip only is doablebut not economical
Cost effective TVD supported by clutch slip control in criticaloperation conditions only is the overal most efficient solution
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Wet Clutch Dry Clutch
Max. Launch Heat Capacity240 kJ
120 kJ
Efficient DualTronic XCT Clutch CoolingLaunch Clutch Performance Comparison
0
2
4
6
8
10
R
elative
Launch
Perform
ance
Dry Clutch Wet Clutch
Basis: Repeated WOT Launches
Wet vs. Dry DCT Efficiency Comparison
7,89 7,79
0
2
4
6
8
10
FuelConsumption
[l/100km]
Wet DCT Dry DCT
NEFZ (MPEG) DCT Fuel Consumption Simulation
Power Consumption for Clutch and Shift Actuation included
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DCT Synchronizer System
DCTs do not Require a Synchronizer
System Design Change from a Manual
Base Transmission
Utilizing BWs Composite
Friction Material on the Synchronizers
Simplifies the Transmission Fluid
Development
BW Synchronizer Allow for SmallerPackaging (No Lining Wear)
Dualtronic Mechatronic Transmission Controls
Clutch PressureControl Solenoids
Gear ActuatorSolenoids
Line RegulatorSolenoid
Lube RegulatorSolenoid
Cut-offSolenoid
Cut-offSolenoid
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DualTronic Mechatronic Module
Hydraulic Controls + Electronic Controls = Mechatronic Module:
Integrates All Necessary Control Components
Provides All Transmission Control Functions
+=
Lower Cost/Simplified Assembly/Improved Packaging
Increased Performance /Reliability, Only One Connector to the Vehicle/Engine
CAN-BUS System
Dual Clutch Transmission Pump Options
Fixed Displacement Pumps
Single Stage Pump (14 to 18 cm/rev)
- Single Rotor (Spur Gear, Gerotor)
- Lowest Cost
Binary Pump
- Dual Rotor
- Lower Idle Speed, Improved Efficiency
Variable Displacement Pump
- Maximum Efficiency
- Increased Complexity
Pump on Demand
- Supplemental Oil Supply, Start/Stop Enabler
- Improved Efficiency with 42 Volt System
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Summary
Environmental Requirements and Government RegulationsNecessitate New Transmission Technology
DCTs are the Only Automatic Transmissions Addressing AllNew Engine Trends
DCTs are The First Automatics in the Market to Provide theEntire Drive Comfort of a Traditional Step-Automatic, BetterFuel Efficiency then Manuals and a Very Responsive, Fun toDrive Experience
DCTs are Cost Competitive, in Particular when Existing OEMInvestment in Manual Transmission Manufacture can be
Utilized Existing OEM Manual Transmission Technology and BW Wet
Clutch and Transmission Controls Technology Enables ShortTime to Market
DualTronic
The Key Systems for Dual Clutch
Transmissions
Thank You for Your Attention.