Mps6 Dct Ford Dtf 2012 04 Dct300

New GETRAG FWD DCT Family B ased o n 7DC 7DCT300 T300 Ernest DeVincent, DeVincent, Vice Presid President ent Produc t Develop Develop ment GETRAG © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne

New GETRAG FWD DCT Family based on 7DCT300

Ag A g end en d a 

Curren Currentt GETRAG GETRAG Front Front Wheel Wheel Drive Drive DCT Port Portfol folio io



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



7DCT 7DCT30 300 0 – The The Anch Anchor or of of the the Next Next Gen Gen DCT DCT Pla Plan n



GETRAG Future FWD DCT Technology Roadmap



GETRAG GETRAG Next Gen DCT Family Family – Modularity Modularity Strategy Strategy



Summary



Q &A

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

2

Curren Currentt GETRAG GETRAG FWD DCT DCT Portfo Portfolio lio © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne


FWD DCT Current Produ ct Portfolio Marketplace Inputs

•

s t n e m g e s e u q r o T

h g i H

Increase gear counts to be available in mid and high torque segments • Improve launch performance and refinement mid torque • Need for low torque low cost DCT • Need for modular application capability among products

6DCT470 6DCT450

d i M

6DCT250

l l a m S

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022

Legend: in production in development to be developed © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne

4

Creating the Next Generation FWD DCT Based on Customer and Market Requirements © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne


Customer and Market Requirements FUN 2 DRIVE CO2 IMPROVEMENTS

COSTS

CUSTOMER/OEM NEEDS

FUNCTIONALITY


6


Customer and Market Requirements CO2 IMPROVEMENTS 

Highly efficient gearset

 Ratio

flexibility

FUN 2 DRIVE 

Increased launch performance



Increased input speed Improved low speed refinement



Intelligent gear ratio span





Power on demand actuation

 Lower



Weight reduction



Extended sailing functionality



Active thermal management

inertia

COSTS  Volume  Global

of Scale

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

7


Market Requirements 





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

Higher Fuel Economy



7,500 rpm

Overall improvement of 4% over 6DCT250

Gear ratio count 6

-

Intelligent gear ratio span 7.2

-

Low viscosity oil



7 

> 8.5

Weight improvement: 71 kg



65 kg (dry, with TCU)

Improved Driveability & NVH Refinement: -





-



GETRAG Next Generation 7DCT300 Response

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

8

7DCT300 Technical Overview © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne


7DCT300 – Overview 7DCT300 - 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


10


7DCT300 – Main View

TCU

Motor for clutch cooling pump

CONFIDENTIAL / All ri ght s reserved / Patent pend ing © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne

11


7DCT300 – Side View Motor for shift actuator 2

Motor for shift actuator 1

Motor for pump actuator 2

CONFIDENTIAL / All ri ght s reserved / Patent pend ing © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne

12


7DCT300 – Shift Actuation General  E-motors wit h intermediate gears

Shift drum even gears

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

Shift drum odd gears


Shift forks and linkages with push rods and shift rods

13


7DCT300 – Clutch Hardware 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


14


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


15


7DCT300 – Clutch Softw are Controls Base Functi onality

des. clutch torque

Launch characteristic map

Clutch Trq transfer behavior

des. pressure

- Pedal position - Clutch temp.

Pressurecontrol

act. pressure

- Trailer, Hill,… 



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


16


7DCT300 – Electronics incl. TCU General 

Stand-alone TCU mounted to transmission housing



External wiring harness mounted on transmission



Interfaces comparable to existing 6DCT250

Transmission cont rol uni t 

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


17


GETRAG Next Gen DCT Response CO2 IMPROVEMENTS  Highly  Ratio

efficient gearset

flexibility

 Intelligent  Power

on demand actuation

 Weight

sailing functionality

thermal management

CUSTOMER/OEM NEEDS  7-speed 

needs for mid-segment

Upscale brand also need hybrid

 Some  Drive

 Increased

launch performance

 Increased

input speed



Improved low speed refinement

 Lower

inertia

reduction

 Extended  Active

gear ratio span

FUN 2 DRIVE

require wet clutch for Best-in-Class quality

 Modularity

across platforms


COSTS  Volume  Global

of Scale

footprint

FEATURES / FUNCTIONS  Shift-by-Wire  Park-by-Wire  Hybridization  Start/Stop

capability

18

GETRAG Future FWD DCT Technology Roadmap © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne


FWD DCT Product Roadmap

Marketplace Inputs •

• s t n e m g e s e u q r o T

h g i H

6DCT470

•

6DCT450

•

Increase gear counts to be available in mid and high torque segments Improve launch performance and refinement mid torque Need f or l ow t or qu e l ow c os t DCT Need for modular application capability among products

d i M

6DCT250

l l a m S

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


20




h g i H

6DCT470 6DCT450

Product freshening – updated clutch

6DCT451

d i M

6DCT250

l l a m S

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


21




h g i H

Market request fo r 7 speeds, impr oved refinement and launch performance

6DCT470 6DCT450 6DCT451

d i M

7DCT300 6DCT250

l l a m S

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


22




h g i H

Market request for low torque / low cost DCT

6DCT470 6DCT450 6DCT451

d i M

7DCT300 6DCT250

l l a m S

2012

6DCT150

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


23



7DCT500


h g i H

Further efficiency incr ease, high er torqu e capacity, and high er no. of gears to fulfil l market requirements

6DCT470 6DCT450 6DCT451

d i M

7DCT300 6DCT250

l l a m S

2012

6DCT150

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


24



7DCT500


h g i H

Market also requires hybrid versions

6DCT470 6DCT450 6DCT451

6DCT451 7HDT300

d i M

7DCT300 6DCT250

l l a m S

2012

XDCT150

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


25



Market also r equires hybrid versions 7HDT500 7DCT500


h g i H

6DCT470 6DCT450 6DCT451

6DCT451 7HDT300

d i M

7DCT300 6DCT250

l l a m S

2012

XDCT150

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


26



7HDT500 7DCT500


h g i H

6DCT470 6DCT450 6DCT451

6DCT451 7HDT300

d i M

7DCT300 6DCT250

l l a m S

2012

XDCT150

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022


27

GETRAG Next Gen FWD DCT Modularity Strategy © GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne


Subsystem Gear set Shift System Clutch Clutch Actuator Park Lock Actuator Cooling/Lube Oil Hybridization, Full Hybridization, Mild TCU

DCT300 7 speed Dual EM shift drum DC300 Pump actuator Mechanical E-motor driven pump Fuel economy and cost optimized lubricant E-motor in transm. housing or axle-split hynrid E-motor in transm. Housing Standalone TCU

Park By Wire

Gear driven shift drum

Software

SW features common

GETRAG Drivetrain Forum, September 25, 2012, Cologne

29


Subsystem Gear set Shift System Clutch Clutch Actuator Park Lock Actuator

DCT300

DCT150

7 speed

6 speed

Dual EM shift drum

Single EM Dual shift drum

DC300

DC300

Pump actuator

Pump actuator

Mechanical

Mechanical

E-motor driven pump

E-motor driven pump

Fuel economy and cost optimized lubricant

Common with DCT300

E-motor in transm. housing or axle-split hynrid

N/A

E-motor in transm. Housing

N/A

Standalone TCU

Standalone TCU

Park By Wire


N/A

Software

SW features common

SW features common

Cooling/Lube Oil Hybridization, Full Hybridization, Mild TCU


30


Subsystem Gear set

DCT300

DCT150

DCT500

7 speed

6 speed

7 speed

Dual EM shift drum


Dual shift drum (note: common drums and motors, different linkage)

DC300

DC300

DC500

Shift System

Clutch Clutch Actuator Park Lock Actuator

Pump actuator

Pump actuator

Pump actuator (higher current vs DCT300)

Mechanical

Mechanical

Mechanical

E-motor driven pump

E-motor driven pump

E-motor driven pump


Common with DCT300

Common with DCT300


N/A

E-motor in transm. housing or axle-split hybrid


N/A

E-motor coaxial to clutch

Standalone TCU

Standalone TCU

Standalone TCU (common motherboard)

Park By Wire


N/A


Software

SW features common

SW features common

SW features common



31


Subsystem Gear set Shift System Clutch Clutch Actuator Park Lock Actuator Cooling/Lube Oil Hybridization, Full Hybridization, Mild TCU

DCT300 7 speed Dual EM shift drum DC300 Pump actuator Mechanical E-motor driven pump Fuel economy and cost optimized lubricant E-motor in transm. housing or axle-split hynrid E-motor in transm. Housing Standalone TCU

Park By Wire


Software

SW features common


32


Subsystem Gear set Shift System Clutch Clutch Actuator Park Lock Actuator

DCT300

DCT150

7 speed

6 speed

Dual EM shift drum


DC300

DC300

Pump actuator

Pump actuator

Mechanical

Mechanical

E-motor driven pump

E-motor driven pump


Common with DCT300


N/A


N/A

Standalone TCU

Standalone TCU

Park By Wire


N/A

Software

SW features common

SW features common



33


Subsystem Gear set

DCT300

DCT150

DCT500

7 speed

6 speed

7 speed

Dual EM shift drum


Dual shift drum (note: common drums and motors, different linkage)

DC300

DC300

DC500

Shift System

Clutch Clutch Actuator Park Lock Actuator

Pump actuator

Pump actuator

Pump actuator (higher current vs DCT300)

Mechanical

Mechanical

Mechanical

E-motor driven pump

E-motor driven pump

E-motor driven pump


Common with DCT300

Common with DCT300


N/A

E-motor in transm. housing or axle-split hybrid


N/A

E-motor coaxial to clutch

Standalone TCU

Standalone TCU

Standalone TCU (common motherboard)

Park By Wire


N/A


Software

SW features common

SW features common

SW features common



34


6DCT150 Technical Data Transmission Maximum speed: Maximum torque: Weight (dry): Installation length: Input shaft - differential: Overall ratio 1st gear: Gear ratio spread: Ac tu ators: Transmission oil: Dual clutch Other details:

6DCT150 7,000 rpm 170 Nm* approx. 56 kg** 350 - 355 mm 170 mm or higher 13 – 18.5 4.5 – 8.0 Electro -mechanical gear actuatio n and electro-hydrauli c clutch actuation 4 liters Nested wet dual clutch, with interface to dual mass flywheel 3-shaft gear set layout all-wheel application possible mechanically actuated parking loc k start/stop- and sailing capable without hardware change


35

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

Mps6 Dct Ford Dtf 2012 04 Dct300

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