Mps6 Dct Ford Dtf 2012 04 Dct300

(1)

©

New GETRAG FWD DCT Family

B

Based

ased o

on

n 7D

7DC

CT3

T300

00

Ernest De

Ernest DeVincent, Vice P

Vincent, Vice Presid

resident Produc

ent Produc t Deve

t Develop

lopment

ment

GETRAG

(2)

(3)

(4)

©



Cur

Curren

rentt GET

GETRAG Fr

RAG Front Wh

ont Wheel

eel Dri

Drive DCT P

ve DCT Port

ortfol

folio

io

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Creat

Creating

ing the

the Next

Next Gene

Generatio

ration FW

n FWD DCT

D DCT Base

Based on

d on Custo

Customer a

mer and

nd

Market Requirements



7D

7DCT

CT30

300 –

0 – Th

The

e An

Anch

chor o

or off th

the

e Ne

Next G

xt Gen D

en DCT P

CT Pla

lan

n



GETRAG Future FWD DCT Technology Roadmap



GETR

GETRAG

AG Next

Next Gen

Gen DCT

DCT Famil

Family –

y – Modul

Modularity

arity Strat

Strategy

egy



Summary



Q &

Q & A

A

Ag

gen

end

da

a

New GETRAG FWD DCT Family based on 7DCT300 New GETRAG FWD DCT Family based on 7DCT300

2 2

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©

Cur

(6)

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© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2014 2015 2016 2017 2018 2019 S m a l l M i d H i g h 2020 2021 2022 6DCT470 6DCT450 6DCT250 Marketplace Inputs

•

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

New GETRAG FWD DCT Family based on 7DCT300

FWD DCT Current Produ ct Portfolio

Legend:

in production in development to be developed

(8)

Creating the Next Generation FWD DCT Based on

Customer and Market Requirements

(9)

(10)

CUSTOMER/OEM NEEDS

FUNCTIONALITY

FUN 2 DRIVE

COSTS

CO

₂

IMPROVEMENTS

Customer and Market Requirements

(11)

CO

₂

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

(12)



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

(13)

(14)

(15)

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 – Overview

7DCT300 - Overview

(16)

CONFIDENTIAL / All ri ght s reserved / Patent pend ing

Motor for clutch

cooling pump

TCU

7DCT300 – Main View

(17)

CONFIDENTIAL / All ri ght s reserved / Patent pend ing

Motor for pump

actuator 2

Motor for shift

actuator 2

Motor for shift

actuator 1

7DCT300 – Side View

(18)

Shift forks and linkages with push rods and shift rods Shift drum even gears E-motors wit h intermediate gears Shift drum odd 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

(19)

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

(20)

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

(21)



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.

clutch

torque

Clutch

Trq transfer

behavior

des.

pressure

Pressure-control

- Pedal position

- Clutch temp.

- Trailer, Hill,…

act.

pressure

Launch

characteristic map

Base Functi onality

7DCT300 – Clutch Softw are Controls

(22)

General



Stand-alone TCU mounted to transmission housing



External wiring harness mounted on transmission



Interfaces comparable to existing 6DCT250

Transmission cont rol 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

(23)

GETRAG Next Gen DCT Response

CO

₂

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

(24)

(25)

(26)

Marketplace Inputs

• Increase gear counts to be

available in mid and high torque

segments

• Improve launch performance

and refinement mid torque

• Need for l ow tor que l ow c os t

DCT

• Need for modular application

capability among products

Legend:

FWD DCT Product Roadmap

(27)

Product

freshening –

updated clutch

Legend: in production in development to be developed

FWD DCT Product Roadmap

(28)

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2014 2015 2016 2017 2018 2019 S m a l l 2020 2021 2022 7DCT300 6DCT250 M i d H i g h 6DCT470 6DCT451 6DCT450

Market request fo r 7

speeds, impr oved

refinement and

launch performance

Legend: in production in development to be developed

FWD DCT Product Roadmap

(29)

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2015 2016 2017 2018 2019 6DCT150 2014 S m a l l 2020 2021 2022 M i d H i g h 6DCT250 6DCT470 6DCT451 6DCT450 7DCT300

Market request for

low torque / low

cost DCT

Legend:

FWD DCT Product Roadmap

(30)

(31)

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2014 2015 2016 2017 2018 2019 S m a l l 2020 2021 2022 7DCT500 7DCT300 M i d H i g h 6DCT250 6DCT470 6DCT451 6DCT450

Further efficiency

incr ease, high er torqu e

capacity, and high er no.

of gears to fulfil l market

requirements

6DCT150 Legend: in production in development to be developed

FWD DCT Product Roadmap

(32)

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2014 2015 2016 2017 2018 2019 S m a l l 2020 2021 2022 7DCT500 7DCT300 7HDT300 M i d H i g h 6DCT250 6DCT470 6DCT451 6DCT450 6DCT451

Market also

requires hybrid

versions

XDCT150 Legend: in production in development to be developed

FWD DCT Product Roadmap

(33)

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2014 2015 2016 2017 2018 2019 S m a l l 2020 2021 2022 7DCT500 7DCT300 7HDT300 7HDT500 M i d H i g h 6DCT250 6DCT470 6DCT451 6DCT450 6DCT451

Market also r equires

hybrid versions

XDCT150 Legend: in production in development to be developed

FWD DCT Product Roadmap

(34)

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne T o r q u e s e g m e n t s 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 Legend: in production in development to be developed 7DCT500 7DCT300 7HDT300 7HDT500 M i d H i g h 6DCT451 6DCT250 6DCT470 6DCT450 6DCT451 S m a l l XDCT150

FWD DCT Product Roadmap

(35)

(36)

(37)

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 cost

optimized lubricant

Hybridization, Full

E-motor in transm. housing or

axle-split hynrid

Hybridization,

Mild

E-motor in transm. Housing

TCU

_{Standalone TCU}

Park By Wire

Gear driven shift drum

Software

SW features common

(38)

Subsystem

DCT300

DCT150

Gear set

7speed 6speed

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

optimized lubricant Common with DCT300

Hybridization, Full

axle-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

(39)

Subsystem

DCT300

DCT150

DCT500

Gear set

7speed 6speed 7speed

Shift System

Dual 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

optimized lubricant Common with DCT300 Common with DCT300

Hybridization, Full

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 (common

motherboard)

Park By Wire

Gear driven shift drum N/A Gear driven shift drum

Software

SW features common SW features common SW features common

(40)

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

optimized lubricant

Hybridization, Full

axle-split hynrid

Hybridization,

Mild

E-motor in transm. Housing

TCU

_{Standalone TCU}

Park By Wire

Gear driven shift drum

Software

SW features common

(41)

Subsystem

DCT300

DCT150

Gear set

7speed 6speed

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

optimized lubricant Common with DCT300

Hybridization, Full

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

(42)

Subsystem

DCT300

DCT150

DCT500

Gear set

7speed 6speed 7speed

Shift System

Dual 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

optimized lubricant Common with DCT300 Common with DCT300

Hybridization, Full

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 (common

motherboard)

Park By Wire

Gear driven shift drum N/A Gear driven shift drum

Software

SW features common SW features common SW features common

(43)

Transmission

6DCT150

Maximum speed:

7,000 rpm

Maximum torque:

170 Nm*

Weight (dry):

approx. 56 kg**

Installation length:

350 - 355 mm

Input shaft - differential:

170 mm or higher

Overall ratio 1

st

_gear:

_{13 – 18.5}

Gear ratio spread:

4.5 – 8.0

Ac tu ators:

Electro -mechanical gear actuatio n and electro-hydrauli c

clutch actuation

Transmission oil:

4 liters

Dual clutch

Nested wet dual clutch, with interface to dual mass flywheel

Other details:

3-shaft gear set layout

all-wheel application possible

mechanically actuated parking loc k

start/stop- and sailing capable without hardware change

6DCT150 Technical Data

(44)

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