GETRAG DCT New Modular Platform From 100Nm to 500 Nm

Ernest DeVincent, GETRAG Corporate Group. 1 ... Drive for Best-in-Class quality. ▫ Modularity .... Optional integrated transmission cooler for severe applications.
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GETRAG DCT New Modular Platform From 100Nm to 500 Nm

Ernest DeVincent, VP Engineering and Global Platform Director DCT300 7th International Symposium May 2013, Detroit 7th International CTICTI Symposium, May 2013, Detroit Ernest DeVincent, GETRAG Corporate Group

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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 Ernest DeVincent, GETRAG Corporate Group

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Current GETRAG FWD DCT Portfolio

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

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FWD DCT Current Product Portfolio

Marketplace Inputs •

High

6DCT470



6DCT450

Mid



6DCT250

Small

Torque segments



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

2012

2013

2014

2015

2016

2017

2018

2019

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

2020

2021

2022

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

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

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Customer and Market Requirements CO2 IMPROVEMENTS

FUN 2 DRIVE

COSTS CUSTOMER/OEM NEEDS

FUNCTIONALITY

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

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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  Extended sailing functionality  Active thermal management

COSTS

 Volume of Scale  Global footprint

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

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

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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 Ernest DeVincent, GETRAG Corporate Group

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7DCT300 Technical Overview

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

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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 Ernest DeVincent, GETRAG Corporate Group

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7DCT300 – Overview

TCU

Motor for clutch cooling pump CONFIDENTIAL / All rights reserved / Patent pending

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

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7DCT300 – Overview Motor for shift actuator 2

Motor for shift actuator 1

Motor for pump actuator 2

CONFIDENTIAL / All rights reserved / Patent pending

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

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7DCT300 – Transmission length

10,8 215,1

165 380,1

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

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7DCT300 – Gear Layout 3

5 4

R

Key Features  Centerdistance: - 183 mm - 188 mm available for AWD - 197 mm dedicated for AWD





7 6 1

2

Gear ratio span of > 8.5 possible - Shortest 1st gear: ~18 - Longest 7th gear: 1.87 Max. output torque: - 4,500 Nm

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

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7DCT300 – Gear Layout

R

2

4 5

6 7

3

1

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

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7DCT300 – Shift Actuation

E-motors with intermediate gears

Shift drum odd gears

Shift drum even 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

Shift forks and linkages with push rods and shift rods 7th International CTI Symposium, May 2013, Detroit Ernest DeVincent, GETRAG Corporate Group

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

PICTURE LIMITED TO ON-SCREEN VERSION

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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 Ernest DeVincent, GETRAG Corporate Group

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7DCT300 – Hydraulic Schematic Clutch cooling system Actuation system for clutch 1 E-Cooling pump

Actuation system for clutch 2

PICTURE LIMITED TO ON-SCREEN VERSION

Pressure sensor Electric pump Orifice

Temperature sensor

Suction filter

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

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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 Ernest DeVincent, GETRAG Corporate Group

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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 Ernest DeVincent, GETRAG Corporate Group

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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 Ernest DeVincent, GETRAG Corporate Group

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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

E-motor for shift drum 2

Shift drum 2 R/2/4/6 gear

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

Parking lock system based on 6DCT250 design w/o external park lock lever and rooster comb

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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 LIMITED TO ON-SCREEN VERSION

water oil

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

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Next Gen 7DCT300 Results CO2 IMPROVEMENTS  Highly efficient gearset

FUN 2 DRIVE  Increased launch performance  Increased input speed

 Ratio flexibility  Intelligent gear ratio span  Power on demand actuation

 Improved low speed refinement  Lower inertia

 Weight reduction  Extended sailing functionality  Active thermal management

COSTS  Volume of Scale  Global footprint

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

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

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GETRAG Future FWD DCT Technology Roadmap

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

26

FWD DCT Product Roadmap Marketplace Inputs •

6DCT470



6DCT450

Mid



6DCT250

Small

Torque segments

High



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

2012

2013

2014

2015

2016

2017

2018

2019

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

2020

2021

2022

27

High

6DCT470

NEW 7DCT500 §

6DCT450

Mid

NEW 7DCT300 6DCT250

Small

Torque segments

FWD DCT Product Roadmap

NEW 6DCT150 § 2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022

§ Not Intended to Indicate Introduction Timing 7th International CTI Symposium, May 2013, Detroit Ernest DeVincent, GETRAG Corporate Group

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GETRAG Next Gen FWD DCT Family Modularity Approach

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

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FWD DCT Family - Modularity 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

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

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FWD DCT Family - Modularity Subsystem

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

Gear driven shift drum

Shift Drum Actuated

Software

SW features common

SW features common

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

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

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FWD DCT Family - Modularity Subsystem

DCT300

DCT150

DCT500

7 speed

6 speed

7 speed

Dual EM shift drum

Single EM Dual shift drum

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

DC300

DC300

DC500

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

Fuel economy and cost optimized lubricant

Common with DCT300

Common with DCT300

Hybridization, Full

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

N/A

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

Hybridization, Mild

E-motor in Trans Housing

N/A

E-motor in Trans Housing

Standalone TCU

Standalone TCU

Standalone TCU (common motherboard)

Park By Wire

Gear driven shift drum

Shift Drum Actuated

Shift Drum Actuated

Software

SW features common

SW features common

SW features common

Gear set Shift System

Clutch Clutch Actuator Park Lock Actuator Cooling/Lube Oil

TCU

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

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6DCT150 Technical Data Transmission Maximum speed: Maximum torque: Weight (dry): Installation length: Input shaft differential: Overall ratio 1st gear: Gear ratio spread: Actuators: 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 actuation and electro-hydraulic clutch actuation 4 liters Nested wet dual clutch 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 Ernest DeVincent, GETRAG Corporate Group

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7DCT500 Technical Data Transmission Maximum speed: Maximum torque: Weight (dry): Installation length: Input shaft differential: Overall ratio 1st gear: Gear ratio spread: Actuators: Transmission oil: Dual clutch Other details:

7DCT500 7,500 rpm 560 Nm approx. 87 kg approx. 380 mm 197 mm or higher 13.8 - 17.5 6.7 - 8.5 Electro-mechanical gear actuation and electro-hydraulic clutch actuation approx. 6 liters Nested wet dual clutch 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 Ernest DeVincent, GETRAG Corporate Group

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

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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 Ernest DeVincent, GETRAG Corporate Group

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

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