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Drivetrain Forum 2016, Untergruppenbach
Modular and Scalable Approaches in Layshaft Transmission Design
Dr. Jörg Willert Vice President Central Core Engineering Dr. Carsten Bünder Senior Manager Product Engineering
General Framework for Designing Transmission Architectures
Increasing No. of architectures/ applications
Tougher quality and warranty requirements
Requirements get more diverse
Reduced development time and cost
CO2 goals allow no efficiency compromises
2
No. of Architectures / Applications is Increasing
2000 2005 2010 2015 2020 (FC) 2000 2005 2010 2015 2020 (FC)
Tran
smis
sion
Arc
hite
ctur
es
Tran
smis
sion
App
licat
ions
2x No. of
Architectures
5x No. of
Applications
100% 100%
3
Requirements Get More Diverse
Stop-Start
Autonomous Driving
Sailing
Park by Wire
SW-Interfaces Downspeeding
Hybrid
Downsizing
NVH
Drivability Package
Weight Reduction
No of Gears
More Drive Modes
Increased Warranty CO2
Source: caranddriver.com
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The Challenge: Integrating Modularity with Scalability to Enable Economy of Scales and Flexibility
Scalable Approach
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Modular Approach
5
General Modules and Advantages of Layshaft Transmission Architecture
Shift Actuation
Clutch Actuation
Software
TCU
E-Machine
Power Electronics
Clutch
Layshaft Transmission
Advantages of layshaft transmissions:
– Only positive-locking connections in load path
– Extremely low actuation power – Easily adoptable ratios
and gear spread – Single speed ratios can be defined
independently – Overall very efficient and flexible
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Layshaft Transmission
The Essential Layshaft Transmission
Clutch Base Characteristics – Flexible gearset layout – Lowest parasitic losses
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Example for Modularity and Scalability of Manual Layshaft Transmissions (MX65 Family)
A versatile and efficient solution for low- to mid-torque applications
Design Characteristics – Identical synchronizer and bearing design – Single, double or triple synchronizers – All loose gears on one shaft
(keeps assembly simple) – Two sizes for different torque classes – 5 or 6 gears within one design – Option for AMT and hybridization
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Modular Base Transmissions – Three Scaled Variants
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Layshaft Transmission
From MT to AMT – Additional Modules
Clutch
Clutch Actuation
Software
TCU
Shift Actuation
+ 110011001001100011 110011011010010100 011011010111001001
Base Characteristics – Flexible gearset layout – Lowest parasitic losses
Plus – Automatic clutch
& shift actuation – TCU & software module
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Example for Modularity and Scalability of Automated Manual Transmissions (Automated MX65)
Scaling from MT to AMT with an actuation module
Design Characteristics – Top-mounted actuation module – Electromechanical shift and clutch
actuation – TCU/Software allows shaping customer
”DNA”
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Layshaft Transmission
From AMT to DCT – Additional Modules
Clutch
Clutch Actuation
Software
TCU
Shift Actuation
+ 110011001001100011 110011011010010100 011011010111001001
Base Characteristics – Flexible gearset layout – Lowest parasitic losses – Automatic clutch
& shift actuation – TCU & software module
Plus – Second sub-transmission – Second clutch – Actuators
Layshaft Transmission
Clutch
12
GETRAG Evolutionary Path to a Modular DC (Front-Transverse)
2007: 6DCT450 DCT with mechanically driven hydraulic pump
Ford Focus 2008
wet clutch fully hydraulic No modular
concept for functional components
Renault Mégane
dry clutch electro mechanic on-
demand (smart actuation with low energy consumption)
Shift actuation as first step towards modularity
2010: 6DCT250 DCT with fully electro-mechanic on-demand actuation
2015: 7DCT300 DCT with pump actuator modules for clutch actuation
wet clutch electrohydraulic on-demand
(pump actuation) Pump actuator modules enable
modular / scalable layout
1st Generation (2007) 2nd Generation (2010) 3rd Generation (2015)
Corporate DCT Architecture
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GETRAG Corporate DCT Architecture (Front-Transverse)
1st Generation (2007) 2nd Generation (2010) Dedicated architectures
Limited commonality across product lines
Limited functional and performance scalability
6DCT250 6DCT451
3rd Generation (2015) Scalable architectures with modular components and sub-systems
6DCT150 6DCT200
7DCT300
A Corporate DCT Architecture Definition of functional
modules Cross-product economies of
scale Adaptable characteristics Scalable performance
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GETRAG Corporate DCT Architecture - 3rd Generation DCT Commonality
Subsystem 7DCT300 6DCT150 6DCT200
Clutch DC300 clutch
Clutch Actuation Pump actuator
TCU Stand-alone TCU c/oTCU 7DCT300 (geometrically adapted)
c/oTCU 7DCT300 (geometrically adapted)
Software Base software Base software + Software for single drum
Base software + Software for single drum
Shift Actuation Dual shift drum Single shift drum Single shift drum
Layshaft Transmission 7-speed 6-speed bridge 6-speed bridge
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Pump Actuation – an Example for Functional Modules
Pump Actuation Benefits – Identical motors – Same gerotor pump – Characteristics can be varied by
software
7DCT300 6DCT200 6DCT150
Actuator Module
16
E-machine
From DCT to HDT – Additional Modules
Clutch
Clutch Actuation
Software
TCU
Shift Actuation
110011001001100011 110011011010010100 011011010111001001
Base Characteristics – Flexible gearset layout – Lowest parasitic losses – Automatic clutch
& shift actuation – TCU & Software module – Second sub-transmission – Second clutch – Actuators
Plus – Scalable e-machine
and power electronics – Software module with
added shift strategy
Clutch
+ Power
electronics
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More Scalability by Electrification
Design characteristics – Based on Corporate DCT Architecture – Identical case package for e-machines – Scalable e-machine (48V to high voltage) – Common software in 6HDT200 and
7HDT300
7HDT300
6HDT200
Torque-split enables scalable hybrid applications based on modular common Corporate DCT Architecture
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Overall Overview - Modular DCT/HDT Family (Front-Transverse)
From Corporate DCT Architecture… – Robust layshaft transmission technology – Efficient and smart actuation – Modular, scalable platform strategy
… to Corporate Hybrid-DCT Architecture
– DCT + E-Motor – Scalable from mild to plug-in Hybrid – High efficiency in electric and
conventional operation – Scalable range
6DCT150 6DCT200 7DCT300
6HDT200 7HDT300 Mild
7HDT300 Plug-In
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Modularity and Scalability of the GETRAG Corporate Transmission Architecture
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Scalable Approach with Layshaft Transmissions Variable gear sets Flexibility for different car applications Scalable electrification options
Modular Approach with Layshaft Transmissions Use of common parts within
and across product families Variable positioning of
functional components Functional flexibility
from MT to HDT Cost reduction via
standardization
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