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

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No. of Architectures / Applications is Increasing

2000 2005 2010 2015 2020 (FC) 2000 2005 2010 2015 2020 (FC)

Tran

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Arc

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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

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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

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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

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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

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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

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E-machine

From DCT to HDT – Additional Modules

Clutch

Clutch Actuation

Software

TCU

Shift Actuation

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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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