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© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
New GETRAG FWD DCT Family Based on 7DCT300Ernest DeVincent, Vice President Product DevelopmentGETRAG
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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 – Modularity Strategy Summary Q & A
Agenda
New GETRAG FWD DCT Family based on 7DCT300
2
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Current GETRAG FWD DCT Portfolio
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014
Sm
all
Mid
Hig
h
2020 2021 2022
6DCT470
6DCT450
6DCT250
Marketplace Inputs
• Increase gear counts to be availablein mid and high torque segments
• Improve launch performance andrefinement 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 Product Portfolio
Legend:
in productionin developmentto be developed
4
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Creating the Next Generation FWD DCT Based on Customer and Market Requirements
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
CUSTOMER/OEM NEEDS
FUNCTIONALITY
FUN 2 DRIVE
COSTS
CO2 IMPROVEMENTS
New GETRAG FWD DCT Family based on 7DCT300
Customer and Market Requirements
6
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
CO2 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
New GETRAG FWD DCT Family based on 7DCT300
Customer and Market Requirements
7
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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
New GETRAG FWD DCT Family based on 7DCT300
Market Requirements GETRAG Next Generation 7DCT300 Response
8
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
7DCT300 Technical Overview
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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 – Overview7DCT300 - Overview
New GETRAG FWD DCT Family based on 7DCT300
10
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
CONFIDENTIAL / All rights reserved / Patent pending
Motor for clutch cooling pump
TCU
7DCT300 – Main ViewNew GETRAG FWD DCT Family based on 7DCT300
11
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
CONFIDENTIAL / All rights reserved / Patent pending
Motor for pump actuator 2
Motor for shift actuator 2
Motor for shift actuator 1
7DCT300 – Side ViewNew GETRAG FWD DCT Family based on 7DCT300
12
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Shift forks and linkages with push rods and shift rods
Shift drumeven gearsE-motors with
intermediate gears
Shift drumodd 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
New GETRAG FWD DCT Family based on 7DCT300
7DCT300 – Shift Actuation
13
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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
New GETRAG FWD DCT Family based on 7DCT300
7DCT300 – Clutch Hardware
14
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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
New GETRAG FWD DCT Family based on 7DCT300
7DCT300 – Electro Hydraulic Actuation
15
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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. clutchtorque
ClutchTrq transfer behavior
des. pressure
Pressure-control
- Pedal position
- Clutch temp.
- Trailer, Hill,…
act. pressure
Launch characteristic map
Base Functionality
New GETRAG FWD DCT Family based on 7DCT300
7DCT300 – Clutch Software Controls
16
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
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
New GETRAG FWD DCT Family based on 7DCT300
7DCT300 – Electronics incl. TCU
17
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
GETRAG Next Gen DCT ResponseCO2 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
New GETRAG FWD DCT Family based on 7DCT300
18
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
GETRAG Future FWD DCT Technology Roadmap
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014
Sm
all
Mid
Hig
h
2020 2021 2022
6DCT470
6DCT450
6DCT250
Marketplace Inputs
• Increase gear counts to beavailable in mid and high torquesegments
• Improve launch performanceand refinement mid torque
• Need for low torque low costDCT
• Need for modular applicationcapability among products
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
20
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 2019
6DCT470
2014
Sm
all
Mid
Hig
h
2020 2021 2022
6DCT451
6DCT250
6DCT450
Productfreshening –updated clutch
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
21
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014
Sm
all
2020 2021 2022
7DCT300
6DCT250
Mid
Hig
h 6DCT470
6DCT451
6DCT450
Market request for 7 speeds, improved refinement and launch performance
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
22
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 2019
6DCT150
2014
Sm
all
2020 2021 2022
Mid
Hig
h
6DCT250
6DCT470
6DCT451
6DCT450
7DCT300
Market request forlow torque / lowcost DCT
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
23
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014
Sm
all
2020 2021 2022
7DCT500
7DCT300
Mid
Hig
h
6DCT250
6DCT470
6DCT451
6DCT450
Further efficiency increase, higher torque capacity, and higher no. of gears to fulfill market requirements
6DCT150
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
24
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014
Sm
all
2020 2021 2022
7DCT500
7DCT300
7HDT300
Mid
Hig
h
6DCT250
6DCT470
6DCT451
6DCT450
6DCT451
Market also requires hybrid versions
XDCT150
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
25
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014
Sm
all
2020 2021 2022
7DCT500
7DCT300
7HDT300
7HDT500
Mid
Hig
h
6DCT250
6DCT470
6DCT451
6DCT450
6DCT451
Market also requireshybrid versions
XDCT150
Legend:
in productionin developmentto be developed
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
26
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Torq
ue s
egm
ents
2012 2013 2015 2016 2017 2018 20192014 2020 2021 2022
Legend:
in productionin developmentto be developed
7DCT500
7DCT300
7HDT300
7HDT500
Mid
Hig
h
6DCT451
6DCT250
6DCT470
6DCT450
6DCT451
Sm
all
XDCT150
New GETRAG FWD DCT Family based on 7DCT300
FWD DCT Product Roadmap
27
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
GETRAG Next Gen FWD DCT Modularity Strategy
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 costoptimized lubricant
Hybridization, Full E-motor in transm. housing oraxle-split hynrid
Hybridization, Mild E-motor in transm. Housing
TCU Standalone TCU
Park By Wire Gear driven shift drum
Software SW features common
New GETRAG FWD DCT Family based on 7DCT300
29
GETRAG Drivetrain Forum, September 25, 2012, Cologne
Subsystem DCT300 DCT150
Gear set 7 speed 6 speed
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 Fuel economy and costoptimized lubricant Common with DCT300
Hybridization, Full E-motor in transm. housing oraxle-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
New GETRAG FWD DCT Family based on 7DCT300
30
GETRAG Drivetrain Forum, September 25, 2012, Cologne
Subsystem DCT300 DCT150 DCT500
Gear set 7 speed 6 speed 7 speed
Shift SystemDual 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 Fuel economy and costoptimized lubricant Common with DCT300 Common with DCT300
Hybridization, Full E-motor in transm. housing oraxle-split hynrid N/A 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 (commonmotherboard)
Park By Wire Gear driven shift drum N/A Gear driven shift drum
Software SW features common SW features common SW features common
New GETRAG FWD DCT Family based on 7DCT300
31
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, 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 costoptimized lubricant
Hybridization, Full E-motor in transm. housing oraxle-split hynrid
Hybridization, Mild E-motor in transm. Housing
TCU Standalone TCU
Park By Wire Gear driven shift drum
Software SW features common
New GETRAG FWD DCT Family based on 7DCT300
32
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Subsystem DCT300 DCT150
Gear set 7 speed 6 speed
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 Fuel economy and costoptimized lubricant Common with DCT300
Hybridization, Full E-motor in transm. housing oraxle-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
New GETRAG FWD DCT Family based on 7DCT300
33
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Subsystem DCT300 DCT150 DCT500
Gear set 7 speed 6 speed 7 speed
Shift SystemDual 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 Fuel economy and costoptimized lubricant Common with DCT300 Common with DCT300
Hybridization, Full E-motor in transm. housing oraxle-split hynrid N/A 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 (commonmotherboard)
Park By Wire Gear driven shift drum N/A Gear driven shift drum
Software SW features common SW features common SW features common
New GETRAG FWD DCT Family based on 7DCT300
34
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Transmission 6DCT150Maximum speed: 7,000 rpmMaximum torque: 170 Nm*Weight (dry): approx. 56 kg**Installation length: 350 - 355 mmInput shaft - differential: 170 mm or higherOverall ratio 1st gear: 13 – 18.5Gear ratio spread: 4.5 – 8.0
Actuators: Electro-mechanical gear actuation and electro-hydraulic clutch actuation
Transmission oil: 4 litersDual clutch Nested wet dual clutch, with interface to dual mass flywheelOther details: 3-shaft gear set layout
all-wheel application possiblemechanically actuated parking lockstart/stop- and sailing capable without hardware change
New GETRAG FWD DCT Family based on 7DCT300
6DCT150 Technical Data
35
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
Summary
© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne
GETRAG expands its FWD DCT portfolio to industry leadership with newmainstream products in all three torque ranges produced on threecontinents.
7DCT300 to be launched as the first of the next generation of GETRAG FWD DCT products. It has been designed to be a new industrybenchmark, achieving the most important OEM and final customerrequirements
6DCT150 and 7DCT500 achieve high degrees of commonality andmodularity 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 AUTOMOTIVE INDUSTRY
New GETRAG FWD DCT Family based on 7DCT300
Summary
37