china autoshow 2004 - guenter

8/6/2019 China Autoshow 2004 - Guenter

1/13

1

Powertrain New Technologies and Solutions

The Key Systems for Dual Clutch Transmissions

June 12, 2004

BorgWarner Transmission Systems GmbH, Germany

Powertrain Trends

Higher Environmental Requirements

Better Fuel Efficiency Demand

Increasing Engine Torque / Power and NarrowingUsable RPM Range for Gas DI Engines and DIDiesels (=> More Gears)

Higher Gas Engine Speeds

Higher Comfort Expectations

AWD Systems as Safety and Vehicle DynamicsFeature

More and Different Transmission / PowertrainConcepts


2/13

2

Transmission Comfort vs. Fuel Efficiency Comparison

5

6

7

8

9

10

0 5 10 15Fuel Savings %

ComfortRating

CVTAT 6 speed

Wet DCT

AT 5 speed

AMT6 speed

Goal

Dry DCT

MT

6 speed

6 Speed AMT

6 Speed Dry DCT

6/7 Speed Wet DCT

6 Speed Step AT

CVT

SUV

CommercialVans

Fullsize(C)

High

EndPerformance(DP)

H

ighEndTraditional(D)

SportsCars

Micro-Cars(A00)

SubCompact(A0)

Compact(A)

Midsize(B)

Preferred Transmission Application by Market Segment


3/13

3

CVT 1.5%AMT 4.6%

MT 68.7%

Step AT24.3%

2004

MT 62.4%

2009

DCT 0.9%

MT 59.2% Step AT22.3%

CVT 1.8%

AMT 7.1%

DCT 9.6%

MT 45%

AMT 18%

DCT 16%

2013

MT 52%

Step AT20%

DCT 16%

CVT 2%

AMT 10%

Transmission Technology Shift in Europe

13

5R

2

6

42

6

4

Differential

Damper Clutch

Inner Shaft

Dual

Hollow Shaft

Dual

Hollow ShaftHollow Shaft

EngineEngineTorqueEngineTorque

DCT Schematic


4/13

4

6. Gear 5. Gear

4. Gear 3. Gear 1. Gear(active)

2. Gear(Preselected)

Engine

Input Shaft 1

Input Shaft 2

Differential

Clutch 2

Clutch 1

Output toDifferential

Output toDifferential

Reverse Gear

DCT Layout

Very Good Fuel Efficiency

Are Fun to Drive (Responsiveness /Accelaration, Engineand Drivetrain Decoupling Possible)

Good Shift and Launch Quality (Programmable / AdjustableControl Strategy)

Offers Large Variety of Gear Ratios and Ratio Spread forPerfect Adaptation to Engines and Vehicles at MinimalOncost

The Only AT Addressing all New Engine Trends (HighTorque TDI and High Power / High Speed Gas Engines)

Compact Design and Packaging and Low Weight

DCT Drivers


5/13

5

Existing (OEM) Investment in MT Technology

Competitive Pricing (MT


6/13

6

VW / Audi DSG (DCT) Transmission

Transmission Efficiency & Performance

0

20

4060

80

100

120

140

160

180

200

0 30

0,0 5,0 10,0 15,0 20,0 25,0

DCT

MTDCT: 10.3 l/100 km

Manual: 11.5 l/100 km

Top Speed:Manual 247 km/h / 154 mphDCT 247 km/h / 154 mph

Time

Speed Manual

DCT

Source: VW


7/13

7

BW DualTronic Systems Solutions

DualTronic

BorgWarner DCT Sub-Modules

Dual Clutch and Damper

Synchronizer Systems

Mechatronic Transmission Control Module

Hydraulic Pump

DualTronic Clutch Module


8/13

8

55 kW 750 kW

DualTronic Clutch System Application Range

External Dry Damper Integrated BW-Damper

Oil VapourGrease

EngineEngine

Torsional Vibration Damper


9/13

9

DualTronic Torsional Vibration Damper

Stable Damper Characteristics overLifetime

Minimal Temperature Impact onPerformance

Excellent Vehicle Response andEngine Agility through Low Inertia

Simplified System Tuning inCombination with DualTronicClutch Module

Space Efficient Packaging whenIntegrated with DualTronic ClutchModule

Engine Vibration Damping without Damper

Higher Clutch Slip:

Slip Loss ~ 4.5 kW

Lower Clutch Slip

Slip Loss ~ 3.5 kW

Conclusion:

Torsional vibration damping through clutch slip only is doablebut not economical

Cost effective TVD supported by clutch slip control in criticaloperation conditions only is the overal most efficient solution


10/13

10

Wet Clutch Dry Clutch

Max. Launch Heat Capacity240 kJ

120 kJ

Efficient DualTronic XCT Clutch CoolingLaunch Clutch Performance Comparison

0

2

4

6

8

10

R

elative

Launch

Perform

ance

Dry Clutch Wet Clutch

Basis: Repeated WOT Launches

Wet vs. Dry DCT Efficiency Comparison

7,89 7,79

0

2

4

6

8

10

FuelConsumption

[l/100km]

Wet DCT Dry DCT

NEFZ (MPEG) DCT Fuel Consumption Simulation

Power Consumption for Clutch and Shift Actuation included


11/13

11

DCT Synchronizer System

DCTs do not Require a Synchronizer

System Design Change from a Manual

Base Transmission

Utilizing BWs Composite

Friction Material on the Synchronizers

Simplifies the Transmission Fluid

Development

BW Synchronizer Allow for SmallerPackaging (No Lining Wear)

Dualtronic Mechatronic Transmission Controls

Clutch PressureControl Solenoids

Gear ActuatorSolenoids

Line RegulatorSolenoid

Lube RegulatorSolenoid

Cut-offSolenoid

Cut-offSolenoid


12/13

12

DualTronic Mechatronic Module

Hydraulic Controls + Electronic Controls = Mechatronic Module:

Integrates All Necessary Control Components

Provides All Transmission Control Functions

+=

Lower Cost/Simplified Assembly/Improved Packaging

Increased Performance /Reliability, Only One Connector to the Vehicle/Engine

CAN-BUS System

Dual Clutch Transmission Pump Options

Fixed Displacement Pumps

Single Stage Pump (14 to 18 cm/rev)

- Single Rotor (Spur Gear, Gerotor)

- Lowest Cost

Binary Pump

- Dual Rotor

- Lower Idle Speed, Improved Efficiency

Variable Displacement Pump

- Maximum Efficiency

- Increased Complexity

Pump on Demand

- Supplemental Oil Supply, Start/Stop Enabler

- Improved Efficiency with 42 Volt System


13/13

13

Summary

Environmental Requirements and Government RegulationsNecessitate New Transmission Technology

DCTs are the Only Automatic Transmissions Addressing AllNew Engine Trends

DCTs are The First Automatics in the Market to Provide theEntire Drive Comfort of a Traditional Step-Automatic, BetterFuel Efficiency then Manuals and a Very Responsive, Fun toDrive Experience

DCTs are Cost Competitive, in Particular when Existing OEMInvestment in Manual Transmission Manufacture can be

Utilized Existing OEM Manual Transmission Technology and BW Wet

Clutch and Transmission Controls Technology Enables ShortTime to Market

DualTronic

The Key Systems for Dual Clutch

Transmissions

Thank You for Your Attention.

china autoshow 2004 - guenter

Documents