Entry Level Dual-Clutch Transmission for India

The paper presents a new 7-speed dual-clutch transmission (DCT) for transverse applications and a torque capacity of 200 Nm with an option for 300 Nm engine torque. Advantageously the system is designed for supplier parts of dual-clutch system, gear and clutch actuation, differential as well as bearings, synchronizers and additional standardized parts. The actuation could be also realized by an already developed hydraulic module which can be used and produced locally with supplier parts of valves, sensors and so on. Furthermore, the gear set is a state-of-the-art system which can be supplied by manual transmission manufacturer. Beside the cost focus. the DCT has a favorable gear set in terms of robustness and compactness. The design with a total length of 350 mm is realized through a common gear on the main shaft for each gear pair on the countershafts and multiple use of gears in the first speed. The influence of these dependencies on the series of ratios is quite less with this new transmission system. The reverse speed is realized without an idler gear only by engaged countershafts which is more robust, efficient and state-of-the-art. Moreover, the layout and the design is made for a maximum flexibility of ratios and center distances between the transmission input and output shaft. This realizes a usage of the system from A- to SUV-segment. Finally, the hybridization could be realized by a cost effective P2 configuration from mild to full hybrid. The additional oil pump and the modifications of the hydraulic system are already recognized and integrated in the already developed alternative hydraulic module.