New GETRAG FWD DCT Family Based on 7DCT300

<strong>New</strong> <strong>GETRAG</strong> <strong>FWD</strong> <strong>DCT</strong> <strong>Family</strong> 

<strong>Based</strong> on 7<strong>DCT</strong>300 

Ernest DeVincent, Vice President Product Development 

<strong>GETRAG</strong> 

© <strong>GETRAG</strong>, <strong>GETRAG</strong> Drivetrain Forum, 2012-09-25, Cologne

<strong>New</strong> <strong>GETRAG</strong> <strong>FWD</strong> <strong>DCT</strong> <strong>Family</strong> based on 7<strong>DCT</strong>300 

Agenda 

• Current <strong>GETRAG</strong> Front Wheel Drive <strong>DCT</strong> Portfolio 

• Creating the Next Generation <strong>FWD</strong> <strong>DCT</strong> <strong>Based</strong> on Customer and 

Market Requirements 

• 7<strong>DCT</strong>300 – The Anchor of the Next Gen <strong>DCT</strong> Plan 

• <strong>GETRAG</strong> Future <strong>FWD</strong> <strong>DCT</strong> Technology Roadmap 

• <strong>GETRAG</strong> Next Gen <strong>DCT</strong> <strong>Family</strong> – Modularity Strategy 

• Summary 

• Q & A 

© <strong>GETRAG</strong>, <strong>GETRAG</strong> Drivetrain Forum, 2012-09-25, Cologne 

2

Current <strong>GETRAG</strong> <strong>FWD</strong> <strong>DCT</strong> Portfolio 



<strong>FWD</strong> <strong>DCT</strong> Current Product Portfolio 

Marketplace Inputs 

Torque segments 

Small Mid High 

6<strong>DCT</strong>470 



• Increase gear counts to be available 

in mid and high torque segments 

• Improve launch performance and 

refinement mid torque 

• Need for low torque low cost <strong>DCT</strong> 

• Need for modular application 

capability among products 

2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 

in production 

in development 

to be developed 


4

Creating the Next Generation <strong>FWD</strong> <strong>DCT</strong> <strong>Based</strong> on 

Customer and Market Requirements 




CO 2 IMPROVEMENTS 

FUN 2 DRIVE 

COSTS 

CUSTOMER/OEM NEEDS 

FUNCTIONALITY 


6




• 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 

FUN 2 DRIVE 

• Increased launch performance 

• Increased input speed 

• Improved low speed refinement 

• Lower inertia 

COSTS 

• Volume of Scale 

• Global footprint 

FEATURES / FUNCTIONS 

• Shift-by-Wire 

• Park-by-Wire 

• Hybridization 

• Start/Stop capability 


7


Market Requirements <strong>GETRAG</strong> Next Generation 7<strong>DCT</strong>300 Response 

• 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 6<strong>DCT</strong>250 

- 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 


8

7<strong>DCT</strong>300 Technical Overview 



7<strong>DCT</strong>300 – Overview 

7<strong>DCT</strong>300 - Overview 

Key Features 

• Next generation of 6<strong>DCT</strong>250 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 


10


7<strong>DCT</strong>300 – Main View 

TCU 

Motor for clutch 

cooling pump 

CONFIDENTIAL / All rights reserved / Patent pending 


11


7<strong>DCT</strong>300 – Side View 

Motor for shift 

actuator 2 

Motor for shift 

actuator 1 

Motor for pump 

actuator 2 

CONFIDENTIAL / All rights reserved / Patent pending 


12


7<strong>DCT</strong>300 – Shift Actuation 

E-motors with 

intermediate 

gears 

Shift drum 

even 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 6<strong>DCT</strong>250 

Shift drum 

odd gears 

Shift forks and 

linkages with 

push rods and 

shift rods 


13


7<strong>DCT</strong>300 – Clutch Hardware 

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 


14


7<strong>DCT</strong>300 – Electro Hydraulic Actuation 

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 


15


7<strong>DCT</strong>300 – Clutch Software Controls 

Base Functionality 

des. 

clutch 

torque 

Clutch 

Trq transfer 

behavior 

des. 

pressure 

Pressurecontrol 

Launch 

characteristic map 

- Pedal position 

- Clutch temp. 

- Trailer, Hill,… 

act. 

pressure 

• Base functionality is running in several series programs 

- 7DCI700 (BMW) 

- 7DCL750 (Ferrari) 

- 6<strong>DCT</strong>450/470 (Ford, Volvo, Mitsubishi, …) 

• Pump low level control has SOP 12/2012 


16


7<strong>DCT</strong>300 – Electronics incl. TCU 

General 

• Stand-alone TCU mounted to transmission housing 

• External wiring harness mounted on transmission 

• Interfaces comparable to existing 6<strong>DCT</strong>250 

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 


17


<strong>GETRAG</strong> Next Gen <strong>DCT</strong> Response 


• 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 

FUN 2 DRIVE 

• Increased launch performance 

• Increased input speed 

• Improved low speed refinement 

• Lower inertia 

COSTS 

• Volume of Scale 

• Global footprint 

FEATURES / FUNCTIONS 

• Shift-by-Wire 

• Park-by-Wire 

• Hybridization 

• Start/Stop capability 


18

<strong>GETRAG</strong> Future <strong>FWD</strong> <strong>DCT</strong> Technology Roadmap 



<strong>FWD</strong> <strong>DCT</strong> Product Roadmap 

Marketplace Inputs 






• Increase gear counts to be 

available in mid and high torque 

segments 

• Improve launch performance 

and refinement mid torque 

• Need for low torque low cost 

<strong>DCT</strong> 

• Need for modular application 

capability among products 

2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





20








Product 

freshening – 

updated clutch 


2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





21




Mid High 





Market request for 7 

speeds, improved 

refinement and 

launch performance 


Small 

2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





22




Mid High 






Market request for 

low torque / low 

cost <strong>DCT</strong> 

Small 


2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





23




Mid High 






Further efficiency 

increase, higher torque 

capacity, and higher no. 

of gears to fulfill market 

requirements 


Small 


2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





24




Mid High 





7HDT300 




Market also 

requires hybrid 

versions 

Small 

X<strong>DCT</strong>150 

2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





25



Market also requires 

hybrid versions 


7HDT500 


Mid High 




7HDT300 




Small 


2012 2013 2014 2015 2016 2017 2018 2019 

2020 2021 2022 

Legend: 





26




7HDT500 


Mid High 




7HDT300 




Small 


2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 

Legend: 





27

<strong>GETRAG</strong> Next Gen <strong>FWD</strong> <strong>DCT</strong> Modularity Strategy 



Subsystem 

Gear set 

Shift System 

Clutch 

Clutch Actuator 

Park Lock 

Actuator 

Cooling/Lube 

Oil 

Hybridization, Full 

Hybridization, 

Mild 

TCU 

Park By Wire 

Software 

<strong>DCT</strong>300 

7 speed 

Dual EM shift drum 

DC300 

Pump actuator 

Mechanical 

E-motor driven pump 

Fuel economy and cost 

optimized lubricant 

E-motor in transm. housing or 

axle-split hynrid 

E-motor in transm. Housing 

Standalone TCU 

Gear driven shift drum 

SW features common 

<strong>GETRAG</strong> Drivetrain Forum, September 25, 2012, Cologne 

29


Subsystem <strong>DCT</strong>300 <strong>DCT</strong>150 

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 



Mild 






Common with <strong>DCT</strong>300 

N/A 

N/A 

TCU Standalone TCU Standalone TCU 

Park By Wire Gear driven shift drum N/A 

Software SW features common SW features common 


30


Subsystem <strong>DCT</strong>300 <strong>DCT</strong>150 <strong>DCT</strong>500 

Gear set 7 speed 6 speed 7 speed 

Shift System 


Single EM Dual shift drum 

Dual shift drum (note: 

common drums and motors, 

different linkage) 

Clutch DC300 DC300 DC500 


Park Lock 

Actuator 

Pump actuator (higher current 

vs <strong>DCT</strong>300) 

Mechanical Mechanical Mechanical 

Cooling/Lube E-motor driven pump E-motor driven pump E-motor driven pump 

Oil 



Mild 






N/A 



axle-split hybrid 

E-motor in transm. Housing N/A E-motor coaxial to clutch 


Standalone TCU (common 

motherboard) 

Park By Wire Gear driven shift drum N/A Gear driven shift drum 

Software SW features common SW features common SW features common 


31


Subsystem 

Gear set 

Shift System 

Clutch 

Clutch Actuator 

Park Lock 

Actuator 

Cooling/Lube 

Oil 



Mild 

TCU 

Park By Wire 

Software 

<strong>DCT</strong>300 

7 speed 


DC300 

Pump actuator 

Mechanical 

E-motor driven pump 






Standalone TCU 

Gear driven shift drum 

SW features common 


32


Subsystem <strong>DCT</strong>300 <strong>DCT</strong>150 

Gear set 7 speed 6 speed 

Shift System Dual EM shift drum Single EM Dual shift drum 

Clutch DC300 DC300 


Park Lock 

Actuator 

Mechanical 

Mechanical 

Cooling/Lube E-motor driven pump E-motor driven pump 

Oil 



Mild 







N/A 

N/A 


Park By Wire Gear driven shift drum N/A 

Software SW features common SW features common 


33


Subsystem <strong>DCT</strong>300 <strong>DCT</strong>150 <strong>DCT</strong>500 

Gear set 7 speed 6 speed 7 speed 

Shift System 


Single EM Dual shift drum 

Dual shift drum (note: 

common drums and motors, 

different linkage) 

Clutch DC300 DC300 DC500 


Park Lock 

Actuator 

Pump actuator (higher current 

vs <strong>DCT</strong>300) 

Mechanical Mechanical Mechanical 

Cooling/Lube E-motor driven pump E-motor driven pump E-motor driven pump 

Oil 



Mild 






N/A 



axle-split hybrid 

E-motor in transm. Housing N/A E-motor coaxial to clutch 


Standalone TCU (common 

motherboard) 

Park By Wire Gear driven shift drum N/A Gear driven shift drum 

Software SW features common SW features common SW features common 


34


6<strong>DCT</strong>150 Technical Data 

Transmission 


Maximum speed: 

7,000 rpm 

Maximum torque: 

170 Nm* 

Weight (dry): 

approx. 56 kg** 

Installation length: 350 - 355 mm 

Input shaft - differential: 170 mm or higher 

Overall ratio 1 st gear: 13 – 18.5 

Gear ratio spread: 4.5 – 8.0 

Actuators: 

Electro-mechanical gear actuation and electro-hydraulic 

clutch actuation 

Transmission oil: 

4 liters 

Dual clutch 

Nested wet dual clutch, with interface to dual mass flywheel 

Other details: 

3-shaft gear set layout 

all-wheel application possible 

mechanically actuated parking lock 

start/stop- and sailing capable without hardware change 


35

Summary 



Summary 

• <strong>GETRAG</strong> expands its <strong>FWD</strong> <strong>DCT</strong> portfolio to industry leadership with new 

mainstream products in all three torque ranges produced on three 

continents. 

• 7<strong>DCT</strong>300 to be launched as the first of the next generation of <strong>GETRAG</strong> 

<strong>FWD</strong> <strong>DCT</strong> products. It has been designed to be a new industry 

benchmark, achieving the most important OEM and final customer 

requirements 

• 6<strong>DCT</strong>150 and 7<strong>DCT</strong>500 achieve high degrees of commonality and 

modularity of key subsystems from 7<strong>DCT</strong>300 

• 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 

<strong>GETRAG</strong> WILL HAVE THE MOST COMPLETE LINE OF <strong>DCT</strong> 

PRODUCTS AVAILABLE IN THE GLOBAL AUTOMOTIVE 

INDUSTRY 


37

New GETRAG FWD DCT Family Based on 7DCT300

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