New Wet Clutch Development

Andrew Kearsey

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 1

New Wet Clutch Development

Content

Development Aims

Current Competence

Extend Competence - Clutch Design Concept

Extend Competence - Friction Element

Result / Benefits

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 2

Development

Aims

To achieve our efficiency improvement targets

- we need to understand and optimise the interaction of all
subsystems and the software influence

To introduce new functions such as idle assisted sailing and start-

stop
- we need to understand and optimise the interaction of all
subsystems and the software influence

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 3

Engineering and Manufacturing

Competence

Gears, Shafts, Differential

Internal Shift Control

Synchronizer System

Hydraulic Control
Electronic Control
Software

Park Mechanism

Housings

Wet Clutch
© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 4
Engineering and Manufacturing

Competence

Wet Clutch Gears, Shafts, Differential

- Is critical to shift quality – friction characteristic, etc.
- Is a major contributor to transmission efficiencyInternal Shift Control
Synchronizer System
- Is one of the most expensive single components
Hydraulic Control
Electronic Control
Software

Park Mechanism

Housings

Wet Clutch
© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 5
Extend Our Competence

Clutch Design Concept

We have 5 dual clutches in our existing product program

- We have a great depth of knowledge related to the application of dual clutches,
but need to understand clutch design & manufacture better

Decision was taken in 2008 to:

- Design a clutch ourselves
- Verify our design to establish the dependency between design parameters and
performance issues
- Use expertise to be able to react quicker to customer requirements
- Maintain option of second source of hardware

Clutch assembly
- We currently manufacture the DC750WH clutch for Ferrari / AMG DCT
- Reserve the right to assemble for future high volume applications

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 6

Design of Clutch

Design Features

Efficiency
- Low drag piston rings and seals
- Low pressure actuation
Ø 200 mm - Low cooling flow
- Low weight

Static (bell housing mounted) support

Nested design with symmetric

actuation system

Axial needle bearings

92,5 mm

Axial fixation of clutch on input shaft 1

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 7

Design of Clutch

Technical Details

Technical Details

Torque capacity 175 Nm

Clutch CO CI

No. friction
6 8
surfaces
Friction surface 4,982 5,240 mm²
area
Lining pressure
0.6 0.6 N/mm²
(brutto)
Ma x. line
7 7 Bar
pressure

Piston balancing 81 81 %

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 8

Design of Clutch

Tribo- System

- To be able to understand and optimise the clutch you have to understand the
tribo-system

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 9

Extend Our Competence

Tribo-System Design & Manufacture

Our aim:
1. Manufacture the friction material ourselves
2. Use an existing technology
3. Develop using a series production machine
(no machine change from prototypes to series production)
4. Machine capacity scaled to our requirements
5. Use existing component test rigs and power train dynos for
verification purposes

Status
- Our friction material runs in our clutches in vehicles
- Performance is already as good as our benchmark

Implementation
- We will maintain the option of sourcing internally for future projects
© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 10
Design and Manufacture – Tribo-System

• State of the art equipment

• Correctly scaled to transmission
manufacturing requirements
• Efficient environmentally friendly
process
© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 11
Tribo-System – The Product

Features

Concentric concept

Cut radial groves

Milled waffle pattern

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 12

Results / Benefits

Clutch design and manufacture is a new competence for GETRAG

Corporate Group

Friction component design and manufacture is a new competence

for GETRAG Corporate Group

With this step we have further enhanced our capability to design

and manufacture excellent transmissions

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 13

Engineering and Manufacturing Competency

Result

© GETRAG C orporate Group, DTF 2010-09-16, Andrew Kearsey 14