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 Narrowing
Usable RPM Range for Gas DI Engines and DI
Diesels (=> More Gears)
• Higher Gas Engine Speeds
• Higher Comfort Expectations
• AWD Systems as Safety and Vehicle Dynamics
Feature
• More and Different Transmission / Powertrain
Concepts

1
 Transmission Comfort vs. Fuel Efficiency Comparison

10
CVT Wet DCT
AT 6 speed
9
Comfort Rating

AT 5 speed
Dry DCT
8
a l
7 Go AMT
6 speed

6
MT
6 speed
5
0 5 10 15
Fuel Savings %

Preferred Transmission Application by Market Segment

High End Performance (DP)

High End Traditional (D)

Sub Compact (A0)

Commercial Vans
Micro-Cars (A00)

Compact (A)

Sports Cars
Fullsize (C)
Midsize (B)

SUV

6 Speed AMT
6 Speed Dry DCT
6/7 Speed Wet DCT
6 Speed Step AT
CVT

2
Transmission Technology Shift in Europe

AMT 4.6% AMT 7.1% AMT 10%

CVT 1.5%
CVT 1.8%
DCT 0.9% CVT 2%
DCT 9.6%

AMT 18%
Step AT
24.3% DCT 16%
MT 68.7% MT62.4%
MT 59.2% Step AT MT
MT 45%
52%
22.3% DCT 16%
Step AT
20%

2004 2009 2013

DCT Schematic

R 6 5
Differential

Damper DualClutch

Engine
Engine
Torque

Hollow Shaft Inner Shaft

2 4 3
1

3
DCT Layout

Reverse Gear 6. Gear 5. Gear

Output to
Differential
Clutch 1

Clutch 2

Input Shaft 2

Engine

Input Shaft 1

Differential

Output to
Differential 2. Gear 1. Gear
4. Gear 3. Gear
(Preselected) (active)

DCT Drivers

• Very Good Fuel Efficiency

• Are Fun to Drive (Responsiveness / Accelaration, Engine
and Drivetrain Decoupling Possible)
• Good Shift and Launch Quality (Programmable / Adjustable
Control Strategy)
• Offers Large Variety of Gear Ratios and Ratio Spread for
Perfect Adaptation to Engines and Vehicles at Minimal
Oncost
• The Only AT Addressing all New Engine Trends (High
Torque TDI and High Power / High Speed Gas Engines)
• Compact Design and Packaging and Low Weight

4
DCT Drivers (Cont’d)
• Existing (OEM) Investment in MT Technology
• Competitive Pricing (MT<AMT<DCT<AT<CVT) Through
Synergies in Particular if OEM MT Investment is in Place
• Existing Technology in an Intelligent New Arrangement
• Short Time to Market
• VW and Audi have Launched their First Models Using
BorgWarner’s DualTronic™ Technology into the Market
• The Next Car Manufacturer will Follow 2004
• Additional High Volume Developments are Under Way
• Europe is the First and Primary DCT Market Followed by
Asia and North America

BW DualTronic™ Systems

DualTronic™ Module Applications

• Transverse and Longitudinal Powertrains
• FWD, RWD and AWD Vehicles
• Sub-Compact, Compact, Midsize and High End
Performance Oriented Cars, SUV’s, Trucks and
Sports-Cars
• Diesel and Gas Engines
• Engine Displacement: 1.4 to 8.0 Liter
• Engine Power: 75 to 1000 HP
• Engine Torque: 150 to 1250 Nm

5
 VW / Audi DSG (DCT) Transmission

Transmission Efficiency & Performance

200
180
160
140
DCT
120
Speed

100 Manual
80
60
40 Top Speed:
Manual 247 km/h / 154 mph
20
DCT 247 km/h / 154 mph
0
0 30
Time

DCT:
MT
10.3 l/100 km
Manual:
DCT
11.5 l/100 km
0, 0 5, 0 10, 0 15, 0 20, 0 25, 0
Source: VW

6
BW DualTronic™ Systems Solutions

DualTronic™
BorgWarner DCT Sub-Modules
Dual Clutch and Damper
Synchronizer Systems
Mechatronic Transmission Control Module
Hydraulic Pump

DualTronic™ Clutch Module

7
DualTronic™ Clutch System Application Range

55 kW 750 kW

Torsional Vibration Damper

External Dry Damper Integrated BW-Damper

Grease Oil Vapour

Engine Engine

8
DualTronic™ Torsional Vibration Damper

Stable Damper Characteristics over

Lifetime

Minimal Temperature Impact on

Performance

Excellent Vehicle Response and

Engine Agility through Low Inertia

Simplified System Tuning in

Combination with DualTronic™
Clutch Module

Space Efficient Packaging when

Integrated with DualTronic™ Clutch
Module

Engine Vibration Damping without Damper

Higher Clutch Slip: Lower Clutch Slip

Slip Loss ~ 4.5 kW Slip Loss ~ 3.5 kW

Conclusion:
Torsional vibration damping through clutch slip only is doable
but not economical
Cost effective TVD supported by clutch slip control in critical
operation conditions only is the overal most efficient solution

9
Launch Clutch
Efficient Performance
DualTronic™ XCTComparison
Clutch Cooling

Max. Launch Heat Capacity Basis: Repeated WOT Launches

240 kJ
10

R e la tiv e L a u n c h P e rfo rm a n c e
8
120 kJ
6

0
Wet Clutch Dry Clutch Dry Clutch Wet Clutch

Wet vs. Dry DCT Efficiency Comparison

NEFZ (MPEG) DCT Fuel Consumption Simulation

10 7,89 7,79
Fuel Consumption

8
[l/100km]

0
Wet DCT Dry DCT
Power Consumption for Clutch and Shift Actuation included

10
 DCT Synchronizer System

DCT‘s do not Require a Synchronizer

System Design Change from a Manual
Base Transmission

Utilizing BW‘s Composite

Friction Material on the Synchronizers
Simplifies the Transmission Fluid
Development

BW Synchronizer Allow for Smaller

Packaging (No Lining Wear)

Dualtronic™ Mechatronic Transmission Controls

Clutch Pressure Line Regulator

Control Solenoids Solenoid

Lube Regulator
Solenoid
Cut-off
Solenoid
Cut-off
Solenoid

Gear Actuator
Solenoids

11
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 Variable Displacement Pump

Single Stage Pump (14 to 18 cm³/rev) - Maximum Efficiency
- Single Rotor (Spur Gear, Gerotor) - Increased Complexity
- Lowest Cost
Binary Pump
- Dual Rotor
- Lower Idle Speed, Improved Efficiency

Pump on Demand
- Supplemental Oil Supply, Start/Stop Enabler
- Improved Efficiency with 42 Volt System

12
Summary
• Environmental Requirements and Government Regulations
Necessitate New Transmission Technology
• DCT‘s are the Only Automatic Transmissions Addressing All
New Engine Trends
• DCT‘s are The First Automatics in the Market to Provide the
Entire Drive Comfort of a Traditional Step-Automatic, Better
Fuel Efficiency then Manuals and a Very Responsive, Fun to
Drive Experience
• DCT‘s are Cost Competitive, in Particular when Existing OEM
Investment in Manual Transmission Manufacture can be
Utilized
• Existing OEM Manual Transmission Technology and BW Wet
Clutch and Transmission Controls Technology Enables Short
Time to Market

DualTronic™
The Key Systems for Dual Clutch
Transmissions

Thank You for Your Attention.

13