Modular 7-speed hybrid dual-clutch transmission 7H-DCT280

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Modular 7-speed hybrid dual-clutch transmission 7H-DCT280

Müller, Jörg / Leesch, Mirko / Paul, Stephan / Liebold, Jens

The market studies presented illustrate the strong competition between the various transmission technologies, with dual-clutch transmissions (DCTs) in particular gaining significance worldwide by the end of this decade. Mainly providing seven speeds, these will then be used almost exclusively in front transversal position for combustion engines up to 300 Nm. Low-cost transmissions must be developed for the future rising - but in absolute terms - small number of hybrid systems. Following this trend, the paper presents a new structurally optimized 7- speed DCT which, by cutting out a second countershaft of the type familiar in current transmissions on the market, paves the way for a modular system somewhere between a conventional and a hybrid transmission. Here, by way of option, either a mechanical reverse-speed module or an electric motor is integrated in the package gained. The electric motor connected at the final-drive end provides wide-ranging and efficient hybrid functions without exerting additional strain on the gear set components. The design produced for both transmission versions shows that a large number of common components can be used for the gear set components, the housing and the add-on parts, thus helping to save costs for the hybrid variant. The electric motor is configured as a permanent-magnet synchronous motor and delivers a continuous rating of 20 kW. Its design is derived on the basis of a new multi-criteria optimization program which, among other aspects, is capable of boosting efficiency. The result of this paper is a forward-pointing family of transmissions comprising a conventional and hybrid DCT for drive torque of up to 280 Nm that are more compact, lighter and less expensive in design than current systems.