ABSTRACT
This
paper presents an alternative launch device for layshaft
dual clutch transmissions (DCT's). The launch device
incorporates a hydrodynamic torque converter, a lockup
clutch with controlled slip capability and two wet multi-plate
clutches to engage the input shafts of the transmission. The
device is intended to overcome the deficiencies associated
with using conventional dry or wet launch clutches in DCT's,
such as limited torque capacity at vehicle launch, clutch
thermal capacity and cooling, launch shudder, lubricant
quality and requirement for interval oil changes. The
alternative device enhances drive quality and performance at
vehicle launch and adds the capability of controlled capacity
slip to attenuate gear rattle without early downshifting.
Parasitic torque loss will increase but is shown not to
drastically influence fuel consumption compared to a dry
clutch system, however synchronizer engagement can
become a concern at cold operating temperatures. The
performance of the dual clutch torque converter is assessed in
a 7 speed front wheel drive DCT application and compared
against the dry clutch system in the areas of launch, start/stop,
driveline torsional isolation, gear rattle mitigation and fuel
consumption. The dual clutch torque converter is shown to
overcome the shortcomings of a dry friction launch system
and deliver equivalent fuel economy performance.
INTRODUCTION
Dual
clutch transmissions are steadily gaining market share
with the increased focus on improving overall powertrain
efficiency to reduce emissions and fuel consumption. Dry or
wet DCT's (dDCT or wDCT, respectively) hold an inherent
spin loss advantage over planetary gear set automatic
transmissions due to the mechanical design of the
transmission. The use of splash lubrication, low power
consuming hydraulic or electro-mechanical actuators for thetorque transfer devices, greater ratio selection flexibility and
virtually
no clutch drag are the main contributors to the
advantage over planetary automatics; see [ 1 and 2]. Wet
DCT's, however, have a slight decrease in mechanical
efficiency (fuel economy) compared to dDCT's because a
higher capacity pump is required to supply continuous apply
pressure and cooling flow to the clutch pack, [ 3]. When
compared to planetary type automatic transmissions, DCT's
have performance advantages with reduced shift times,
minimizing torque interrupt and lower reflected inertia at the
input shafts. However, dry or wet DCT's have a few
mechanical and drive quality concerns when compared to
planetary automatics, namely lack of sustained vehicle creep
on grade, hill hold capability, towing capability, clutch
thermal capacity, launch shudder and degradation in
perceived launch performance. The DMF assemblies required
to mitigate gear rattle can have adverse effects on packaging,
12V start/stop integration and can add significant inertia/mass
to the drivetrain hindering acceleration performance and
increasing fuel consumption. Additionally, for wDCT's, high
quality lubricating oil is required to achieve adequate friction
and cooling characteristics which requires interval changes,
leading to increased initial and routine maintenance costs.
The goal of this paper is to demonstrate that the use of a
torque converter with integrated wet shifting clutches within
a single pressure vessel can be beneficial to drive quality
without negatively affecting fuel economy. This alternative
device will hereafter be referred to as a dual clutch torque
converter, DCTC. The performance of the DCTC will be
compared against a dry clutch system for a front wheel drive
(FWD) 7 speed DCT. The performance characteristics to be
assessed include launch, 12 volt start/stop, driveline isolation,
gear rattle mitigation, and fuel consumption on the FTP city-
highway schedule.
A Dual Clutch Torque Converter for Dual Input
Shaft Transmissions2013-01-0232
Published
04/08/2013
Darrell Robinette and Ted Skrzycke
General Motors Company
Copyrig
SAE_2013-01-0232_GM_A Dual Clutch Torque Converter for Dual Input Shaft Transmissions
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