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BorgWarner to Quintuple Dual-Clutch Production

9 October 2007

Dualtronic
DualTronic clutch module. Click to enlarge.

BorgWarner expects production of its dual-clutch transmission modules to increase 500% over the next six years, a key driver of the company’s growth. At full-launch of announced programs under contract in 2012-2013, the company will be providing its DualTronic technology to an expected 2.3 million dual-clutch transmissions per year. Fewer than 450,000 dual-clutch transmissions per year are produced today, all of which have BorgWarner modules, according to the company.

BorgWarner has been awarded business from transmission and vehicle makers around the world, including VW, Audi, Bugatti, SAIC, and a Japanese automaker. BorgWarner is also a key supplier to Getrag programs with five global automakers.

Dtornic2
Sample application of the DualTronic clutch module and controller. Click to enlarge. Source: BorgWarner

With the DualTronic system, engine output can be coupled to either of two transmission input shafts. Each clutch functions as both a launch clutch and a dynamic shifting clutch, enabling clutch-to-clutch shifts without torque interruption. The design features tunable launch characteristics and scalable torque capacity in a modular design.

The DualTronic control module comprises the complete hydraulic valve body; proportional, on/off and PWM solenoids; transmission control micro-processor; speed, position, temperature, and pressure sensors; plus circuit assembly with integrated connectors.

A dual-clutch transmission delivers fuel economy that rivals single-clutch automated gearboxes and shift quality that rivals the best conventional automatic transmission. Global manufacturing capacity for BorgWarner dual-clutch transmission modules will be supported by expansion of its facilities in Germany and China, and a new facility in Mexico.

BorgWarner will be introducing next generation dual-clutch technology as its customers launch future programs. In addition, BorgWarner is developing a new concept dual-clutch transmission for emerging markets.

October 9, 2007 in Fuel Efficiency, Transmissions | Permalink | Comments (5) | TrackBack (0)

Comments

"...and a Japanese automaker" Which would most likely be Mitsubishi as they are the only Japanese manufacturer with a production vehicle utilizing a dual clutch tranny (Lancer Evolution X).

Dual clutch is almost the only way I would consider an automatic and it is good enough that I would go without a typical manual tranny if my next car is available with the dual clutch tranny.

Posted by: Patrick | October 09, 2007 at 10:09 AM

BW has certainly hit something of a home run with this technology. It cuts the cost of a fully automatic transmission, yet delivers better fuel economy. For engines with modest torque (<250Nm), further savings are possible by using dry rather than wet clutches.

Future drivetrain concepts may be able to deliver high fuel economy because of DCT technology:

Engines can satisfy a given power demand at various speeds, with the optimum usually somewhere fairly low down in the range (at high torque, e.g. via a small diameter turbo). If you take the engine's SFC diagram and draw lines of constant power in it, there will be a point or small speed range representing the optimum fuel economy for each power level. Connect these individual optima and you get a target curve, possibly with varying width.

A dual clutch transmission with a sufficient number of gears (e.g. 6, with long ratios) can always map the engine into an operating point on or at least near this target curve. Further accleration quickly forces a kickdown, but a DCT can handle those very smoothly - especially if the engine features minimized polar inertia. The result is a drivetrain with a susbtantially smaller, less powerful engine that is always operated as efficiently as possible. You simply no longer need the kind of massive torque reserve common in today's cars, because you can better anticipate kick-down events and minimize the discomfort they cause. Obviously, the solution is not appropriate for high-performance cars but it should make sense for urban runabouts and family haulers. Note that a DCT can jump gears if a hard kickdown is required, e.g. in an emergency maneuver: 6th -> 5th -> 2nd in the blink of any eye.

The target curve strategy can be employed with a manual as well, but it requires a lot of concentration and gear manipulation, reducing the attention the driver can pay to traffic. Conventional ATs with a high number of gears (e.g. 7, from M-B) are quite heavy, bulky and expensive.

Regardless of the transmission technology, a key requirement for driver comfort is to re-interpret the accelerator pedal as power demand. Currently, it represents torque demand, forcing uncomfortable foot positions when using high gears at moderate vehicle speeds.

Posted by: Rafael Seidl | October 09, 2007 at 12:40 PM

Good to see the Quintuple word revived.

Posted by: K | October 09, 2007 at 05:29 PM

What's interesting is that dual-clutch transmission technology will be the thing that may obsolete the traditional manual transmission. The reason is simple: it offers the fuel efficiency of traditional manuals but offers the ability to switch to full automatic mode, which is very useful in urban driving.

Posted by: Raymond | October 11, 2007 at 07:28 AM

@ Raymond -

Fifth Gear recently tested the new Audi TT with both
manual and DSG transmissions.

The DSG premium is still GBP 1000 (~4% of the manual's list price) but appears to be well worth it, even in a sports car. BW's announcement of a five-fold increase in production capacity suggests that the technology may become quite commonplace in European cars in the next few years, at substantially lower markups.

Posted by: Rafael Seidl | October 11, 2007 at 09:03 AM

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