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The paper addresses the challenges of higher efficiency and lower cost than the current DCT from VW (DQ250) fitted with twin wet clutches and hydraulic control. Responsible for the design and supply of the Bugatti Veyron 7-DCT and controller. Ricardo now present some aspects of their ongoing R&D applied to the other end of the market for controlled ratio transmissions with powershift capability. The practical DCT concept is targeted at B/C class with engines up to 200 Nm with very different targets.
The shan layout, meshes, and synchronization are standard: the rest of the transmission is targeted at high efficiency which is derived from two main areas: Dry clutches using a novel failsafe latching mechanism and Electrical Linear Actuators used for the clutches and shift-rails to eliminate hydraulics.
Cost is reduced as a result of these mentioned devices, and the following features: Mechanical multiplexing of the linear actuators to control the entire transmission using three or potentially just two primary actuators and lubrication using carefully designed active splash channels which eliminate the need for a pump. Regarding what the driver notices, simulation and rig data suggests the combination of a friction material and the accuracy and frequency response of the linear actuation device will provide shin quality approaching that of a wet clutch system with hydraulics. Fuel economy simulation results are presented using rig-validated sub-system models to identify the magnitude of the savings from each of the design features leading to an overall improvement of 9% versus a conventional b\hydraulic DCT.
Finally, the concept is shown packaged for a small EU car and a robust prediction is made of system cost.

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Abstract
1. INTRODUCTION
2. SHAFT AND GEAR LAYOUT
3. ACTUATION REQUIREMENTS
4. NEW ACTUATION TECHNOLOGY
5. FMEA AND SAFETY CONSTRAINTS
6. SUB-SYSTEM SOLUTIONS
7. COMBINED ACTUATION OF CLUTCHES AND RAILS
8. OVERALL DESIGN
9. FUEL ECONOMY SIMULATION
10. CONCLUSIONS
11. REFERENCES
12. GLOSSARY
13. APPENDIX 1: CLUTCH ACTUATION CALCULATIONS

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UCI(KEPA) : I410-ECN-0101-2009-556-017551688