Concentric Dual Clutch Transmission Layout for Compact 6-Speed Mounting
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Solution Overview
Problem
Dual clutch transmissions (DCTs) face challenges in achieving compactness while maintaining a high number of gears, particularly in front engine front drive vehicles, where space constraints limit the ability to mount the transmission effectively, affecting fuel efficiency.
Innovation Solution
The design incorporates a dual clutch transmission with concentric and parallel input and output shafts, strategically positioned gears, and synchronizers to achieve a compact configuration that allows for a plurality of gear positions, including six forward gears and a reverse gear, while minimizing the overall length of the transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the number of transmission gears is increased to improve fuel efficiency, then fuel efficiency is improved, but the length of the transmission increases and vehicle mountability is restricted
Solution Approach 1:
The patent implements a nested gear arrangement where gears are positioned both radially and axially to overlap in space. Multiple gears are arranged concentrically around a central axis, with some gears positioned inside hollow shafts or between other components, allowing 6 forward gears and reverse gear to be packed into a compact axial length while maintaining all necessary gear ratios for fuel efficiency
Solution Approach 2:
The transmission design transitions from a traditional linear axial arrangement to a three-dimensional configuration utilizing radial, axial, and circumferential dimensions. Gears are distributed in multiple layers around the central axis, with input and output shafts arranged concentrically, enabling high gear count within limited axial space by exploiting the third dimension (radial direction) for component placement
2Use of energy by moving object
If the number of transmission gears is increased to improve fuel efficiency, then fuel efficiency is improved, but the transmission becomes more complex and difficult to mount on the vehicle
Solution Approach 1:
The patent combines multiple functions into integrated components: the input shafts and output shafts serve both as rotational axes and as structural support elements for multiple gears; hollow shafts simultaneously provide structural support and housing for internal gears; synchronizers are integrated directly onto the shafts rather than being separate assemblies. This merging reduces the number of discrete parts and simplifies the overall assembly process despite the high gear count
Solution Approach 2:
The hollow shafts serve multiple functions: they provide structural support, house internal gears, act as mounting surfaces for synchronizers, and serve as rotational axes. The input and output shafts simultaneously transmit power, support multiple gear sets, and provide mounting points for clutch assemblies. This multi-functionality reduces the total component count and assembly complexity while maintaining 6 forward gears and reverse gear capability
Data Source
AI summary
Provided is a dual clutch transmission. First and second input shafts are mounted concentrically. First and second output shafts are mounted in parallel to the first input shaft and respectively include output gears engaged with a ring gear of a differential. The rotations of first and second gears are restrained by the first input shaft. The rotations of third and fourth gears are restrained by the second input shaft. The rotations of fifth and sixth gears engaged with the second and third gears, respectively, are restrained by the first output shaft. The rotation of a seventh gear engaged with the first gear is restrained by the second output shaft. An eighth gear is engaged with the second gear to be rotatable about the second output shaft. The rotation of a ninth gear engaged with the fourth gear and restrained by the eighth gear is restrained by the second output shaft.