Dual Clutch Transmission Shaft Layout for Narrower Power Units
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Solution Overview
Problem
The existing dual clutch transmission (DCT) systems increase the width of the power unit due to their lateral placement relative to the engine, reducing flexibility in vehicle component arrangement and occupant space.
Innovation Solution
The DCT-equipped power unit design includes a prime mover and a dual clutch transmission with overlapping input and countershafts, allowing for a reduced axial width by positioning the first and second input shafts and countershaft to overlap the drive shaft, thereby minimizing the overall width of the power unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dual clutch transmission is located lateral to the engine, then the transmission can be properly positioned with both input shafts, but the width of the power unit increases in the axial direction of the crankshaft
Solution Approach 1:
The patent repositions the transmission components from a lateral arrangement to a longitudinal arrangement along the crankshaft axis. The first and second input shafts are positioned at different axial locations along the crankshaft, with the first input shaft receiving power directly from the crankshaft at one location and the second input shaft receiving power from the crankshaft at a different axial location. This dimensional reconfiguration allows the transmission to function properly while reducing the overall width of the power unit in the axial direction.
2Length of stationary object
If the dual clutch transmission is positioned to reduce axial width, then the power unit width is reduced, but the arrangement of multiple input shafts and gear pairs becomes more complex
Solution Approach 1:
The transmission system is segmented into two independent but coordinated transmission paths. The first input shaft has its own clutch and gear pairs for transmitting power to the output shaft, while the second input shaft has its own clutch and gear pairs for the same purpose. This segmentation allows each path to be optimized independently for compactness while maintaining the overall functionality of the dual clutch transmission system.
Solution Approach 2:
The patent merges the two separate input shaft transmissions into a compact integrated unit. Both the first and second input shafts, along with their respective clutches and gear pairs, are positioned within the same transmission housing and share common components such as the output shaft and supporting bearings. This merging reduces the overall width while maintaining the independent operation capability of each clutch path.
Data Source
AI summary
A dual clutch transmission-equipped power unit includes a prime mover including a drive shaft and a dual clutch transmission that changes the speed of rotation produced by rotational power output by the drive shaft. The dual clutch transmission includes a first input shaft which overlaps the drive shaft when viewed in a first direction perpendicular to the drive shaft. The dual clutch transmission includes a second input shaft which overlaps the drive shaft when viewed in a second direction perpendicular to the drive shaft. The dual clutch transmission includes a countershaft which overlaps the drive shaft when viewed in a third direction perpendicular to the drive shaft.