Dual-Clutch Transmission Layout for Compact Off-Road Packaging
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Solution Overview
Problem
Dual-clutch transmissions have not been widely adopted in off-road vehicles due to high manufacturing costs and packaging issues related to limited engine compartment space.
Innovation Solution
A dual-clutch transmission design featuring a central clutch gear with alternating clutch packs and pressure plates on either side, an input damper located outside the clutch pack drum, and a subtransmission with high and low gear configurations, optimized for efficient packaging and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dual-clutch transmission is designed with separate clutch packs and pressure plates for each clutch, then gear shifting performance and torque distribution are improved, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent combines two separate clutch assemblies into a single integrated dual-clutch unit sharing a common housing, input shaft, and counterweight. The first and second clutch packs are positioned on opposite sides of the input shaft, with shared components reducing overall complexity while maintaining independent clutch operation for smooth gear shifting.
Solution Approach 2:
The common housing serves multiple functions: containing both clutch packs, supporting the input shaft, providing mounting points for synchronizers, and housing the counterweight. The input shaft simultaneously transmits torque to both clutch assemblies and serves as a structural support element, reducing the total number of components needed.
2Adaptability or versatility
If a dual-clutch transmission is packaged in a conventional layout, then gear changing capability is achieved, but engine compartment space requirements increase
Solution Approach 1:
The clutch packs are nested within the common housing, with the first clutch pack positioned in a first chamber and the second clutch pack in a second chamber. The counterweight is integrated into the housing structure, and synchronizers are positioned within the same space, creating a compact nested arrangement that minimizes the transmission's external dimensions.
Solution Approach 2:
Instead of arranging clutch packs in series along the input shaft axis, the patent positions them in parallel on opposite sides of the input shaft (first side and second side). This spatial arrangement in three dimensions allows the transmission to fit within a smaller envelope volume while maintaining all necessary gear changing functions.
3Ease of manufacture
If manufacturing costs are reduced by simplifying the dual-clutch transmission design, then production accessibility improves, but torque distribution smoothness and shifting efficiency may deteriorate
Solution Approach 1:
The transmission is segmented into modular components: a common housing containing two independent clutch assemblies, each with its own clutch pack and pressure plate. The synchronizers are also separate modular units that can be independently manufactured and assembled. This segmentation allows each component to be produced using standard manufacturing processes while maintaining the overall performance of the dual-clutch system.
Data Source
AI summary
A dual-clutch transmission for use in a vehicle has a housing, a clutch pack drum adapted to rotate inside the housing, a central clutch gear connected to the clutch pack drum, a first clutch pack, a first clutch hub, a first pressure plate disposed on the first side of the central clutch gear, and a first shaft connected to the first clutch hub. The first shaft drives at least one first transmission gear when the first pressure plate squeezes the first clutch pack. The dual-clutch transmission further includes a second clutch pack, a second clutch hub, a second pressure plate disposed on the second side of the central clutch gear, and a second shaft connected to the second clutch hub. The second shaft drives at least one second transmission gear when the second pressure plate squeezes the second clutch pack. A vehicle having a dual-clutch transmission is also encompassed.