Dual-Clutch Transmission Layout for Compact Six-Gear Shifting

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Solution Overview

Problem

Existing dual-clutch transmissions face challenges in achieving a compact design while accommodating a large number of shiftable transmission gears with low complexity and minimal installation space requirements.

Innovation Solution

A dual-clutch transmission design featuring a first and second input shaft connected to power-shift clutches, with three countershafts and six switching units arranged between two adjacent gearwheel levels, allowing for a compact axial configuration and efficient shifting of at least six sequentially shiftable gears.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If all six shift units are arranged between two directly adjacent gear planes, then the transmission becomes compact in the axial direction, but the complexity of gear arrangement increases

Engineering Contradiction:
Improveaxial lengthVSAvoidgear arrangement complexity
Core Design Contradiction:
Length of moving objectVSDevice complexity

Solution Approach 1:

The patent implements nesting by placing multiple gear levels (at least four gear levels) within a compact axial space. The shift units are arranged between two directly adjacent gear planes, with gears nested at different radial positions and axial locations. This allows six shift units to be accommodated in a condensed configuration without excessive axial length, resolving the contradiction between compactness and arrangement complexity.

Inventive Principle:
Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent utilizes three-dimensional space efficiently by arranging gears not only axially but also radially and in different planes. With at least four gear levels and multiple countershafts (first, second, third countershaft), the system distributes gear elements across multiple dimensions. This dimensional distribution allows compact axial packaging while maintaining manageable gear arrangement complexity through spatial organization.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Volume of stationary object

If six shift units are concentrated between two adjacent gear planes, then installation space is minimized, but the complexity of the transmission system increases

Engineering Contradiction:
Improveinstallation spaceVSAvoidtransmission system complexity
Core Design Contradiction:
Volume of stationary objectVSDevice complexity

Solution Approach 1:

The transmission system is segmented into multiple independent functional components: at least six shift units, at least four gear levels, first and second input shafts, and first, second, and third countershafts. This segmentation allows each component to be optimized independently and assembled in a compact configuration. The modular arrangement minimizes overall installation space while keeping system complexity manageable through clear functional separation.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The gear levels and countershafts serve multiple functions simultaneously. The at least four gear levels provide both gear transmission and structural support for multiple shift units. The first, second, and third countershafts handle multiple gear engagements and power flow paths. This multi-functionality reduces the number of separate components needed, minimizing installation space without proportionally increasing system complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentEP3559506B1Double clutch transmission
Publication Date: 2021.03.10 MERCEDES BENZ GROUP AG
  • EP3559506B1 patent drawingFigure 1~2
  • EP3559506B1 patent drawingFigure 3
  • EP3559506B1 patent drawingFigure 4~5

AI summary

The invention proceeds from a double clutch transmission for shifting at least six sequentially shiftable transmission gears (V1a-V6a; V1c-V6c), having a first input shaft (11a-11c) which is provided for attachment to a first power shift clutch (K1a-K1c), having a second input shaft (12a-12c) which is provided for attachment to a second power shift clutch (K2a-K2c), having a first countershaft (13a-13c), having a second countershaft (14a-14c), having a third countershaft (15a-15c), having at least six shifting units (S1a-S6a; S1b-S6b; S1c-S6c) and having at least four gearwheel planes (Z1a-Z4a; Z1b-Z4b; Z1c-Z4c). It is proposed that the at least six shifting units (S1a-S6a; S1b-S6b; S1c-S6c) are arranged between precisely two directly adjacent gearwheel planes (Z2a-Z2c, Z3a-Z3c) of the at least four gearwheel planes (Z1a-Z4a; Z1b-Z4b; Z1c-Z4c).