Dual Clutch Transmission Nested Shaft Design
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Solution Overview
Problem
Dual clutch transmissions face challenges in achieving a compact design with extended functionality and high efficiency, particularly in the arrangement and attachment of clutches and electric machines, while also aiming for reduced CO2 emissions by decoupling internal combustion engines.
Innovation Solution
The proposed dual clutch transmission design includes a cylinder portion connected to the second output disc carrier for fixed conjoint rotation, with overlapping and radially surrounding arrangements of force transfer regions, a connection plate, and an electric machine attachment element, allowing for efficient and compact integration of clutches and electric machines, and enabling decoupling of internal combustion engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the dual clutch transmission uses conventional clutch arrangement, then the structure is simple, but the transmission size is large and functionality is limited
Solution Approach 1:
The patent implements a nested configuration where the second sub-transmission input shaft is arranged coaxially with and radially surrounding the first sub-transmission input shaft. The cylinder portion connected to the second output disc carrier radially surrounds and axially overlaps the first output disc carrier. This nesting allows multiple transmission paths and clutches to occupy the same spatial envelope, extending functionality without increasing transmission size.
Solution Approach 2:
The patent transitions from conventional axial stacking to a radial nesting arrangement. The second sub-transmission input shaft is positioned radially outward from the first, and the cylinder portion extends radially outward from the first output disc carrier. This dimensional reorganization allows overlapping axial arrangements while maintaining radial separation, enabling compact multi-functionality.
2Object-generated harmful factors
If the dual clutch transmission integrates electric machines, then CO2 emissions are reduced through engine decoupling, but the device complexity increases
Solution Approach 1:
The cylinder portion serves multiple functions: it is connected to the second output disc carrier for fixed conjoint rotation, radially surrounds and axially overlaps the first output disc carrier, and provides an attachment element for electric machines. This multi-functional design enables engine decoupling and electric machine integration without proportionally increasing device complexity, as a single structural element performs multiple roles.
3Volume of moving object
If the first force transfer region and second force transfer region are arranged axially overlapping, then the transmission is more compact, but the manufacturing precision requirements increase
Solution Approach 1:
The first force transfer region and second force transfer region are arranged axially overlapping with radial separation. The second sub-transmission input shaft is radially surrounding the first, and the cylinder portion radially surrounds the first output disc carrier. This nested radial arrangement allows axial overlap for compactness while maintaining distinct radial zones that facilitate manufacturing and assembly.
Data Source
AI summary
A dual clutch transmission includes an input shaft having a first clutch having a first input disc carrier, a first output disc carrier, a first force transfer region, and a first actuation piston. The transmission includes a second clutch having a second input disc carrier, a second output disc carrier, a second force transfer region, and a second actuation piston. A first sub-transmission includes a first sub-transmission input shaft and a second sub-transmission has a second sub-transmission input shaft. The input shaft, the first input disc carrier, and the second input disc carrier are connected to one another for fixedly conjoint rotation. The first output disc carrier is connected to the first sub-transmission input shaft for fixedly conjoint rotation. The second output disc carrier is connected to the second sub-transmission input shaft for fixedly conjoint rotation. The second sub-transmission input shaft is arranged coaxially with and radially surrounding the first sub-transmission input shaft.