Modularity, Scalability & Weight Reduction
For today’s worldwide applications, scalability takes on both a horizontal and vertical dimension
On the one hand, with one transmission family, it is desirable to cover a broad engine spectrum with a wide torque range and flexible splaying and gear set concept. On the other hand, the world market demands flexible solutions that can be adapted to the requirements of both the car maker and the driver.
One advantage of transfer box gearing is the adaptability of important design attributes together with greater potential for using identical parts. For example, this flexibility affects the number of gears, the layout of the gear set, the gear ratio spread, and components like the clutch, synchronizations and differential.
Corporate transmission architecture
We use these main advantages of transfer box gearing for modular construction of manual transmissions, and even of hybridized dual clutch transmissions, with a large portion of identical parts throughout a family of transmissions. For example, the pump actuators of the 7DCT300 are used in the hybridized 7HDT300 as well as in the smaller 6DCT150 and 6DCT200 and their hybridized version 6HDT200.
The components’ modularity also allows some variable placement, and therefore optimal use of installation space.
Weight Reduction - Efficency by light construction
A vehicle’s consumption can decrease along with its weight. Therefore, it is enormously important for efficient transmissions to be light also.
Reducing weight isn`t just about using lighter materials - it goes way beyond that. Optimizing the parts strategy - which includes reducing a transmission’s components - can decrease weight by about 20 percent, as with the MX65 family, for example.
Even optimizing components to the requirements saves weight. Therefore Transmission Systems allows modular use of components within a single transmission family, thereby optimally adapting the transmission to the torque class. This avoids needless reserves due to oversized and therefore heavier gears.
Weight reduction is carried to extremes in dual clutch transmissions with cascaded gears. On the new 6 speed dual clutch transmissions 6DCT150 and 6DCT200, the first gear is realized with a cascaded gear, dispensing with the size and weight of a physical first gear.