IP Library › Granted Patent US 10,816,061

Granted Patent B2

US 10,816,061 · App. 15/559,626 · Granted Oct 27, 2020

Dual-clutch transmission

Inventor: Jürgen Wafzig (Bermatingen, DE)

Assignee: ZF FRIEDRICHSHAFEN AG

F16H3/093 F16H3/006 F16H2003/0807 F16H2003/0826 F16H2003/0931 F16H2200/0052 F16H2200/0086

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Quick Facts

Patent No.: US 10,816,061
App. No.: 15/559,626
Granted: Oct 27, 2020
Kind: B2

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Abstract

The invention proposes a dual-clutch transmission with two clutches (K 1 , K 2 ), the input sides of which are connected with an input shaft (w_an) and the output sides of which are respectively connected with one of two coaxially disposed transmission input shafts (w_K 1 , w_K 2 ). Further provided are at least two countershafts (w_v 1 , w_v 2 ) on which idlers (i 2 , i 3 , i 4 , i 5 , iR) are rotatably mounted. The dual-clutch transmission comprises fixed gears (F 1 , F 2 , F 3 ), which are disposed on the two transmission input shafts (w_K 1 , w_K 2 ) in a rotationally fixed manner and in engagement with the idlers, and output gears (iab 1 , iab 2 ) respectively provided on the two countershafts (w_v 1 , w_v 2 ), each of which is coupled to a gearing of an output shaft (w_ab), wherein the output shaft (w_ab) is not coaxially disposed to the input shaft (w_an). A plurality of shift elements (S 1 , S 2 , S 3 ) is provided as well, so that at least six power-shiftable forward gears ( 1, 2, 3, 4, 5, 6 ) and at least one reverse gear (R 1 , R 2 ) are shiftable. Only three double-acting shift elements (S 1 , S 2 , S 3 ) are provided according to the invention, wherein two idlers (i 2 , i 3 , i 4 , i 5 , iR) of the countershafts (w_v 1 , w_v 2 ) are allocated to each double-acting shift element (S 1 , S 2 , S 3 ), wherein, in a first operating direction (S 1 a ), one of the shift elements (S 1 ) connects an idler (i 3 ) with the associated countershaft (w_v 1 ) and, in a second operating direction (S 1 b ), connects the two associated idlers (i 3 , i 4 ) with one another, and wherein two shift elements (S 2 , S 3 ) respectively connect the associated idlers (i 2 , i 5 ; i 4 , iR) with the associated countershafts (w_v 1 , w_v 2 ) in a rotationally fixed manner.

Claims (80)

1. A dual-clutch transmission, comprising:

two clutches (K 1 , K 2 );

a drive shaft (w_an), an input side of each of the two clutches (K 1 , K 2 ) connected with the drive shaft (w_an);

two coaxial input shafts (w_K 1 , w_K 2 ), an output side of each of the two clutches (K 1 , K 2 ) connected with a respective one of two input shafts (w_K 1 , w_K 2 ),

two countershafts (w_v 1 , w_v 2 ) on which a plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) is rotatably mounted;

a plurality of fixed gears (F 1 , F 2 , F 3 ) disposed on the two input shafts (w_K 1 , w_K 2 ) in a rotationally fixed manner, the plurality of fixed gears (F 1 , F 2 , F 3 ) engaged with the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR);

two output gears (iab 1 , iab 2 ), each output gear (iab 1 , iab 2 ) provided on a respective one of the two countershafts (w_v 1 , w_v 2 )

an output shaft (w_ab) that is not coaxial with the drive shaft (w_an), the two output gears (iab 1 , iab 2 ) being coupled to a gearing of the output shaft (w_ab); and

a plurality of shift elements (S 1 , S 2 , S 3 ) configured such that at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and at least one reverse gear (R 1 , R 2 ) are shiftable,

wherein the plurality of shift elements (S 1 , S 2 , S 3 ) consists of three double-acting shift elements (S 1 , S 2 , S 3 ),

wherein two idlers of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) are allocated to each double-acting shift element (S 1 , S 2 , S 3 ),

wherein, in a first operating direction (S 1 a ), a first shift element (S 1 ) of the plurality of shift elements (S 1 , S 2 , S 3 ) connects a second idler (i 3 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) with a first countershaft (w_v 1 ) of the two countershafts (w_v 1 , w_v 2 ),

wherein, in a second operating direction (S 1 b ), the first shift element (S 1 ) of the plurality of shift elements (S 1 , S 2 , S 3 ) connects the second idler (i 3 ) with a third idler (i 4 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR), and

wherein a second shift element (S 2 ) and a third shift element (S 3 ) of the plurality of shift elements (S 1 , S 2 , S 3 ) respectively connect associated idlers (i 2 , i 5 ; i 4 , iR) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) with the associated countershaft of the two countershafts (w_v 1 , w_v 2 ) in a rotationally fixed manner.

2. The dual-clutch transmission of claim 1 , wherein:

the first shift element (S 1 ) is a shift actuator controlled double-acting shift element and is allocated to the second idler (i 3 ) as a gear stage of a third forward gear ( 3 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and to the third idler (i 4 ) as a gear stage of a fourth forward gear ( 4 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 );

the second shift element (S 2 ) is a shift actuator controlled double acting shift element and is allocated to the third idler (i 4 ) as a gear stage of a fourth forward gear ( 4 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and to a fifth idler (iR) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a reverse gear (R 1 , R 2 ) of the at least one reverse gear (R 1 , R 2 ); and

the third shift element (S 3 ) is a shift actuator controlled double acting shift element and is allocated to a first idler (i 2 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a second forward gear ( 2 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and to a fourth idler (i 5 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a fifth forward gear ( 5 ) of the at least six power-shiftable forward gears.

3. The dual-clutch transmission of claim 1 , wherein the first shift element (S 1 ) and the second shift element (S 2 ) are allocated to the first countershaft (w_v 1 ), and the third shift element (S 3 ) is allocated to a second countershaft (w_v 2 ) of the two countershafts (w_v 1 , w_v 2 ).

4. The dual-clutch transmission of claim 1 , wherein a first input shaft (w_K 1 ) of two input shafts (w_K 1 , w_K 2 ) is a hollow shaft and includes a first fixed gear (F 1 ) of the plurality of fixed gears (F 1 , F 2 , F 3 ), and a second input shaft (w_K 2 ) of two input shafts (w_K 1 , w_K 2 ) is a solid shaft and includes a second fixed gear (F 2 ) and a third fixed gear (F 3 ) of the plurality of fixed gears (F 1 , F 2 , F 3 ).

5. The dual-clutch transmission of claim 1 , wherein the first countershaft (w_v 1 ) is disposed parallel to a second countershaft (w-v 2 ) of the two countershafts (w_v 1 , w_v 2 ).

6. The dual-clutch transmission of claim 1 , wherein:

the second idler (i 3 ) is allocated to the first countershaft (w_v 1 ) as a gear stage of a third forward gear ( 3 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 );

the third idler (i 4 ) is allocated to the first countershaft (w_v 1 ) as a gear stage of a fourth forward gear ( 4 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 );

a fifth idler (iR) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) is allocated to the first countershaft (w_v 1 ) as a gear stage of a reverse gear (R 1 , R 2 ) of the at least one reverse gear (R 1 , R 2 );

a first idler (i 2 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) is allocated to a second countershaft (w_v 2 ) of the two countershafts (w_v 1 , w_v 2 ) as a gear stage of a second forward gear ( 2 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ); and

a fourth idler (i 5 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) is allocated to the second countershaft (w_v 2 ) as a gear stage of a fifth forward gear ( 5 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ).

7. The dual-clutch transmission of claim 1 , wherein:

a first input shaft (w_K 1 ) of two input shafts (w_K 1 , w_K 2 ) includes a first fixed gear (F 1 ) of the plurality of fixed gears (F 1 , F 2 , F 3 );

a second input shaft (w_K 2 ) of two input shafts (w_K 1 , w_K 2 ) includes a second fixed gear (F 2 ) and a third fixed gear (F 3 ) of the plurality of fixed gears (F 1 , F 2 , F 3 );

in a first gear plane, the first fixed gear (F 1 ) engages with both the second idler (i 3 ) as a gear stage of a third forward gear ( 3 ) of the first countershaft (w_v 1 ) and a fourth idler (i 5 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a fifth forward gear ( 5 ) of a second countershaft (w_v 2 ) of the two countershafts (w_v 1 , w_v 2 );

in a second gear plane, the second fixed gear (F 2 ) engages with the third idler (i 4 ) as a gear stage of a fourth forward gear ( 4 ) of the first countershaft (w_v 1 );

in a third gear plane, the third fixed gear (F 3 ) engages a first idler (i 2 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a second forward gear ( 2 ); and

the first idler (i 2 ) is in engagement with a fifth idler (iR) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a reverse gear (R 1 , R 2 ) of the first countershaft (w_v 1 ).

8. The dual-clutch transmission of claim 1 , wherein a first forward gear ( 1 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) is shiftable by closing the first clutch (K 1 ), by actuating the first shift element (S 1 ) in the second operating direction (S 1 b ) of the first shift element (S 1 ), and by actuating the third shift element (S 3 ) in a second operating direction (S 3 b ) of the third shift element (S 3 );

a second forward gear ( 2 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) is shiftable by closing the second clutch (K 2 ) and by actuating the third shift element (S 3 ) in the second operating direction (S 3 b ) of the third shift element (S 3 );

a third forward gear ( 3 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) is shiftable by closing the first clutch (K 1 ) and by actuating the first shift element (S 1 ) in the first operating direction (S 1 a ) of the first shift element (S 1 );

a fourth forward gear ( 4 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) is shiftable by closing the second clutch (K 2 ) and by actuating the second shift element (S 2 ) in a first operating direction (S 2 a ) of the second shift element (S 2 );

a fifth forward gear ( 5 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) is shiftable by closing the first clutch (K 1 ) and by actuating the third shift element (S 3 ) in a first operating direction (S 3 a ) of the third shift element (S 3 ); and

a sixth forward gear ( 6 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) is shiftable by closing the second clutch (K 2 ), by actuating the first shift element (S 1 ) in the second operating direction (S 1 b ) the first shift element (S 1 ), and by actuating the third shift element (S 3 ) in the first operating direction (S 3 a ) of the third shift element (S 3 ).

9. The dual-clutch transmission of claim 1 , wherein:

a first reverse gear (R 1 ) of the at least one reverse gear (R 1 , R 2 ) is shiftable by closing the first clutch (K 1 ), by actuating the first shift element (S 1 ) in the second operating direction (S 1 b ) of the first shift element (S 1 ), and by actuating the second shift element (S 2 ) in a second operating direction (S 2 b ) of the second shift element (S 2 ); and

a second reverse gear (R 2 ) of the at least one reverse gear (R 1 , R 2 ) is shiftable by closing the second clutch (K 2 ) and by actuating the second shift element (S 2 ) in a second operating direction (S 2 b ) of the second shift element (S 2 ).

10. The dual-clutch transmission of claim 1 , further comprising at least one electric motor that is connectable or connected to one or more of: the input side of each of the two clutches (K 1 , K 2 ); one of plurality of the idlers (i 2 , i 3 , i 4 , i 5 , iR); and one of the two countershafts (w_v 1 , w_v 2 ).

11. A dual-clutch transmission, comprising:

two clutches (K 1 , K 2 );

a drive shaft (w_an), an input side of each of the two clutches (K 1 , K 2 ) connected with the drive shaft (w_an);

two coaxial input shafts (w_K 1 , w_K 2 ), an output side of each of the two clutches (K 1 , K 2 ) connected with a respective one of two input shafts (w_K 1 , w_K 2 ),

two countershafts (w_v 1 , w_v 2 ) on which a plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) is rotatably mounted;

two output gears (iab 1 , iab 2 ), each output gear (iab 1 , iab 2 ) provided on a respective one of the two countershafts (w_v 1 , w_v 2 )

an output shaft (w_ab) that is not coaxial with the drive shaft (w_an), the two output gears (iab 1 , iab 2 ) being coupled to a gearing of the output shaft (w_ab); and

a plurality of shift elements (S 1 , S 2 , S 3 ) configured such that at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and at least one reverse gear (R 1 , R 2 ) are shiftable,

wherein the plurality of shift elements (S 1 , S 2 , S 3 ) has only three double-acting shift elements (S 1 , S 2 , S 3 ),

wherein two idlers of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) are allocated to each double-acting shift element (S 1 , S 2 , S 3 ),

wherein the first shift element (S 1 ) is a shift actuator controlled double-acting shift element and is allocated to the second idler (i 3 ) as a gear stage of a third forward gear ( 3 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and to the third idler (i 4 ) as a gear stage of a fourth forward gear ( 4 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ),

wherein the second shift element (S 2 ) is a shift actuator controlled double acting shift element and is allocated to the third idler (i 4 ) as a gear stage of a fourth forward gear ( 4 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and to a fifth idler (iR) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a reverse gear (R 1 , R 2 ) of the at least one reverse gear (R 1 , R 2 ), and

wherein the third shift element (S 3 ) is a shift actuator controlled double acting shift element and is allocated to a first idler (i 2 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a second forward gear ( 2 ) of the at least six power-shiftable forward gears ( 1 , 2 , 3 , 4 , 5 , 6 ) and to a fourth idler (i 5 ) of the plurality of idlers (i 2 , i 3 , i 4 , i 5 , iR) as a gear stage of a fifth forward gear ( 5 ) of the at least six power-shiftable forward gears.

12. A dual-clutch transmission, comprising: