Getrag reveals two-speed, dual-clutch transmission for electric-drive vehicles

German transmission specialist Getrag used the floor of the 2011 Frankfurt Motor Show to reveal its groundbreaking, dual-clutch transmission for electric-drive vehicles.

Dubbed 2eDCT600, Getrag's two-speed unit is supposedly ideal for pure electric vehicles, plug-in hybrids and range-extended automobiles. Getrag claims the 2eDCT600 can cope with a maximum electric motor input torque of 369 pound-feet and an output torque of up to 4,425 lb-ft.

The German firm touts its 2eDCT600 as a multi-speed solution that gives electric-drive vehicles improved launch capability and an increased top speed. Perhaps most importantly, Getrag claims its dual-clutch unit extends an electric-only vehicle's range by up to ten percent. That's a big number in the EV range game. Follow the jump for full details on Getrag's consumption-reducing gearbox.
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Getrag demonstrates "Global Power" with new products

Untergruppenbach/Frankfurt, 14. September 2011

GETRAG consequently aligns its product strategy with the future global challenges of the automotive market and focuses on its core business transmissions.

At this year's Frankfurt Motor Show it is all about global trends. In line with the motto "Discover the Global Power" GETRAG presents a product portfolio that is guided by the worldwide developments of the automotive market. Priorities are growth and market needs in China, increasing demand of dual clutch transmissions worldwide and further engineering activities in e-mobility.

Electric drive unit 2eDCT600 is celebrating its world premiere

The dual clutch transmission provides an overlap shift under full load without having the need for engagement of synchronisations or dog clutches. The usage of multiple gears offers better launch performance and an increased maximum speed. Thanks to the modular kit this topology allows for parallel axis and coaxial drive train assemblies. The 2eDCT600 is ideal for pure electric vehicles, plug-in hybrid vehicles and range extenders. It is designed for a maximum electric motor input torque of 500 Nm and an output torque of 6,000 Nm. This architecture extends the range by up to ten percent in electric mode. The concept simultaneously enables energy savings, range extension and high driving comfort by the integrated PowerShift transmission without torque break.

Fully functional prototype of GETRAG's Boosted Range Extender in testing phase

The study presented at Frankfurt Motor Show 2009 has meanwhile become a prototype being integrated into a Ford Fiesta equipped with additional components needed for electrical driving. The entire control for the hybrid powertrain was developed by GETRAG. The conventional powertrain was able to be replaced in the engine compartment by the new transmission with a cost-efficient 3-cylinder gas engine at an efficiency level of a Diesel engine and an 88 kW electric motor without changing the vehicle structure. That is also where the power electronics for the electric motor and a modified cooling system for the additional e-drive components is integrated. The high-voltage battery is located in the trunk. Additional hybrid components such as control units and DC/DC converters with charge function are located beneath the floor of the trunk, meaning the passenger space can still be used in full. The Boosted Range Extender offers with two gears for the e-motor as well as for direct drive by the combustion engine a cost-optimised, scalable concept with high ranges and dynamic driving comfort in each operating mode.

Getrag introduces the future PowerShift transmission

The dual clutch transmissions DCT451 provides higher efficiency, new software features, optionally park-by-wire and up to seven gears compared to the previous model. The transmission supports start/stop without additional hardware like electrically driven pump or oil pressure accumulator.

Based on the DCT451 a mild hybrid variant with an integrated e-motor has been developed: the 6/7HDT451. This mild hybrid with the same installation length as the basic transmission is ideal for front transverse installation in the middle class and upper middle class segments and in sport utility vehicles (SUV). The avoidance of torque break and a high continuous e-motor torque of 110 Nm enable sporty, dynamic driving experiences. The 6/7HDT451 increases driving performance with an unchanged, compact combustion engine or alternatively supports further downsizing of the combustion engine and consequently the reduction of CO2 emission.

New dual wet clutch is now developed in-house

In order to further optimise the GETRAG PowerShift® transmission GETRAG developed the clutch inhouse being the most important component. The dual wet clutch DC500 allows an integrated optimization of the subsystem interactions and enhances the individual tailoring capabilities of transmission characteristics to vehicle attributes. Hereby, GETRAG concentrated on minimizing drag torque, weight and inertias to further improve the best-in-class fuel efficiency attributes. The dual wet clutch DC500 supports Diesel as well as gasoline applications up to 8,200 rpm. Within the modular kit another dual wet clutch, the DC300, has been developed and supports all smaller future PowerShift transmissions up to 300 Nm.

GETRAG continues to back manual transmissions as segment with strong global growth
With the 6MTT250 GETRAG develops and manufactures the basic transmission architecture for the new generation of small engines. The manual transmission sets new standards in shiftability and offers an ideal relation between torque and weight. It covers a globally growing market segment. With the 6MTI300 the modular kit of inline manual transmissions was extended by a further variant with direct fourth gear for gasoline engines. Thus, the torque capacity of the existing architecture is significantly increased without additional weight.

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