Documente Academic
Documente Profesional
Documente Cultură
Seminar Report
On
By
Vinayak S. Mhaske
Guided By:
Prof. Mrs. A.B. Mane
Mechanical Engineering
1
University of Pune
CERTIFICATE
Mechanical Engineering
2
University of Pune
ACKNOWLEDGEMENT
I take this opportunity to thank all who have contributed in seminar work. I would like
to express my gratitude to my guide Prof. Mrs. A.B. Mane, who has encouraged me
to work on this topic and guided me whenever required. I would like to express my
sincere gratitude to Prof. N.MURLI, H.O.D, Mechanical Department, for their
constant support and valuable suggestion without which the successful completion of
this seminar would not have been possible. I wish to express my thanks to Mechanical
Engineering Dept. and faculty members of Mechanical Dept. for their support and the
help extended. Finally, I am thankful to non-teaching staff, Mechanical Engineering
Dept. for their valuable help in preparation of this report.
Mechanical Engineering
3
University of Pune
INDEX
1 Abstract 6
2 Introduction 7
3 Clutch 9
4 Conventional Transmission 10
5 Dual Clutch Transmission 12
6 Operation of DCT 13
7 Basic Design of DCT 16
8 Comparison with Manual Transmission 22
9 Advantages 23
10 Disadvantages 24
11 Controlling Of DCT 25
12 DCT- Past, Present & Future 25
13 Latest Innovations in DCT 27
14 Applications 27
15 Conclusion 29
16 References 30
Mechanical Engineering
4
University of Pune
LIST OF FIGURES
Mechanical Engineering
5
University of Pune
ABSTRACT
The twin-clutch transmission, also known as the Direct Shift Gearbox (DSG)
or dual-clutch transmission, is an automated transmission that can change gears faster
than any other geared transmission. Twin-clutch transmissions deliver more power
and better control than a traditional automatic transmission and faster performance
than a manual transmission. Two separate clutches for odd and even gear sets are
utilized by it. It can be imagined as two separate manual transmission working as one
unit. They are operated in a fully automatic mode. It eliminates torque converter as
used in conventional epicyclical-geared automatic transmissions but use two oil-
bathed two wet multi-plate clutches. It eliminates the lag, thus improving acceleration
and engine performance overall. One of them is responsible for controlling the odd
gears, such as first, third and reverse, while the other manages the even gears –
second, fourth and others.
Efforts are being made to overcome the disadvantages of the DCT and
make it environment friendly so that it can be used in all commercial vehicles. Also
efforts are being made to make it compact so that it can be used in motorcycles too.
Mechanical Engineering
6
University of Pune
1. INTRODUCTION
1.1 Transmission
Transmission is the mechanism through which the driving torque of the engine
is transmitted to the driving wheel of the vehicle so that the motor vehicle can move
on the road. The reciprocating motion of the piston turns a crankshaft rotating a
flywheel through the connecting rod .The circular motion of the crankshaft is to be
now transmitted to the rear wheels .It is transmitted through the clutch, gear box,
universal joints, propeller shaft or the drive shaft, differential and axles extending to
the wheels .The application of the engine power to the driving wheels through all
these parts is called POWER TRANSMISSION .The power system is usually the
same on all modern passenger cars and trucks, but its arrangement may vary
according to the method of drive and type of transmission units.
Mechanical Engineering
7
University of Pune
1.3 Clutch:
Mechanical Engineering
8
University of Pune
2. CLUTCH
A clutch is a mechanical device that provides for the transmission (and therefore
usually motion) from one component (the driving member) to another (the driven
member) when engaged, but can be disengaged.
Clutches are used whenever the transmission of power or motion must be controlled
either in amount or over time (e.g., electric screwdrivers limit how much torque is
transmitted through use of a clutch; clutches control whether automobiles transmit
engine power to the wheels).
In the simplest application, clutches connect and disconnect two rotating shafts (drive
shafts or line shafts). In these devices, one shaft is typically attached to a motor or
other power unit (the driving member) while the other shaft (the driven member)
provides output power for work. While typically the motions involved are rotary,
linear clutches are also possible.
In a torque-controlled drill, for instance, one shaft is driven by a motor and the other
drives a drill chuck. The clutch connects the two shafts so that they may be locked
together and spin at the same speed (engaged), locked together but spinning at
different speeds (slipping), or unlocked and spinning at different speeds (disengaged).
The various types of important clutches used are :
Friction clutch
Centrifugal clutch
Cone clutch
Torque limiter
Non-slip clutches
Mechanical Engineering
9
University of Pune
Other clutches:
Belt clutch
Dog clutch
Hydraulic clutch
Electromagnetic clutch
Overrunning clutch or freewheel
Wrap-spring clutches
3. CONVENTIONAL TRANSMISSION
A manual transmission, also known as a manual gearbox, stick shift (for vehicles
with hand-lever shifters) or standard transmission is a type of transmission used
in vehicle applications. It uses a driver-operated clutch engaged and disengaged by a
foot pedal (automobile) or hand lever (motorcycle), for regulating torque transfer
from the engine to the transmission; and a gear stick operated by foot (motorcycle) or
by hand (automobile).
Manual transmissions often feature a driver-operated clutch and a movable gear stick.
Most automobile manual transmissions allow the driver to select any forward gear
ratio ("gear") at any time, but some, such as those commonly mounted
on motorcycles and some types of racing cars, only allow the driver to select the next-
higher or next-lower gear. This type of transmission is sometimes called a sequential
manual transmission.
The way a manual transmission works is that the flywheel is attached to the engine,
the clutch disk is in between the pressure plate and the flywheel. When running, the
Mechanical Engineering
10
University of Pune
clutch disk spins with the flywheel. As the clutch pedal is depressed, the throw out
bearing is pushed in, which makes the pressure plate stop applying pressure to the
clutch disk. This makes it stop receiving power from the engine so that the gear can
be shifted without damaging the transmission. When the clutch pedal is released, the
clutch disk is allowed to start receiving power from the engine.
Manual transmissions are characterized by gear ratios that are selectable by locking
selected gear pairs to the output shaft inside the transmission. Conversely,
most automatic transmissions feature epicyclic (planetary) gearing controlled by
brake bands and/or clutch packs to select gear ratio. Automatic transmissions that
allow the driver to manually select the current gear are called Manumatics. A manual-
style transmission operated by computer is often called an automated transmission
rather than an automatic.
Waste of fuel
Power lost during the shifting
Shift shock
Discomfort
Power interruption at gear shifting
Decrease in speed
Low Efficiency
Mechanical Engineering
11
University of Pune
Elaborated form of manual transmission in which two internal shafts, each connected
to the input via an electronically controlled clutch, are coordinated such as to achieve
an uninterrupted flow of torque to the driven wheels during gear changes. As well as
reducing acceleration times, a dual clutch transmission also enhances refinement over
a convectional manual or manual gearbox.
Mechanical Engineering
12
University of Pune
shift, and automatics, which do all of the shifting work for drivers using clutches, a
torque converter and sets of planetary gears. But there's also something in between
that offers the best of both worlds -- the dual-clutch transmission, also called the
semi-automatic transmission, the "clutch less" manual transmission and the automated
manual transmission.
In the world of race cars, semi-automatic transmissions, such as the sequential manual
gearbox (or SMG), have been a staple for years. But in the world of production
vehicles, it's a relatively new technology -- one that is being defined by a very specific
design known as the dual-clutch, or direct-shift, gearbox.
Mechanical Engineering
13
University of Pune
Hall Effect sensors sense the direction of requested shift, and this input, together
with a sensor in the gear box which senses the current speed and gear selected, feeds
into a central processing unit. This unit then determines the optimal timing and torque
required for a smooth clutch engagement, based on input from these two sensors as
well as other factors, such as engine rotation, the Electronic Stability Program, air
conditioner and dashboard instruments.
Mechanical Engineering
14
University of Pune
The power of the system lies in the fact that electronic equipment can react much
faster and more precisely than a human, and takes advantage of the precision of
electronic signals to allow a complete clutch operation without the intervention of the
driver.
Mechanical Engineering
15
University of Pune
For the needs of parking, reversing and neutralizing the transmission, the driver must
engage both paddles at once, after this has been accomplished the car will prompt for
one of the three options.
The clutch is really only needed to start the car. For a quicker upshift, the engine
power can be cut, and the collar disengaged until the engine drops to the correct speed
for the next gear. For the teeth of the collar to slide into the teeth of the rings not only
the speed, but also the position must match. This needs sensors to measure not only
the speed, but the positions of the teeth, and the throttle may need to open softer or
harder. The even faster shifting techniques like power shifting require a heavier
gearbox or clutch or even a twin-clutch gearbox.
Mechanical Engineering
16
University of Pune
A dual-clutch gearbox, by contrast, uses two clutches, but has no clutch pedal.
Sophisticated electronics and hydraulics control the clutches, just as they do in a
Standard automatic transmission. In a DCT, however, the clutches operate
independently. One clutch controls the odd gears (first, third, fifth and reverse), while
the other controls the even gears (second, fourth and sixth). Using this arrangement,
gears can be changed without interrupting the power flow from the engine to the
transmission.
Mechanical Engineering
17
University of Pune
As the car increases speed, the computer detects the next gearshift point
and the third gear is pre-selected.
When the driver changes gears, the inner clutch disengages and the outer
clutch is activated.
The power is transferred along the inner transmission shafts to the pre-
selected gear.
Drivers can also choose a fully automatic mode that relinquishes all gear-changing
duties to the computer. In this mode, the driving experience is very similar to that
delivered by a conventional automatic. Because a DCT transmission can "phase out"
one gear and "phase in" a second gear, shift shock is reduced. More importantly, the
gear change takes place under load so that a permanent flow of power is maintained.
An ingenious two-shaft construction separating the odd and even gears makes all of
this possible.
Mechanical Engineering
18
University of Pune
inner shaft, which is nested inside. The outer hollow shaft feeds second and fourth
gears, while the inner shaft feeds first, third and fifth.
The diagram below shows this arrangement for a typical 5-speed DCT. Notice that
one clutch controls second and fourth gears, while another; independent clutch
controls first, third and fifth gears. That's the trick that allows lightning-fast gear
changes and keeps power delivery constant. A standard manual transmission can't do
this because it must use one clutch for all odd and even gears.
Mechanical Engineering
19
University of Pune
one that bathes the clutch components in lubricating fluid to reduce friction and limit
the production of heat. Several manufacturers are developing DCTs that use dry
clutches, like those usually associated with manual transmissions, but all production
vehicles equipped with DCTs today use the wet version. Many motorcycles have.
Single multi-plate clutches
Like torque converters, wet multi-plate clutches use hydraulic pressure to drive the
gears. The fluid does its work inside the clutch piston, seen in the diagram above.
When the clutch is engaged, hydraulic pressure inside the piston forces a set of coil
springs part, which pushes a series of stacked clutch plates and friction discs against a
fixed pressure plate. The friction discs have internal teeth that are sized and shaped to
mesh with splines on the clutch drum. In turn, the drum is connected to the gear set
Mechanical Engineering
20
University of Pune
that will receive the transfer force. Audi's dual-clutch transmission has both a small
coil spring and a large diaphragm spring in its wet multi-plate clutches.
To disengage the clutch, fluid pressure inside the piston is reduced. This allows the
piston springs to relax, which eases pressure on the clutch pack and pressure plate.
Mechanical Engineering
21
University of Pune
Mechanical Engineering
22
University of Pune
4.5 Advantages
It's got input and auxiliary shafts to house gears, synchronizers and a clutch. It
doesn't have a clutch pedal, because computers, solenoids and hydraulics do the
actual shifting. Even without a clutch pedal, the driver can still "tell" the computer
when to take action through paddles, buttons or a gearshift.
Driver experience is just one of the many advantages of a DCT. With upshifts
taking a mere 8 milliseconds, many feel that the DCT offers the most dynamic
acceleration of any vehicle on the market.
It certainly offers smooth acceleration by eliminating the shift shock that
accompanies gearshifts in manual transmissions and even some automatics. Best of
all, it affords drivers the luxury of choosing whether they prefer to control the shifting
or let the computer do all of the work.
Mechanical Engineering
23
University of Pune
4.6 Disadvantages
Mechanical Engineering
24
University of Pune
[6]The man who invented the dual-clutch gearbox was a pioneer in automotive
engineering. Adolph Kégresse is best known for developing the half-track, a type of
vehicle equipped with endless rubber treads allowing it to drive off-road over various
forms of terrain. In 1939, Kégresse conceived the idea for a dual-clutch gearbox,
which he hoped to use on the legendary Citroën "Traction" vehicle. Unfortunately,
adverse business circumstances prevented further development.
Both Audi and Porsche picked up on the dual-clutch concept, although its use was
limited at first to race cars. The 956 and 962C race cars included the Porsche Dual
Clutch, or PDK. In 1986, a Porsche 962 won the Monza 1000 Kilometre World
Sports Prototype Championship race -- the first win for a car equipped with the PDK
semi-automatic paddle-shifted transmission. Audi also made history in 1985 when a
Sport Quattro S1 rally car equipped with dual-clutch transmission won the Pikes Peak
hill climb, a race up the 4,300-meter-high mountain.
Mechanical Engineering
25
University of Pune
Mechanical Engineering
26
University of Pune
the 2005 Frankfurt International Motor Show. However, production vehicles using a
first generation Power shift are approximately two years away.
6. Applications
Semi-automatic transmissions have also made its way into the truck and bus market in
the early 2000s. Volvo offers its I-shift on its heavier trucks and buses, while ZF
markets its AS Tronic system for buses and coaches. These gearboxes have a place in
public transport as they have been shown to significantly reduce fuel consumption.
In the UK though, semi-automatic transmission has been very popular on buses for
some time, from the 1950s right through to the 1980s, an example being the well-
known London Route master, although the latter could also be driven as a fully
automatic in the 3 highest gears. Leyland manufactured many buses with semi-
Mechanical Engineering
27
University of Pune
automatic transmission, including its Leopard and Tiger coaches. Fully automatic
transmission became popular with increasing numbers of continental buses being
bought in the UK, and more and more British manufacturers began offering automatic
options, mostly using imported gearboxes, and semi-automatic transmission lost
favor. These days, very few buses with semi-automatic transmission remain in
service, although many are still on the roads with private owners. Modern types of
semi-automatic transmission though are becoming more common, mostly replacing
manual gearboxes in coaches and small buses.
Motorcycles
Mechanical Engineering
28
University of Pune
7. CONCLUSION
Mechanical Engineering
29
University of Pune
8. REFERENCES
1. Koos van Berkel, Theo Hofman, Alex Serrarens, Maarten Steinbuch, “Fast
and smooth clutch engagement control for dual clutch
transmission” Original Research Article Control Engineering
Practice, Volume 22, January 2014, Pages 57-68
2. Paul D. Walker, Nong Zhang, Richard Tamba, “Control of gear shifts in
dual clutch transmission powertrains” Original Research Article,
Mechanical Systems and Signal Processing, Volume 25, Issue 6, August
2011, Pages 1923-1936
3. S. N. Doğan, G. Henning, T. Gödecke,M. Sommer, K. Fronius, M. Krohn, J.
Kieseland J. Dorfschmid “Advanced transmission technologies to improve
vehicle performance” DOI :10.1533/9780857097422.2.393, Pages 393-432
4. Automobile engineering by R.B. Gupta
5. www.nap.edu
6. www.team-bhp.com
7. auto.howstuffwork.com
8. www.wikipedia.com
9. www.totalmotorcycle.com
Mechanical Engineering
30