Double Clutch Transmissions - An Interplay of Innovations

The dry double clutch is the key element of what is the most efficient type of transmission worldwide. The number of carmakers and their customers who have been persuaded by the benefits of this highly innovative technology, which has been available since 2008, has risen strongly. Through the use of dry clutch linings, it has been possible to make significant improvements in the energy efficiency of double clutch transmissions capable of shifting without any interruption to traction power. An advantage is gained in terms of efficiency since there is no need to provide the oil volume flow that would otherwise be required for cooling purposes in so-called wet solutions. In comparison with a classical manual transmission, the lightning fast gearshifting of this transmission technology gives fuel consumption benefits of up to six percent. The essential advantage of this transmission technology is the combination of efficiency and driving enjoyment.

The dry double clutch – the heart of this efficient transmission technology – is composed of many more parts than is suggested by the term. Together with the electromechanical clutch, the component now supplied in millions of units by the LuK brand of Schaeffler consists of more than 500 individual parts that are produced – depending on the customer’s location – in Europe, North America and Asia and joined together to create a fully coordinated unit. “We currently manufacture more than 100,000 dry double clutches per month” explains Norbert Indlekofer, Member of the Executive Board responsible for transmission systems, “and the number of customers and applications is continually on the increase.”

The double clutch is, however, by no means the only contribution made by Schaeffler to this transmission technology. The system is completed by dual mass flywheels specially tailored to the requirements of double clutch transmissions. The dual mass flywheel acts as a torsion damper and prevents the torsional vibrations originating in the engine from being transmitted into the drive train. It prevents the occurrence of any body boom and so-called gear rattle. It thus makes a decisive contribution towards increasing driving comfort and to driving in fuel-efficient operating points.

The Schaeffler product range also extends well beyond the clutch and damping elements from LuK. It also includes an engagement system designed for double clutch applications. This comprises an engagement bearing and engagement lever and is fitted, depending on the application, with electrohydraulic or electromechanical actuator system. The Schaeffler portfolio for double clutch products also includes the development of control devices that simplify the clutch and actuation mechanism and represent a further component for automated clutch activation.

Furthermore – as with manual or automatic transmissions – a large number of bearing solutions from Schaeffler specifically designed for the requirements of transmissions contribute to the success of double clutch transmissions. These include needle roller bearings, cylindrical roller bearings, angular contact ball bearings and synchro rings under the Schaeffler brand INA as well as various tapered roller bearings and ball bearings under the Schaeffler brand FAG. “As a result, the total number of individual parts from Schaeffler in a double clutch transmission runs into the thousands” says Norbert Indlekofer. “In addition, these individual parts are matched to each other and tailored to the specific customer requirements. The perfect interplay is part of the energy-efficient innovation that is celebrating a considerable triumph.”

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