A New P2 Hybrid 7DCT Design with Integrated Off-Axis E-Machine

Authors

dr.ir. Alex Serrarens, dr.ir. Roëll van Druten, dr.ir. Dirk Kok, Punch Powertrain Nederland B.V., Eindhoven

Summary

In this paper, we discuss a new hybrid DCT designed for transmitting up to 350 Nm system input torque. Prior to the technical explanation, we motivate the need for such a new hybrid DCT within the rapidly changing automotive and societal spectrum. Moving
forward to the technology, the hybrid structure is based on P2, however not using an expensive on-axis 'pancake type' e-machine but rather a compact off-axis machine. It also constitutes a totally new DCT mechanical and functional principle and has an integrated engine decoupling clutch (C0 clutch). This new hybrid DCT – named 'DT2' – is unique in this combination: new DCT principle, P2, off-axis, integrated. Other integrated solutions such as P2.5 or P3 topology also use off-axis design but do not have the C0 clutch. Consequently these topologies loose functionality and operational consistency unless a more expensive P0 machine is added to them. The pivot design of DT2 is a 48V mild hybrid, whereas the non-hybrid DT2 (conventional) and the high voltage (PHEV) are variants thereof. Some design aspects of the 20+kW 48V propulsion system are also discussed. The paper concludes with the main findings and a brief outlook to product developments towards SOP (early 2022).

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