Dual-clutch Transmission Shafts
A two-part transmission shaft is at the heart of a DCT. Unlike a conventional manual gearbox, which houses all of its gears on a single input shaft, the DCT splits up odd and even gears on two input shafts. How is this possible? The outer shaft is hollowed out, making room for an 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 five-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.
Because a dual-clutch transmission is similar to an automatic, you might think that it requires a torque converter, which is how an automatic transfers engine torque from the engine to the transmission. DCTs, however, don't require torque converters. Instead, DCTs currently on the market use wet multi-plate clutches. A "wet" clutch is 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 gearset 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.
We'll look at the pros and cons of dual-clutch transmissions next.