The Gearbox And Dual-Clutch System Physical Architecture

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DPS6 has 2 clutches:

1. Clutch A - on in 1st, 3rd and 5th gear
2. Clutch B - on in Reverse, 2nd, 4th and 6th gear

Each clutch system consists of:

• Clutch
• 3 phase electric motor - rotates a screw driven fulcrum that controls clutch position (and torque). There are end stops at the full open and full closed positions
• Each motor phase has a hall position sensor that combine to provide a relative position - the system must sweep the clutch full open to full closed, then count increments on the sensors to know position. It takes many rotations of the motor to sweep the clutch from fully open to fully closed.
• Spring that returns the clutch to the full open position if the motor is turned off.

DPS6 has 2 shift drums:

1. Shift Drum A - controls the shift forks that engage 1st, 3rd and 5th gear
2. Shift Drum B - controls the shift forks that engage Reverse, 2nd, 4th and 6th gear

Each shift drum system consists of:

• Shift drum with groove that controls the position of shift forks
• Shift forks that engage synchronizers and gears
• 3 phase electric motor that controls the position of the shift drum
• Hall sensor system that knows the position of the motor within a rotation, used to calculate the shift drum angular position (the shift drum motor rotates 61.44 times for a single revolution of the shift drum)

Relationship between shift drum angle and gears;