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Dual-clutch transmissions have so far been primarily restricted to cars from the VW group or expensive sports and luxury cars, with little trickle-down to the ranks of the econobox and people-mover. That’s set to change, thanks to transmission specialist BorgWarner.

The Michigan company thinks it can turn out as many as 2.3million units of the new, low-cost transmission by 2013. A lofty goal, for sure, but such volume will definitely help to keep per-unit costs down. The new system, named DualTronic, will help BorgWarner reach its goal of increasing transmission production by 500%, reports Automotive News Europe. The company claims the new transmissions will be cost competitive with the latest 6sp automatic transmissions, however will likely still remain more expensive than the 4sp and 5sp gearboxes still common on the cheapest cars.

The dual-clutch system allows gear shifts to be completed without interrupting power to the tires, by preselecting the next gear while the current gear is still engaged. The performance benefits are obvious, which is why the system has proliferated in the sports and luxury categories. However, many makers see its 13% efficiency advantage over regular automatics as relevant to the low-cost car segment as well, especially for the burgeoning small-car markets in India and China.

The first prototypes of the new transmission are in test cars now.

CITE AUTOMOTIVE NEWS EUROPE

BorgWarner builds double-clutch for Cheap Cars
Borg Warner is pursuing ambitious goals and plans in 2013 a production of around 2.3 million units DualTronic gear. A special development for so-called Low-Cost-Cars runs the company already in prototype vehicles.

Ketsch. The U.S. BorgWarner from Aubrun Hills (Michigan) will in the next six years, the annual production of double-clutch transmission components by 500%. If the 2013 model series promised begun, “can we at full capacity up to 2.3 million of its DualTronic gear units produce,” says Frank Guenter, manager at BorgWarner DualTronic Tran Mission Systems in Ketsch at Heidelberg.

Unlike conventional manual system allows gear changes without tractive power interruption. Currently, the company equips each year about 450,000 vehicles from various manufacturers with components for double-clutch gearbox.

Consumption advantage of 13%

Among the customers of BorgWarner include the brands Volkswagen, Audi, Bugatti, the Chinese carmaker SAIC, and a Japanese car maker, Borg Warner currently yet to mention. Also, the manufacturer Getrag Gears, with a double clutch transmission components supplies.

It also wants the supplier in the fast-growing segment of the so-called low cost Cars points. The company develops this a double-clutch transmission concept to new markets such as India and China. According to Guenter first prototypes are already in vehicles. Compared to a comparable vehicle with a conventional automatic transmission will be an advantage consumption of 13% has been achieved.