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Old 01-26-2011, 03:29 PM   #1
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2012 Focus Dual-Clutch Transmission!

Automatic drivers rejoice! Ford has been hard at work at improving their automatic transmissions. Say buh-bye to the 4-gear ATX's of past and hello-hello to the 6-gear dual-clutch ATX's of the future!

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Ford blends math, creative thinking, computing power to bring superior shift quality to Focus

2012 Ford Focus, featuring a 2.0-liter direct-injection gasoline engine and Powershift dry-clutch six-speed automatic transmission, incorporates Ford's patented Torque Hole Filling (THF) technology for smoother, more seamless shift quality

THF uses a combination of mathematical modeling and computer-aided engineering tools, along with other enabling transmission technologies to deliver smoother upshifts

Originally penned in 1986, the Ford-developed THF invention disclosure came to fruition as computing power and transmission technologies caught up with the pioneering idea

In internal evaluations, THF improved shift quality ratings by up to 2 points (out of 10) in comparison to baseline shifts with conventional controls

DEARBORN, Mich., Jan. 26, 2010 The 2012 Ford Focus will offer up exceptional shift quality to drivers, powered in part by an inventive Ford transmission technology that has been waiting nearly 25 years for computing power to catch up to make it a reality.

Focus features the Ford Powershift dry-clutch six-speed automatic transmission, one of the first transmissions to benefit from Torque Hole Filling (THF), a Ford-developed and patented concept and methodology conceived a quarter-century ago. THF uses a combination of mathematical algorithms, computer-aided engineering (CAE) tools and transmission control technologies to fill what is commonly known as the torque hole the slight hesitation drivers may feel during an upshift when there is a momentary drop in transmission torque output followed by a rise in torque.

The torque hole has been inherent to automatic transmissions since the 1940s, said Ford Research Technical Expert Chris Teslak. "Even though much work in controls and calibration has been done over the years, it has remained a major challenge," he added.

To address this challenge, Dr. Davor Hrovat, a Ford Technical Fellow in Controls Research, authored an invention disclosure in the mid '80s on how to coordinate engine and transmission controls to help eliminate the torque hole. Further analytical work and simulation revealed this pioneering concept was promising, but the technology needed to implement it wasn't fully mature yet.

"Although the team has known what was needed to create smoother shifts, the actual implementation had to wait for drive-by-wire technologies, electronic throttle control and processing power to catch up to transform this inventive idea into a reality," said Teslak, who credits THF project technical leaders Yuji Fujii and Eric Tseng, along with other core technical experts/engineers Jahan Asgari, Tom Brown, Chad Griffin, Don Levens and Brad Riedle for helping to bring THF to fruition under Hrovat's guidance.

Enabling technologies such as electronic throttle control and improved actuators and sensors, coupled with the THF methodology, gave the team of Ford engineers the tools needed to precisely sync transmission and engine to transfer and smooth out the torque during a portion of an upshift lasting a fraction of a second. Adding that little extra torque during the shift helps fill the hole, creating a smoother drive experience for the customer.

In internal engineering evaluations using a PowerShift prototype, THF improved shift quality ratings by up to 2 points on a scale of 1 to10 in comparison to baseline shifts with conventional controls.

"THF uses dynamic modeling and proprietary algorithms to command the additional engine torque that's essential for maintaining driver-desired (communicated via the gas pedal) wheel torque in a precise, coordinated way with the clutch control," said Riedle, a Ford technical expert in transmission electronics.

To pre-stage this fraction-of-a-second "conversation" between engine and transmission, a certain degree of finesse, coordination and upfront knowledge of what customers perceive as a quality shift was needed. The technology also required the Ford engineering teams from several disciplines to throw away preconceived notions about conventional engine and shift controls.

In total, the team logged approximately three years or 6,000 man hours of computer-aided mathematical modeling, simulation and analysis of engine speeds, torque and clutch capacity in only 24 months real time to prove the THF concept was production-ready.

"This methodology is the result of persistence, teamwork, creative thinking and a desire to move beyond existing shift dynamics," said Teslak, "THF enables a consistently smooth shift feel with minimum calibration effort and no incremental hardware cost.

"More importantly, it's a portable technology that can be applied across multiple powertrain/transmission powerpacks, giving us the ability to quickly deliver best-in-class shift quality across platforms."

Ford has two U.S. patents covering broad THF applications and several other related patents are pending. Further research on how to most effectively incorporate THF into more conventional planetary gear-based transmissions is ongoing.
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Old 01-26-2011, 04:40 PM   #2
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Don't mean to be rude but this has been well known for a while now. It's been Ford's original goal to completely phase out all 4-speed automatics in favor of the PowerShift dual-clutch system by 2012. It all started with the 2011 Fiesta... :-)
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Old 01-26-2011, 04:44 PM   #3
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Posted via FF Mobile Old news, but good way to remind people lol. The powershift 6spd dct is already in the Fiesta, and will be offered in the 2012 ford focus. As of now the dry system can only handle so much power, but it'll be beefed up throughout the years to handle more power. Can't wait to see if in more applications. Btw in the focus with sport package and titanium trims there is select shift, which allows you to manually shift with the push of a button.
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Old 01-26-2011, 05:10 PM   #4
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No thanks, I'll stick with the three pedal version!
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Old 01-26-2011, 05:12 PM   #5
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Btw in the focus with sport package and titanium trims there is select shift, which allows you to manually shift with the push of a button.
Really?? That's almost a paddle shifter.....
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Old 01-26-2011, 07:16 PM   #6
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Dont worry man not everyone knew about this. It was a good read. It doesn't sound like it is a true Dual Clutch transmition though. I don't know i need to do somemore reading about it.
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Old 01-27-2011, 12:17 AM   #7
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Quote:
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Really?? That's almost a paddle shifter.....
LOL almost...I suspect that they will come in a year or so. It better.....

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Dont worry man not everyone knew about this. It was a good read. It doesn't sound like it is a true Dual Clutch transmition though. I don't know i need to do somemore reading about it.
Why? Because it is one. One clutch does 1 3 5 R and one does 2 4 6.
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Old 01-27-2011, 04:46 AM   #8
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Dont worry man not everyone knew about this. It was a good read. It doesn't sound like it is a true Dual Clutch transmition though. I don't know i need to do somemore reading about it.
The new Dual-clutch automatic has two clutches, one for odd gears and one for even. It really is a dual clutch system, and gets better fuel economy and shifts faster than a human could due to the implementation.

With SelectShift, you also have more control over what gear the car is in, so it would be hard to say that the manual is a BETTER choice. It has gone from being a clear case of which is better to being a matter of personal preference. Acceleration is at least as good as what the manual has, you get better fuel economy, you can switch gears faster with the SelectShift automatic, etc.
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Old 01-27-2011, 09:51 AM   #9
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It is true dual clutch transmission. What is different about the Ford as compared to all the other DCTs I've read about, is that the new Ford is a dry clutch system. All the others are wet clutch which is similar to torque converters using centrifugal force of fluid to engage clutches. The Ford design is more compact as well, removing the extra unwanted weight of wet clutch DCTs or torque converter ATs. When this transmission design is beefed up for higher power engines, we'll see it replacing all the traditional ATs in vehicles like the Mustang and F series.
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Old 01-27-2011, 10:15 AM   #10
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It doesn't sound like it is a true Dual Clutch transmition though.
You did not really write this did you??

Did you know that the dry-clutch PowerShift transmission can weigh nearly 30 pounds less than, for example, the four-speed automatic transmission featured on today’s North American Ford Focus.

PowerShift six-speed automatic
Gear ratios (2012 Ford Focus)
1st 3.917
2nd 2.429
3rd 1.436
4th 1.021
5th 0.867
6th 0.702
Reverse 3.507
Final drive 3.850 for gears 1, 2, 5 and 6; 4.278 for gears 3, 4 and R

Lots of details here http://www.at.ford.com/news/cn/Pages...canin2010.aspx

and here
http://www.dctfacts.com/emerging-tec...iesta-dct.aspx
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