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X451 DCT

Performance, Driveability and Fuel Economy

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INTRODUCTION

PUNCH DCT (DT1) on X451

The PD & E attribute simulations presented in this slide pack are on basis of the following assumptions:-

Assumptions:

1. Kerb weight of X451 DCT is assumed to be 20 Kg higher than X451 MT.


[X451 Kerb weight DCT = X451 Kerb weight MT + 20]kg
2. Polo DCT is taken as reference for X451 DCT.
3. Tiago AMT share the same engine as X451 MT and DCT, thus it is used for comparison.
4. Power and Torque of 1.2 NGNA MBU (Updated Air Filter) is considered. BSFC data of production release 1.2 NGNA
MBU considered.
5. Pedal Map of Tiago AMT is used for analysis.
6. New Shift Schedules of both the modes [City and Sport] are made for X451 DCT.
7. Wet Clutch is considered
8. Gear Box and shifting efficiency is considered 95%.
9. As the 1st gear ratio of Punch DT1 is very high, feasibility of both 1st gear launch and 2nd gear launch is simulated and
analysed.

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Vehicle Specification

Level 2 Level 3 Level 4 Level 5 Polo DCT Tiago Petrol X451 Petrol MT X451 Petrol DCT

Units Actual Actual


Powertrain Specifications

Kerb Weight (kg) 1109 1020 990 1010

Engine Displacement (cc) 1198 1197 1197 1197


Power Ps @ rpm 105 @ 5000 85 @ 6000 83 @ 3750 83 @ 6000 Considerably lower as compared to
Power to weight Ps/ton 94.7 83.3 83.8 82.2 Polo, which uses a 7 speed DCT
Torque Nm @ rpm 175@ 1500-4100 112@ 3500 106 @ 3500 106 @ 3500

Torque to weight Nm/ton 157.8 109.8 107.1 104.9


Transmission
1st gear ratio 146.71 3.64 138.5 3.64 140.7 3.96 157.7
2nd gear ratio 88.38 1.95 74.2 1.95 75.4 2.87 114.0
3rd gear ratio 57.43 1.27 48.3 1.27 49.1 1.91 76.2

N/V Ratio 4th gear ratio 40.59 0.95 36.2 0.95 36.7 1.28 51.0

5th gear ratio 31.74 0.77 29.3 0.77 29.8 0.93 36.9

6th gear ratio 25.61 NA NA 0.67 26.5


7th gear ratio 21.51 NA NA 0.48 19.2
Final Drive ratio 1.0 4.06 4.4 4.53
Tyres

Front tyre size 185/60 R15 175/65 R14 195/55 R16 195/55 R16

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0.302 0.283 0.301 0.301
Overall Specification Comparison

Gasoline
Polo DCT Tiago MT/AMT X451 MT X451 DCT Case 1 X451 DCT Case 2
 6th and 7th Gears are very shallow as
Weight [kg] 1109 1020 990 -3% 1010 -1% 1010 -1% compared to Tiago MT and X451 MT
Vehicle Resistance
 Usability of 6th and 7th Gears in real
A [N] 166.3 124.2 102.9 -17.1% 104.7 -15.7% 104.7 -15.7% driving conditions is questionable.
B [N/kph^2] 0.027 0.035 0.0344 -1.7% 0.0344 -1.7% 0.0344 -1.7%
Engine 1.2 NGNA 1.2 NGNA 1.2 NGNA 1.2 NGNA
Max. Torque [Nm] 175 112 106 -5% 106 -5% 106 -5%
Max. Power [PS] 110 85 85 0% 85 0% 85 0%
Gear Ratios [N/V]
1 146.71 138.5 140.7 2% 157.7 14% 114.0 -18%
2 88.38 74.2 75.4 2% 114.0 54% 76.2 3%
3 57.43 48.3 49.1 2% 76.2 58% 51.0 6%
4 40.59 36.2 36.7 2% 51.0 41% 36.9 2%
5 31.74 29.3 29.8 2% 36.9 26% 26.5 -9%
6 25.61 NA NA 26.5 -9 * 19.2 -34.5 *
7 21.51 NA NA 19.2 -34.5 *

Reference X451 ratios DCT Ratio1st DCT Ratio2nd


gear launch gear launch * Difference as compared to highest gear in Tiago

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Gearbox layout

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Traction Analysis

Tiago MT G1 Tiago MT G2 Tiago MT G3  Minimum acceleration


Tiago MT G4 Tiago MT G5 X451 DCT G1 required in highest gear is 0.4
X451 DCT G2 X451 DCT G3 X451 DCT G4
X451 DCT G5 X451 DCT G6 X451 DCT G7
m/sec^2.
Minimum Acceleration Required for highest gear
 Max speed of the vehicle can
be achieved in 5th gear.
3.50

 Acceleration in 3rd, 4th and 5th


Gears of 7 Speed DCT is
higher as compared to Tiago
2.50
and is acceptable.
Acceleration [m/s^2]

1.50

0.50 Minimum Acceptable acceleration for highest gear

0.000 20.000 40.000 60.000 80.000 100.000 120.000 140.000 160.000 180.000 200.000

-0.50

-1.50
Vehicle Speed [Kmph]

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Traction Analysis

Tiago MT G1 Tiago MT G2 Tiago MT G3  7th Gear Acceleration is


Tiago MT G4 Tiago MT G5 X451 DCT G1 always below 0.4 m/s2
X451 DCT G2 X451 DCT G3 X451 DCT G4
X451 DCT G5 X451 DCT G6 X451 DCT G7
Minimum Acceleration Required for highest gear  Maximum Speed of 7th Gear
is 120 kph, which is much
lower than acceptable.
3.50 Minimum 140 kph is
required in 7th Gear.

100 -120 kph, acceleration is lower than 0.4 m/s^2 in 6th and 7th  Hence usability of 7th Gear is
2.50
gears. Hence, small rise in demand @ 120 kph will result in double from 80 kph [landing rpm
downshift downshift to 5th gear and consequently gear looping after 67 shift = 1700 rpm]
between acceleration and cruising cycles.
Acceleration [m/s^2]

to 120 kph [ maximum speed]


1.50
 Hence, if the user drives
around 120 kph [ common
Minimum Acceptable acceleration for highest gear
driving speeds in express
0.50 ways], there will be gear
looping between 6th and 7th
0.000 20.000 40.000 60.000 80.000 100.000 120.000 140.000 160.000 180.000 200.000
Gear . This is not acceptable.
-0.50

7th Gear Maximum Speed 120 kph  Hence, 7th Gear is not usable
6thGear Acceleration falls with the current engine
-1.50
below acceptability limit beyond 90 kph specification of 106 Nm and
Vehicle Speed [Kmph] 83 PS
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Pedal Map

City Mode Sport Mode  Pedal Map [both modes]


120 120 of Tiago AMT is used for
X451 DCT’s simulation.
100 100

80 80  In City mode, full load is


60 achieved beyond 70%
Torque [Nm]

60

Torque [Nm]
pedal.
40 40

20 20  In sport mode, full load is


0 0 achieved beyond 60%
-20 -20
pedal.

-40 -40
1000 2000 3000 4000 5000 6000 7000 1000 2000 3000 4000 5000 6000 7000
Engine Speed [rpm] Engine Speed [rpm]
0% 10% AVL 20% AVL 30% AVL
40% AVL 50 % AVL 60% AVL 70% AVL 0% 10% AVL 20 % AVL 30% AVL 40% AVL
80% AVL 90% AVL 100% AVL 50 % AVL 60 % AVL 70 % AVL 100 % AVL

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Shift Schedule Illustration

Upshift
< 30% Accelerator Pedal Input
Upshift Line

30-90 %Accelerator Pedal Input

> 90 %Accelerator Pedal Input


Downshift

Downshift Line

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Shift Schedule [ City Mode ]

2>3 3>4 4>5 5>6 6>7


2>3 Engine Speed before shift  Shift Schedule
3>4 Engine Speed before shift forbefore
4>5 Engine Speed X451 shift

3>2 4>3 5>4 6>5 7>6


5>6 Engine Speed before shift 6>7 Engine Speed before shift DCT is made.
3>2 Engine Speed after shift

4>3 Engine Speed after shift 5>4 Engine Speed after shift 6>5 Engine Speed after shift
110
7>6 Engine Speed after shift
100
100
90
90
80
Operation: 3500 -5500
80
rpm
Accelerator Pedal [%]

Accelerator Pedal [%]


70 70

60
Deviation from 60
minimum
50
Operation from 1600 -
50
accelerator pedal 3000 rpm
40 hysteresis criteria 40

30 30

20 20

10 10 Operation from 1000 -1900 rpm


0 0
0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 900 1400 1900 2400 2900 3400 3900 4400 4900 5400 5900
Vehicle Speed [kph] Engine Speed [rpm]

 Minimum 5kph and 20% accelerator pedal hysteresis is maintained  In Fuel Economy zone (Low Pedals), engine speed operation is
between upshift and downshift. concentrated between 1000 – 1900 rpm.

 Vertical double sided arrow represent 20% accelerator pedal change.  In medium pedal, operating engine speed ranges from 1600 – 3000 rpm.

 Horizontal double sided arrow represent 5 kph vehicle speed.  At high pedals, engine speed operation is > 3500rpm.

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Shift Schedule [ Sports Mode ]
SPORTS MODE SPORTS MODE  Shift Schedule for X451
1>2 Engine Speed before shift 2>3 Engine Speed before shift DCT isSpeed
3>4 Engine made.before shift
1>2 2>3 3>4 4>5 5>6 6>7 4>5 Engine Speed before shift 5>6 Engine Speed before shift 6>7 Engine Speed before shift

2>1 3>2 4>3 5>4 6>5 7>6 2>1 Engine Speed before shift 3>2 Engine Speed after shift 4>3 Engine Speed after shift

5>4 Engine Speed after shift 6>5 Engine Speed after shift 7>6 Engine Speed after shift
110 100
100 1st gear used @
90 Operation: 4500 -
90 >80 % 6000rpm
80
80
accelerator
pedal input
Accelerator Pedal [%]

70

Accelerator Pedal [%]


70
60
60
50
50 Operation from 2200 –
40 40 4000 rpm
30 30

20 20

10 10
Operation from 1600 -2500 rpm
0
0
-20.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0
-500 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Vehicle Speed [kph] Engine Speed [rpm]

 In Fuel Economy zone (Low Pedals), engine speed operation is higher than city
 Minimum 5kph and 20% accelerator pedal hysteresis is maintained
mode by at least 600 rpm.
between upshift and downshift.
 In medium pedal, operating engine speed range is more than city mode by 600-
 1st Gear is used for launch.
1000 rpm.

 At high pedals, engine speed operation is more than city mode by ~ 1000 rpm.
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Full load performance
Velocity [1st gear launch] Velocity [2nd gear launch] Gear [1st gear launch] Gear [2nd gear launch]
 Full load performance with 1st gear launch and
180 7 2nd gear launch is simulated.

160
 Acceleration performance with 1st gear launch is
6 inferior as compared to second gear launch due
to an extra gear shift.
140

5  1st gear launch is not preferable and should only


120 be used for climbing maneuvers

 Vehicle is able to reach upto 160 kph in 60 sec


Velocity [Kmph]

4
100

Gear
80
3

X451 DCT
60 Polo DCT
City Mode Sport Mode
2
In case of 2nd Gear Launch, there is 0-60 kmph 5.5 7.2 7.3
40 one shift till 60 kph, whereas for 1st 0-100 kmph 12.5 16.3 16.01
gear launch there are 2 gear shifts till
1
20 60 kph.

0 0
0 10 20 30 40 50 60
Time [sec]

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Acceleration and ARAI Fuel Economy Comparison

Polo DCT Tiago AMT X451 MT X451 DCT

City Sports City City Sports


Metric D Mode S Mode
Mode Mode Mode Mode Mode

0 - 60 kph sec 5.5 5.7 8.8 7.9 6.6 7.2 7.4

0 - 100 kph sec 12.5 12.9 20.7 18.6 16.6 16.3 16.1

19.24
ARAI Fuel Economy kmpl 17.21 x 22.3 21.16 19.88
???

 For Acceleration performance, MT is launched at max. torque as compared to idle launch in DCT.

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Acceleration and Driveability and Fuel economy Assessment

Part Load & Full Load Performance  It is possible to achieve part load
18 performance equivalent to Polo DCT.

16  However, at higher speeds,


performance of Polo is considerably
14
better than X451, as encircled with
12
blue.
Time [sec]

10 2 shifts @ >80% 2 shifts @ >80%


pedal within 60 kph pedal within 60 kph  With 1st gear launch, performance @
8 for 1st gear launch. for 1st gear launch. 40 – 60 kph range deteriorates as
Hence slower Hence slower
performance performance
compared to 2nd gear launch.
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0
20-40 40-60 20-40 40-60 60-80 80-100 20-40 40-60 60-80 80-100 100-120 20-40 40-60 60-80 80-100 100-120
kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph
30% Pedal 50% Pedal 80% Pedal 100% Pedal
Accelerator Pedal [%]

Polo DCT D Mode Polo DCT S Mode X451 DCT City Mode 2nd Gear Launch
X341 DCT Sports Mode 2nd gear launch X341 DCT Sports Mode 1st gear launch

Date
# target with IAC+ESS 14
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Acceleration and Driveability and Fuel economy Assessment

Part Load & Full Load Performance  It is possible to achieve part load
25 performance equivalent to Polo DCT.

 However, at higher speeds,


20 performance of Polo is considerably
better than X451, as encircled with
blue.
15
Time [sec]

2 shifts @ >80% 2 shifts @ >80%


pedal within 60 kph pedal within 60 kph  With 1st gear launch, performance @
10
for 1st gear launch. for 1st gear launch. 40 – 60 kph range deteriorates as
Hence slower Hence slower
performance performance
compared to 2nd gear launch.

0
20-40 40-60 20-40 40-60 60-80 80-100 20-40 40-60 60-80 80-100 100-120 20-40 40-60 60-80 80-100 100-120
kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph
30% Pedal 50% Pedal 80% Pedal 100% Pedal
Accelerator Pedal [%]

Polo DCT D Mode Polo DCT S Mode X451 DCT City Mode 2nd Gear Launch
X341 DCT Sports Mode 2nd gear launch X341 DCT Sports Mode 1st gear launch Tiago AMT City Mode
Tiago AMT Sport Mode

Date
# target with IAC+ESS 15
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Acceleration and Driveability and Fuel economy Assessment

Part Load & Full Load Performance  It is possible to achieve part load
18 performance equivalent to Polo DCT.

16  However, at higher speeds,


performance of Polo is considerably
14
better than X451, as encircled with
12
blue.
Time [sec]

10 2 shifts @ >80% 2 shifts @ >80%


pedal within 60 kph pedal within 60 kph  With 1st gear launch, performance @
8 for 1st gear launch. for 1st gear launch. 40 – 60 kph range deteriorates as
Hence slower Hence slower
performance
compared to 2nd gear launch.
6 performance

0
20-40 40-60 20-40 40-60 60-80 80-100 20-40 40-60 60-80 80-100 100-120 20-40 40-60 60-80 80-100 100-120
kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph kmph
30% Pedal 50% Pedal 80% Pedal 100% Pedal
Accelerator Pedal [%]

Polo DCT D Mode Polo DCT S Mode X451 DCT City Mode 2nd Gear Launch
X451 DCT Sports Mode 2nd gear launch X451 DCT Sports Mode 1st gear launch

Date
# target with IAC+ESS 16
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Acceleration and Driveability and Fuel economy Assessment

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