Conventional and Mild Hybrid Powertrain Technologies

Electric Drives are our way into the future.

Efficient conventional drives are in our DNA.

Although market trends show a clear shift towards electrified vehicles, the share of conventional powertrain systems will still be globally significant during the next decade. Therefore, Magna continues to work intensively on efficiency improvement of all conventional and mild hybrid drivetrain solutions. Being a long-term premium supplier for the global automotive industry, we have broad experience and a unique market position. With this expertise, our innovations contribute to the overall performance of the vehicle with any type of powertrain, always pushing to the next level of CO2 emissions reduction.

With the purpose of tailoring to global market needs, Magna supports this development with innovative, efficient, and cost effective advanced all-wheel drive (AWD) and four-wheel drive systems (4WD), in addition to disconnect systems, manual transmissions (MT), dual-clutch transmissions (DCT), and mild hybrid solutions (HDT 48V).

Our field-tested mild hybrid systems provide an answer to multiple existing challenges, like legislation driven CO2 reduction and high-cost pressures. Such systems support high-volume applications of electrified drivelines as well as fleet average targets at reasonable costs. Mild hybrid systems also achieve improved driving dynamics through electric torque vectoring and traction support. These systems even enable functions like autonomous electric parking.

Hybridized Dual-Clutch Transmissions 48V

The scalable mild hybrid transmission solutions, range from various hybridized dual-clutch to cost-efficient hybridized manual transmission solutions. 

Find out more about our hybrid transmissions and download the Deep Dive content:

Technical Paper- Mild hybrid transmissions

Hybrid Dual-Clutch Transmission HDT Eco 48V

Part of the new DHD/HDT/DCT family - 48V hybrid transmission with six speeds

Based on the DCT Eco, one of the three products in the series is the HDT Eco for mild hybrid applications. Like the DHD Eco, this includes the e-motor in a P2.5 configuration; it can be distinguished from its high-voltage cousin by its side-mounted inverter. Thanks to the shorter e-motor with a peak output of 25 kW, this inverter position does not make the overall length of the transmission longer than the DCT model.

Since the combustion engine is the dominant drive source for this model (unlike the DHD, where the main power comes from the e-motor), the HDT relies on the same gear set as the DCT, with four physical gears and six effective speeds, as well as the additional half-shaft for reversing.

Functionally speaking, the HDT Eco is a ‘classic’ add-on hybrid transmission, but it again transfers the lower complexity of the DHD to mild hybrid use. Its short axial length makes it especially useful for transverse hybrid applications with limited installation space, which are common in the B-segment. We expect to see increasing numbers of 48V hybrid solutions in this segment in the near future.

Thanks to its P2.5 architecture, it offers the perfect compromise between power and weight/package. Its recuperation power is much higher than that of 48V P0 hybrid solutions, and it enables electric drive and maneuvering at lower speeds.

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Hybrid Dual-Clutch Transmission 7HDT400 48V

The 7-speed hybrid dual-clutch transmission 7HDT400 for mild (48 V) hybrids enables ideal use of the efficiencies of the combustion engine and the e-motor with its specific torque-split concept for hybridization.

As a consequent evolution of the 7HDT300, the 7HDT400 was designed to achieve higher engine torques, to improve the overall fuel effiency and to offer an excellent power density.

Besides the scalable functionality, it shows benefits such as high modularity with base transmission, fully integrated e-motor as well as independent on demand cooling for clutch and e-motor. Furthermore, all market relevant hybrid functionalities are possible, even in mild hybrid.

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Dual Clutch Transmissions

Two Transmissions in One

Magna dual-clutch transmissions offer the best driving comfort, top-of-the-line efficiency and supercar driving dynamics. Intelligent software ensures that while one gear is active, the next is already preselected. During gear changes, two clutches are actuated alternately. This allows seamless shifts without torque interruption, speeds up gear change and avoids the jolt associated with regular automatics.

Compared to conventional automotive transmissions with torque converters, dual-clutch transmissions are about five percent more economical and in some driving cycles and vehicles even more than 20 percent.

6-Speed Dual-Clutch Transmission DCT Eco

Part of the new DHD/HDT/DCT family - Dual-Clutch Transmission with six speeds

The DCT Eco dual-clutch transmission uses the same gear set as the DHD Eco, thus remaining a simply designed four-speed transmission in ‘physical’ terms. Aside from ‘dropping’ the e-machine, inverter, etc., the only difference inside the transmission is an additional half-shaft for the reverse gear and an additional synchronizer that acts as a bridge.

This is required to provide the logical speeds 1 and 6 (which the DHD does not need due to the wide e-machine power spread). These two speeds are established through winding path gears, where the bridge connects the two transmission sections to form an additional transmission path.

One important question is, whether winding path gears do increase mechanical loss. This is less relevant to the first gear because it is only used for vehicle launch, but it is of great importance for the highest transmission speed – the 6th gear.

However, a comparison with a seven-speed, dual-clutch transmission with no winding path gears in a B-segment vehicle showed that the advantages and disadvantages balance out: Since there are only four physical gearwheel pairs, the slightly higher losses caused by the doubled gearwheel meshing are compensated for by much lower bearing and churning losses.

In addition to this, the configuration with just four mechanical gears is beneficial to both the shaft center distance and the axial length of the transmission, offering advantages in terms of weight and package size that also benefit fuel consumption for the applications included in the investigation.

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8-Speed Dual-Clutch Transmission 8DCL900

Transmission Performance – the 8DCL900 High-End Dual Clutch Transmission

In cooperation with Ferrari, Magna has developed the 8-speed 8DCL900 dual-clutch transmission for a new generation of high-performance engines. Key development objectives were outstanding performance and controllability, higher torque capacity and density, and new technologies to reduce weight and improve longitudinal and lateral performance.

As one of the latest members of the Magna DCT family, the 8DCL900 significantly exceeds all specifications of its predecessors. All building blocks of the transmission have been developed further consequently. Starting with the gearset and shaft layout including shift actuation, the basic layout was consistently tuned to shift performance and driving dynamics, along with an all-new hydraulic system. To allow more gear change accuracy and launch performance, a new clutch design was developed.

To handle the high demands on vehicle lateral performance, the oil circuit including a dry sump concept was newly designed. Compact package and low weight were major requirements, as well as a low installation position for a low center of gravity in the vehicle. To transfer the enormous engine power, many new technologies have been introduced, like special gear design, materials and production methods.

In terms of performance the 8DCL900 is the top product within the Magna transmission family. Many new techniques will be conveyed from the high performance segment to mass production car applications, to further benefit efficiency, weight and package.

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Manual Transmissions

Modular Manual Transmissions

Magna manual transmissions are designed according to a modular concept. By varying the number of speeds and the maximum torque density, we can apply one layout to numerous engines. In addition, we continuously optimize all elements of transmission design, from bearings and sealings to power density and fuel efficiency. Consequent weight reduction rounds off our endeavour to make our manual transmissions as efficient as possible.

For passenger cars as well as light commercial vehicles, we build inline transmissions for rear and four-wheel drives; transaxle longitudinal transmissions for front-wheel, rear-wheel and all-wheel drive; as well as transaxle transmissions for front-wheel or all-wheel drive.

4WD

Dynamic Performance On and Off Road

We offer highest performance in the most dynamic driving situations, reliability for extreme requirements in offroad operation and increased safety through best traction reliability. Magna’s transfer case systems are designed to meet the customer’s needs under various driving conditions. Combined with optimized front axle drives with low weight and small packaging, four-wheel drive (4WD) systems by Magna meet the demand for best-in-class fuel efficiency for each application.

ActiMax™ Transfer Case

Premium 4WD. The Instinct to Perform.

ActiMax™ is a single-speed active transfer case designed for the intensive requirements of sports and premium vehicles. The active system splits torque, distributes it intelligently to the secondary axle and supports the pre-load in speed for the secondary axle. Modular software components allow customized compilation of functional modules to meet different requirements for efficiency, traction and driving dynamics. The Direct Actuation System in combination with Magna's controls strategy guarantees optimal torque accuracy and dynamic torque distribution. ActiMax™ is available with different front output systems (gear and chain drive, concentric drive) to meet specific requirements for torque distribution, packaging, weight and efficiency.

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UltiMax™ Transfer Case

Durable 4WD. Ultimate Offroad Performance.

UltiMax™ by Magna is optimized for the extreme requirements in offroad operation. Thanks to different versions and a variety of possible operational modes, UltiMax™ can effortlessly be adapted to perfectly meet individual vehicle requirements. UltiMax™ is available as a two-speed part time, full time or active transfer case. The deep low ratio enables the operation in extreme offroad terrain or the pulling of heavy loads with best drivability under severe conditions. What makes UltiMax™ unique is the optionally available shift on the move functionality, which allows to switch between high and low ranges while driving.

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TruMax™ Full Time Transfer Case

Permanent 4WD. Truly Reliable Drive.

Magna’s TruMax™ Transfer Case is a single-speed transfer case with an open a center differential and two options for the front output: chain drive or beveloid drive (angular output).

The single speed full-time differential with a purely mechanical function splits the torque and distributes drive power permanently and continuously to both axles, which can provide more acceleration or traction. Customers are able to choose from multiple torque split versions. Innovative features such as the ultra-light design and pumpless lubrication enhance the energy efficiency of the system.

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EcoMax™ Chain Drive Active Transfer Case

Premium 4WD. The Instinct of Efficiency.

EcoMax™ is the next generation of a fully active single-speed transfer case, combining a new level of efficiency and maximum driving dynamics for premium and sports vehicles. The system provides disconnect capability to four-wheel drive vehicles. Thanks to Magna's revolutionary pumpless technology, significant fuel economy and emissions improvements are possible without compromise in dynamics, driver enthusiasm and safety. Optional front output configurations include chain drive, three-gear drive, and beveloid two-gear drive. The integration of a Flex4™ coupling into the transfer case lays the foundations to achieve lowest drag torque and to completely disconnect the secondary drivetrain.

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AWD

All-Wheel Drive for Every Condition

Today's all-wheel drive (AWD) systems need to be light, easy to handle and fully adaptable to various driving conditions without sacrificing traction, performance or safety. Magna's solutions are built to meet the requirements of our customers. To achieve the best results for each driving situation, Magna combines Power Take-Off Units (PTU), AWD couplings and rear-axle drives to complete AWD systems.

Disconnect Systems

Better Fuel Efficiency with Fast Disconnect

Magna Flex4™ is a preemptive disconnect system which greatly increases the fuel efficiency of all-wheel and four-wheel drive vehicles. With its fast and seamless reconnect process, it responds immediately to optimize vehicle safety, traction and dynamics. Disconnect systems help to improve fuel efficiency by engaging the all-wheel drive (AWD), four-wheel drive (4WD) system only when needed, thus providing significant fuel savings.

Powertrain Testing Services

Find here a detailed overview of our Testing Services.

Video Gallery

Picture of Magna Powertrain Hybrid Dual-Clutch Transmission 7HDT400 48V — Hybrid Dual-Clutch Transmission 7HDT400 48V

Picture of the side view of Magna Powertrain TS 7DCT300 Dual Clutch Transmission — 7-Speed Dual-Clutch Transmission 7DCT300

Picture of Magna Powertrain 8 Speed Dual Clutch Transmission 8DCL900 — 8-Speed-Dual-Clutch Transmission 8DCL900

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