Transmission and Driveline Engineering

Gear FEADSD provides an experienced team to steer your new product from first initial idea through to production. Your company may require a new gearbox, transfer box or axle design once every decade: we have completed a dozen in the last year. We understand the wider, vehicle level issues that influence transmission design, such as engine downsizing and hybridisation.

For customers who only require a solution to a specific problem, DSD is able to work as a specialist partner or to supplement your in-house capability, contributing its expertise seamlessly as part of a multi-disciplinary team.

Simulation and Analysis

Efficient engineering at DSD begins with reliable simulation techniques that allow sensitivity analysis in key areas to rank design options long before investing time in detailed CAD models.

DSD uses MASTA simulation software, FEA (including contact analysis) and MATLAB SIMULINK (for torsional systems, selectors, clutches and synchronisers). Our DOE (Design of Experiments) methods provide solutions optimised for each customer’s manufacturing tolerances, not just the nominal component dimensions.

Mechanical Engineering

DSD’s experienced engineers use most of the industry-standard CAD systems, including CATIA, Unigraphics, Pro-E and Inventor (Autodesk). The company’s expertise spans a wide range of industries, manufacturing volumes and torque ratings: it has engineered systems for torque values from 17000Nm down to 0.1Nm.

The company  works on manual, automatic (planetary auto and automated manuals), Automated Manual Transmissions (AMT), Dual Clutch Transmissions (DCT), Continuously Variable Transmissions (CVT) and hybrid transmissions, Power Takeoff Units (PTU), transfer boxes, axles and differentials, and engine gears, such as balancer drives and timing gears.

Shift Systems and Shift Devices

Gear shifting, whether manual or automatic, is the first area where a driver will gain a tangible impression of transmission quality in their vehicle. DSD’s experience of shift system engineering includes actuation systems, hydraulics, electric and manual operation. It is a critical touch point and makes a significant contribution to the perceived quality of not just the transmission, but the whole vehicle.

Through objective measurement, a focus on kinematic analysis and the use of DSD’s proprietary gear shift quality measurement tool, GATE, it engineers shift systems to suit the customers particular vehicle, improving the drivers overall experience.

Troubleshooting and Warranty Support

When issues are uncovered late in a vehicle programme, or post-launch, you need a specialist partner who can quickly identify the root cause and provide a robust solution. The component causing an issue has already gone through an extensive and rigorous analysis and validation programme, so finding and solving the issue is a challenge.

DSD’s range of experience means that, it has the knowledge, capability and analytical systems that make us best placed to find and solve the issue. The company’s track record of producing solutions quickly means it can help minimise your warranty burden. You can review some typical examples in the case study section here.

Engineer for Efficiency

All transmission and driveline engineering takes place in the context of the particular application, whether passenger car, off-highway or industrial. One factor that unifies all these sectors is legislation that is driving improvements in efficiency.

DSD has engineered transmissions and drivelines specifically for high efficiency for customers in all the major industries. Often the efficiency target is combined with challenging load cases or package constraints, or must be achieved with low noise levels.

The company evaluates and calculates the loss of each individual component in the system. By comparing all the available options for each individual element DSD can pick the best solution and reduce losses within the transmission. It can also evaluate and optimise the flow of lubricant to ensure the minimal required amount of churning occurs, reducing parasitic losses and increasing efficiency.