DSG大众湿式双离合器变速箱技术资料.ppt

1、DSG - Direct Shift Gearbox,Presented by Dr William (Bill) Henney PhD F.I.M.I,We will look at the 6 and 7 speed variants Designators 6 Speed 02E 7 Speed 0AM 6 Speed Honda Motor Cycle Transmission,DSG - Direct Shift Gearbox 4x4,The New Audi TT with DSG,Direct-shift gearbox 02E Audi works designation :

2、 DSG 250 Volkswagen works designation : DQ 250 twin clutch gearbox,Direct-shift gearbox 02E Weight : 94 Kg approx FWD 109 Kg approx 4WD Operating Mode : 6 Speed Automatic and Tiptronic Oil volume : 7.2 Litres DSG Oil G052 182,Direct-shift gearbox 02E The DSG was developed by Borg Warner for the Volk

3、swagen Group and has been in production since July 2003. It is available in cars like the Pole,Passat, Golf, Touran and Jetta. It is also fitted to the new Audi TT and Audi A3, but Audi refer to it as the S-tronic. The Bugatti Veryon uses a specially up rated version of the DSG. It is also expected

4、that Lamborghini may introduce DSG-equipped cars soon.,Direct-shift gearbox 02E In principle, the twin clutch gearbox takes the form of two fully functioning manual gearboxes, connected in parallel, with a shared differential (2 gearboxes in one housing) The engine torque is divided between the part

5、 gearboxes via two clutches. One part gearbox selects the even gears and the other the uneven gears. Each gear is allocated to a conventional synchroniser and selector of a manual gearbox as are used in VW manual gearboxes. The selector units can change gear independently of each other. This means t

6、hat the requirement for unrestricted gear selection can be fulfilled. This includes from even to even and uneven to uneven gears,Direct-shift gearbox 02E Put another way. It uses two computer controlled clutches. The outer clutch pack drives gears 1, 3 and 5 as well as reverse gear. The inner clutch

7、 pack drives 2nd, 4th and 6th gear. Each clutch pack is comprised of 4 smaller clutch disc instead of the normal single large plate found in most gearboxes. This system allows extremely precise shifting that requires only 8 milliseconds thanks to gear pre-selection. For example, while you are in 2nd

8、 gear, 3rd gear is pre-selected to cut down on shifting time.,This graph shows the improvement that DSG offers over a conventional manual transmission.,The DSG is currently the fastest shifting automated manual gearbox available. Here are some comparisons. Volkswagen DSG (Golf GTI) 8Ms. BMW SMG II (

9、M3 E46) 80Ms. Ferrari F1 (Maserati 4200GT) 80Ms. Ferrari F1 (360 F1) 150Ms. Ferrari F1 (Enzo) 150Ms. Ferrari F1 (575M) 220Ms. BMW SMG (M3 E36) 220Ms. Aston Martin Vanquish 250Ms. BMW SSG (3-series) 250Ms. Alfa Selespeed (156 Selespeed) 700Ms.,Oil Cooler,Diagram Showing Principle of Operation,The Twi

10、n Clutch System,Setting up the clutch,Oil pressure chamber K2,Plunger 2,Clutch K2,Inner plate carrier K2,Coil Spring,Input shaft 2,Input Shafts,Input Shaft 1,Output Shaft 1,1st Gear Power flow,1st Gear K1 Clutch Input shaft 1 Output shaft 1 Differential,2nd Gear Power flow,2nd Gear K2 Clutch Input s

11、haft 2 Output shaft 1 Differential,3rd Gear Power flow,3rd Gear K1 Clutch Input shaft 1 Output shaft 1 Differential,4th Gear Power flow,4th Gear K2 Clutch Input shaft 2 Output shaft 1 Differential,5th Gear Power flow,5th Gear K1 Clutch Input shaft 1 Output shaft 2 Differential,6th Gear Power flow,6t

12、h Gear K2 Clutch Input shaft 2 Output shaft 2 Differential,Reverse Gear Power flow,Reverse Gear K1 Clutch Input shaft 1 Reverse shaft Output shaft 2 Differential,Valve Body & Mechatronics,N371 Damper,Cooler Damper,N233 Damper,Valve Damper Layout,Solenoid Locations,N217 Line Pressure Control,N216 K2

13、Pressure Control,N215 K1 Pressure Control,N371 6th Gear Pressure Control,N91 No.4 Gear Actuator,N90 No.3 Gear Actuator,N218 4th Gear Pressure Control,Pressure Relief Valve,N233 5th Gear Pressure Control,N92 Multiplexer,N89 No.2 Gear Actuator,N88 No.1 Gear Actuator,Solenoid Details,N215 Pressure Cont

14、rol No.1 Normally Low Pressure 5 Ohm approx solenoid Regulates pressure to the No.1 Clutch. Influenced by engine torque. Failure could cause premature failure of the clutch. Failure in the on position will cause engine stall at a stop. N216 Pressure Control No.2 Normally Low Pressure 5 Ohm approx so

15、lenoid Regulates pressure to the No.2 Clutch. Influenced by engine torque. Failure could cause premature failure of the clutch. Failure in the on position will cause engine stall at a stop. N217 Pressure Control No.3 Normally Applied 5 Ohm solenoid Regulates main line pressure. Engine RPM and engine

16、 temperature are used to adjust pressure. If the solenoid fails, shut down occurs and maximum pressure maintained. N218 Pressure Control No.4 Normally Applied 5 Ohm solenoid Regulates cooling oil to both clutches. The clutch oil temperature sender G509 acts on this solenoid. Failure in the minimum v

17、olume position will cause the clutches to over heat. Failure in the maximum volume position will cause difficult gear engagement at cold ambient temperatures. N233Pressure Control No.5 Normally Applied 5 Ohm solenoid A safety solenoid that isolates section 1 of the gear train so gears are not availa

18、ble from that section . During failure only 2nd gear is available. N371Pressure Control No.6 Normally Applied 5 Ohm solenoid A safety solenoid that isolates section 2 of the gear train so gears are not available from that section. During failure only 1st and 3rd gears are available.,N88 No.1 gear ac

19、tuator N.C. ON/OFF 8 Ohms approx solenoid Allows pressure to 1st and 5th gear actuators. N89 No.2 gear actuator N.C. ON/OFF 8 Ohms approx solenoid Allows pressure to 3rd and “N” gear actuators. N90 No.3 gear actuator N.C. ON/OFF 8 Ohms approx solenoid Allows pressure to 2nd and 6th gear actuators. N

20、91 No.4 gear actuator N.C. ON/OFF 8 Ohms approx solenoid Allows pressure to 4th and “R” gear actuators. N92 No.5 Multiplexer Solenoid N.C. ON/OFF 15-20 Ohms approx solenoid Used to stroke the Multiplexer valve in the valve body to allow a gear actuator to select different gears.,Solenoid Details,G50

21、2 Input Sender No.2,G501 Input Sender No.1,G195 and G196 Output Shaft Sender,Travel Senders,A permanent magnet is fitted to each selector fork. The magnet allows the travel sensor in the mechatronics to detect the precise position of the selector fork.,Magnetic Travel Senders,Travel Senders,Selector

22、 Rollers,Mechatronic Hall Effect Sensors,Oil Pump,An internal gear crescent pump is used for the actuation of hydraulic components. It allows a maximum output of 100 litres per minute and a main pressure of 20 bar. The oil pump supplies the multi-plate clutches, the clutch cooling, gear selection hy

23、draulics and gear wheel lubrication.,Oil Pump,Oil Pump,The following damage situation are known to date,Mechatronics Plated through holes interrupted Caused by excessive voltage. Gear selector defective A ball from the guide sleeve 5th/Neutral was stuck on the solenoid. Syncroniser ring for 6th dest

24、royed. Oil Pump Noises Noise at 1000rpm Toothing of oil pump shaft Replace oil pump Pulsation noise in all gears between 4000 rpm & 6000 rpm Check fluid level or replace oil pump. Oil Leaks Oil leaking from cooler Replace seal on cooler and check for casing pores on mating surface. Clutch cover seal

25、ing ring split. Twin clutch Creep and judder, defective splash oil compensation, delayed automatic up shifts replace twin clutch Emergency operation activated Vehicle goes into emergency mode when cornering caused by low oil level Clutch adaptation Clutch adaptation must be carried out after any rep

26、airs via V.A.G. Diagnostics,Valve Body Layout,Valve Body Layout,Bearing Race Problem,The following damage situation are known to date,Mechatronics Plated through holes interrupted Caused by excessive voltage. Gear selector defective A ball from the guide sleeve 5th/Neutral was stuck on the solenoid.

27、 Synchroniser ring for 6th destroyed. Oil Pump Noises Noise at 1000rpm Toothing of oil pump shaft Replace oil pump Pulsation noise in all gears between 4000 rpm & 6000 rpm Check fluid level or replace oil pump. Oil Leaks Oil leaking from cooler Replace seal on cooler and check for casing pores on ma

28、ting surface. Clutch cover sealing ring split. Twin clutch Creep and judder, defective splash oil compensation, delayed automatic up shifts replace twin clutch Emergency operation activated Vehicle goes into emergency mode when cornering caused by low oil level Clutch adaptation Clutch adaptation mu

29、st be carried out after any repairs via V.A.G. Diagnostics,Twin Clutch Adjustment Procedure,Fit Clutch with a 2mm Circlip from VW # 02E 398 321,0.12mm (Inner shaft reading) 0.04mm (Outer shaft reading) +1.85mm (Standard measurement) = 1.93mm ( Fit 1.90mm circlip ),Note : Always select the nearest lo

30、wer available circlip. Never fit a thicker one.,The most common concern with the DSG is DTC 19143 (Unexpected Implausible Gear),This transmission is fundamentally a Manual Gearbox controlled by sophisticated electronics,Debris created from normal wear collects on the magnetised rings and travel send

31、ers.,This confuses the Mechatronic as it cannot read which gear it should be in.,A simple strip and clean of this transmission can be all that is required. $ $ $ $ $,Shock the splined casing bolts before attempting to remove as they damage very easy.,Re-assembly Tips,Oil Spray Lubrication and Coolin

32、g Pipe,Heat casing to slide over bearing,Locate Bearing in Front Housing,Retain with Circlip,K1 Clutch Pack,K2 Clutch Pack,Twin Clutch,Fit Twin Clutch into Housing,Fit Circlip to close the Clutch,Fitting the Front Cover,Use Seal-e-Zee and the Cone System,Retain cover in casing with circlip,Now we wi

33、ll look at the 7 Speed0AM,Modular design Dry Double Clutch 7 Gears on 4 Shafts Oil Pump driven subject to requirements No Heat Exchanger,Design Features,Designation 0AM Weight Approx. 70 kg including clutch Torque 250 Nm Gears 7 forwards gears, 1 reverse gear Spread 8.1 Operating mode Automatic and Tiptronic Gearbox oil volume 1.7l - G 052 171 Mechatronic unit oi