DSG大众湿式双离合器变速箱技术资料
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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
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
Coil Spring
Input shaft 2
Input Shafts
The engine torque is transmitted to the input shafts from multi-plate clutches K1 and K2 Input shaft 1
Input shaft 2 Input shaft 2 Input shaft 2 is shown in relation to the installation position of input shaft 1 Pulse wheel
DSG - Direct Shift Gearbox 4x4
The New Audi TT with DSG
Direct-shift gearbox 02E Audi works designation : DSG 250
Volkswagen works designation : DQ 250 twin clutch gearbox
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 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 that the requirement for unrestricted gear selection can be fulfilled. This includes from even to even and uneven to uneven gears
N371 Damper
Locations
Filwenku.baidu.comers
G194 Pressure Sender 2
4th/6th gear
2nd gear
Input Shaft 1
Pulse wheel
5th Gear
1st/Rev Gear
3rd Gear
Output Shaft 1
1st Gear 3rd Gear 4th Gear 2nd Gear Output shaft gear
Installation position in gearbox
8Ms.
80Ms. 80Ms. 150Ms. 150Ms. 220Ms. 220Ms. 250Ms. 250Ms. 700Ms.
DSG - Direct Shift Gearbox
Oil Cooler Oil Pressure Filter Oil Pump
Mechatronics
Multi-plate clutch
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 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 gear, 3rd gear is pre-selected to cut down on shifting time.
Volkswagen DSG (Golf GTI)
BMW SMG II (M3 E46) Ferrari F1 (Maserati 4200GT) Ferrari F1 (360 F1) Ferrari F1 (Enzo) Ferrari F1 (575M) BMW SMG (M3 E36) Aston Martin Vanquish BMW SSG (3-series) Alfa Selespeed (156 Selespeed)
5th Gear K1 Clutch Input shaft 1 Output shaft 2 Differential
6th Gear Power flow
6th Gear K2 Clutch Input shaft 2 Output shaft 2 Differential
Reverse Gear Power flow
This graph shows the improvement that DSG offers over a conventional manual transmission.
Time
Conventional manual DSG
Speed
The DSG is currently the fastest shifting automated manual gearbox available. Here are some comparisons.
Direct-shift gearbox 02E Weight Operating Mode : 94 Kg approx FWD – 109 Kg approx 4WD : 6 Speed Automatic and Tiptronic
Oil volume
: 7.2 Litres DSG Oil G052 182
Solenoid Activation Chart
N88 N89 N90 N91 EPC N217 EPC N215 K1 EPC N216 K2 N92
Multiplexer
1st 2nd 3rd 4th 5th 6th Rev N
X
*
X
X
X X X X X X
*
* * * * * * X X X
Direct-shift gearbox 02E The DSG was developed by Borg Warner for the Volkswagen 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 Stronic. The Bugatti Veryon uses a specially up rated version of the DSG. It is also expected that Lamborghini may introduce DSG-equipped cars soon.
1st Gear K1 Clutch Input shaft 1 Output shaft 1 Differential
2nd Gear Power flow
2nd Gear K2 Clutch Input shaft 2 Output shaft 1 Differential
3rd Gear Power flow
Reverse Gear K1 Clutch Input shaft 1 Reverse shaft Output shaft 2 Differential
Selector Lever
Control Unit
Hall Effect Sensors for Tiptronic control
Selector lever sensors control
Plunger 1
Outer plate carrier K1 Clutch K1
Oil pressure chamber K1
Input shaft 1
Diaphragm Spring
Clutch K2 Plunger 2
Oil pressure chamber K2
Inner plate carrier K2
Input shafts
Locking collar
Output Shaft 2
Installation position in gearbox
Pulse wheel for G195 & G196 5th Gear 6th Gear Reverse Gear Output shaft gear
1st Gear Power flow
X
X X
X
X X
Valve Layout
Multiplexer Valve Pressure Reg Valve
Clutch Cooling Valve
N371 Safety Valve N233 Safety Valve
Valve Damper Layout
N233 Damper
Cooler Damper
3rd
1st
K1
The Twin Clutch System
Setting up the clutch
Outer plate carrier K2
Outer plate carrier K1
Dual mass flywheel
Input hub
Drive Plate
Main hub
Inner plate carrier K1
Hall Effect Sensors
Valve Body & Mechatronics
Once the printed circuit is removed, the gear actuator valves N89, N90 and N91 become visible
N90
N89
N92
N91
Diagram Showing Principle of Operation
Transmission unit 2 Multi-plate clutch K2
Engine torque
Multi-plate clutch K1 Transmission unit 1
6th
4th
2nd
K2
Rev
5th
4th Gear Power flow
4th Gear K2 Clutch Input shaft 2 Output shaft 1 Differential
5th Gear Power flow
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
Coil Spring
Input shaft 2
Input Shafts
The engine torque is transmitted to the input shafts from multi-plate clutches K1 and K2 Input shaft 1
Input shaft 2 Input shaft 2 Input shaft 2 is shown in relation to the installation position of input shaft 1 Pulse wheel
DSG - Direct Shift Gearbox 4x4
The New Audi TT with DSG
Direct-shift gearbox 02E Audi works designation : DSG 250
Volkswagen works designation : DQ 250 twin clutch gearbox
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 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 that the requirement for unrestricted gear selection can be fulfilled. This includes from even to even and uneven to uneven gears
N371 Damper
Locations
Filwenku.baidu.comers
G194 Pressure Sender 2
4th/6th gear
2nd gear
Input Shaft 1
Pulse wheel
5th Gear
1st/Rev Gear
3rd Gear
Output Shaft 1
1st Gear 3rd Gear 4th Gear 2nd Gear Output shaft gear
Installation position in gearbox
8Ms.
80Ms. 80Ms. 150Ms. 150Ms. 220Ms. 220Ms. 250Ms. 250Ms. 700Ms.
DSG - Direct Shift Gearbox
Oil Cooler Oil Pressure Filter Oil Pump
Mechatronics
Multi-plate clutch
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 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 gear, 3rd gear is pre-selected to cut down on shifting time.
Volkswagen DSG (Golf GTI)
BMW SMG II (M3 E46) Ferrari F1 (Maserati 4200GT) Ferrari F1 (360 F1) Ferrari F1 (Enzo) Ferrari F1 (575M) BMW SMG (M3 E36) Aston Martin Vanquish BMW SSG (3-series) Alfa Selespeed (156 Selespeed)
5th Gear K1 Clutch Input shaft 1 Output shaft 2 Differential
6th Gear Power flow
6th Gear K2 Clutch Input shaft 2 Output shaft 2 Differential
Reverse Gear Power flow
This graph shows the improvement that DSG offers over a conventional manual transmission.
Time
Conventional manual DSG
Speed
The DSG is currently the fastest shifting automated manual gearbox available. Here are some comparisons.
Direct-shift gearbox 02E Weight Operating Mode : 94 Kg approx FWD – 109 Kg approx 4WD : 6 Speed Automatic and Tiptronic
Oil volume
: 7.2 Litres DSG Oil G052 182
Solenoid Activation Chart
N88 N89 N90 N91 EPC N217 EPC N215 K1 EPC N216 K2 N92
Multiplexer
1st 2nd 3rd 4th 5th 6th Rev N
X
*
X
X
X X X X X X
*
* * * * * * X X X
Direct-shift gearbox 02E The DSG was developed by Borg Warner for the Volkswagen 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 Stronic. The Bugatti Veryon uses a specially up rated version of the DSG. It is also expected that Lamborghini may introduce DSG-equipped cars soon.
1st Gear K1 Clutch Input shaft 1 Output shaft 1 Differential
2nd Gear Power flow
2nd Gear K2 Clutch Input shaft 2 Output shaft 1 Differential
3rd Gear Power flow
Reverse Gear K1 Clutch Input shaft 1 Reverse shaft Output shaft 2 Differential
Selector Lever
Control Unit
Hall Effect Sensors for Tiptronic control
Selector lever sensors control
Plunger 1
Outer plate carrier K1 Clutch K1
Oil pressure chamber K1
Input shaft 1
Diaphragm Spring
Clutch K2 Plunger 2
Oil pressure chamber K2
Inner plate carrier K2
Input shafts
Locking collar
Output Shaft 2
Installation position in gearbox
Pulse wheel for G195 & G196 5th Gear 6th Gear Reverse Gear Output shaft gear
1st Gear Power flow
X
X X
X
X X
Valve Layout
Multiplexer Valve Pressure Reg Valve
Clutch Cooling Valve
N371 Safety Valve N233 Safety Valve
Valve Damper Layout
N233 Damper
Cooler Damper
3rd
1st
K1
The Twin Clutch System
Setting up the clutch
Outer plate carrier K2
Outer plate carrier K1
Dual mass flywheel
Input hub
Drive Plate
Main hub
Inner plate carrier K1
Hall Effect Sensors
Valve Body & Mechatronics
Once the printed circuit is removed, the gear actuator valves N89, N90 and N91 become visible
N90
N89
N92
N91
Diagram Showing Principle of Operation
Transmission unit 2 Multi-plate clutch K2
Engine torque
Multi-plate clutch K1 Transmission unit 1
6th
4th
2nd
K2
Rev
5th