DSG_培训-VW

1ServiceTrainingTT-103V-20107-speed0BHdualclutchgearbox2ServiceTraining06.2010•VSQ/TT•2/31ContentsAimsandopportunitiesCharacteristicsandrangeofapplicationSpecificationsGearboxdiagramPowerflowParkinglockShaftsDifferential3ServiceTraining06.2010•VSQ/TT•3/31ContentsClutchOilpressuresupplyLubricationoftheshaftsHydraulicdiagramMechatronicsActuatorsSensorsSystemoverview4ServiceTraining06.2010•VSQ/TT•4/31ContentsService5ServiceTraining06.2010•VSQ/TT•5/31Aimsandopportunities7-speed0BHdualclutchgearboxThe0BHdualclutchgearbox,alsoreferredtoasDQ500bythemanufacturingcompany,hasbeendevelopedfortransmittinghightorques.Itisbasedonthetechnologyofthedualclutchgearbox02E(DQ250),whichhasundergonefar-reachingfurtherdevelopmentfortheDQ500.Advantages:•Reducedconsumption•Winningovermanualgearboxcustomers•Expansionandfurtherdevelopmentofexpertiserelevantforthecompetitionindualclutchgearboxes6ServiceTraining06.2010•VSQ/TT•6/31Characteristicsandrangeofapplication7-speed0BHdualclutchgearboxDualclutchElectricalconnectionMechatronicsInstallationspectrumVehicles:•FirstGroupuseinVolkswagenCommercialVehiclesT52010withmarketlaunch•Asofweek35,alsoappliedinVolkswagenpassengercarsintheTiguanEnginesfortheTiguan:2.0ltr.-100-103kWTDI2.0ltr.-125-147kWTSIFeatures:•Designedforhighinputtorque•Twomulti-platewetclutches•Noreverseshaftforthereversegear•Bothfrontwheelandall-wheeldrivepossible•IntheTiguanonlyall-wheeldrive7ServiceTraining06.2010•VSQ/TT•7/31MechatronicsInputshaft1Outputshaft2Outputshaft1FinaldriveOilfilterSpecifications7-speed0BHdualclutchgearboxAxlebaseDesignfeaturesandtechnicaldata•Torquecapacityupto600Nmpossible•Highinputpowerupto275kWpossible•Twomulti-platewetclutches•7forwardgearswithoverdrive(CO2optimized)and1reversegear•Spread:max.7.45•Axlebase:Tiguan.197mm•Weight:approx.110kg(all-wheeldrive)•Operatingfunctions:Automatic/tipmode•Oilquantity:approx.7.0linitialfilling,approx.5.5lchangequantity•Oilspecification:G052182•Oilchangeinterval:every60,000km•Oilfilter:lifetime-capable(nochangesplanned)8GearboxdiagramTheenginetorqueistransmittedviaadualmassflywheeltothedualclutch.Thedualclutchgearbox0BHisconfiguredasa3-shaftgearbox.Torquecurvewithingearbox:DualclutchK1orK2↓Inputshaft1or2↓Outputshaft1or2,dependingonengagedgear↓Crownwheel/differential↓Frontwheelsorbeveldrivewith4MotionServiceTraining06.2010•VSQ/TT•8/31GearboxdiagramInputshaft1Outputshaft1Outputshaft2XInputshaft2Sub-gearbox1Sub-gearbox2Dualclutch9ServiceTraining06.2010•VSQ/TT•9/31PowerflowK1K22.1stgearReversegear(Theshaftsareshowninasingleplaneforbetterdescription.)1stgear:Sub-gearbox1:K1→inputshaft1→outputshaft1,1stgearsynchromeshedgear→finaldriveReversegear:Sub-gearbox2:K2→inputshaft2→outputshaft2,2ndgearsynchromeshedgearoutputshaft1,reversegearsynchromeshedgear→finaldriveInthenew7-speeddualclutchgearboxthereversegearprocesshasbeennewlydeveloped.The0BHdualclutchgearboxnolongercontainsthereverseshaft.Therotationaldirectionischangedbytheinterplayofthesynchromeshedgearofthe2ndgear(outputshaft2)withthereversegearsynchromeshedgear(outputshaft1).10ServiceTraining06.2010•VSQ/TT•10/31PowerflowK2K12ndgear3rdgear2ndgear:Sub-gearbox2:K2→inputshaft2→outputshaft2,2ndgearsynchromeshedgear→finaldrive3rdgear:Sub-gearbox1:K2→inputshaft1→outputshaft2,3rdgearsynchromeshedgear→finaldrive11ServiceTraining06.2010•VSQ/TT•11/31PowerflowK1K24thgear5thgear4thgear:Sub-gearbox2:K2→inputshaft2→outputshaft1,4ndgearsynchromeshedgear→finaldrive5thgear:Sub-gearbox1:K2→inputshaft1→outputshaft1,5thgearsynchromeshedgear→finaldrive12ServiceTraining06.2010•VSQ/TT•12/31PowerflowK2K16thgear7thgear6thgear:Sub-gearbox2:K2→inputshaft2→outputshaft2,6thgearsynchromeshedgear→finaldrive7thgear:Sub-gearbox1:K2→inputshaft1→outputshaft2,7thgearsynchromeshedgear→finaldrive13ServiceTraining06.2010•VSQ/TT•13/31ShaftsInputshafts1and2Inputshaft1Inputshaft27thgear3rdgear4thand6thgears2ndgear1stgear5thgearInputshaft1:Runsthroughthehollowinputshaft2.Inputshaft1isconnectedtothemulti-discclutchK1bygearing.Gearwheels(fixedgears)1st,3rd,5th,7thgearsInputshaft2:Hollowedinputshaft.Mountedinacylindricalrollerbearingoninputshaft1.Inputshaft2isconnectedtomulti-discclutch2bygearing.Gearwheels(fixedgears)2nd,4th+6thgear14ServiceTraining06.2010•VSQ/TT•14/31ShaftsOutputshaft11stgear4thgearParkinglockReversegearOutputgear5thgearOutputshaft1:•Synchromeshedgears(idlergears)forthe1st,4th,5thandreversegears•ParkinglockSynchronisation:Allsynchronisersonoutputshaft1havecarbonfrictionlinings.•1stgear+reversegear:3-waysynchronisationonsheetsteelcarriers•4thgear+5thgear:1-waysynchronisationonbrasscarrier15ServiceTraining06.2010•VSQ/TT•15/31ShaftsOutputshaft27thgear6thgear2ndgear3rdgearOutputgearOutputshaft2:Synchromeshedgears(idlergears)forthe2nd,3rd,6thand7thgearsSynchronisation:Allsynchronisersonoutputshaft2havecarbonfrictionlinings.•2ndgear:3-waysynchronisationwithsheetsteelcarriers•3rdgear:3-waysynchronisationwithbrasscarrier•6thgear:1-waysynchronisationwithsheetsteelcarrier•7thgear:1-waysynchronisationwithbrasscarrier16ServiceTraining06.2010•VSQ/TT•16/