7-käiguline 7-käiguline DSG DS G 7-kä 7-käiiguline guline DSG käi kä igukast gukast 0AM
Serv ice Training Training
VSQ/TT
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Tehnilised Tehnilised and med Tehn Te hnilis ilised ed and a ndme med d
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 2/17
Technical data Weight: 70 kg includin includi ng clu cl utch Torque:
max. 250 Nm
Clutch:
2 x dry-plate clutches
Gear stages:
7 x forward, 1 x reverse
Operating modes mode s: automatic/tip mode Oil volume and specification Gearbox:
1.7 lit litre re gear oil: - G 052 171-
Mechatronics:
1 litre central hydraulic / power steering fluid - G 004 004 000000-
Housing:
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Aluminiu Aluminium m
2
Käigukasti skeem Välj Väljun und d võll 2
Välj Väljun und d võll 3 Sisen Si send d v õl õlll 2
Käigukasti osa 2 R 6
4
2
K2 v eoketas eoketas Kahemassiga hooratas
Diff Diff erentsiaal
7
5
3
1
K1
Mootori moment
Sisend v õll 1 Käigukasti osa 1
F414_002
Väljund Väljund v õll 1
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 3/17
Gearbox diagr diag ram The torque of the engine is transferred through a dual-mass flywheel (its inner splines are meshed with the outer splines of the double clutch) to the double clutch. The double clutch gearbox 0AM is designed as a 4 shaft gearbox. Torque curve within gearbox : When clutch K1 is pressed against the drive plate, the torque can be transferred trans ferred to input s haft 1. Input Input shaft 1 rotates rotates . Before Before this can happen, the selector fork is moved by the selector lever e.g. in direction of 1st gear, and the flow of power is created between input s haft 1 and output shaft shaft 1. Output Output shaft 1 rotates and passes passes on the torque to the differential via a gear wheel connection. From the differential, the torque passes to the front wheels and the vehicle is set in motion. The flow of power from clutch K2 to input shaft 2 and output shaft 2 and 3 is i s based on the sa s ame principl principle e.
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Topeltsidur Topelt kuiv sidur sidur sidur K2
survelaager survelaager K1 survelaager survelaager K2
sidur sidur K1
v eoketas eoketas
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 4/17
The double dry-plate clutch The engaging lever lever with wi th engagement bearings bearings is pressed pressed against against the t he disk springs by the clutch actuators, which results in the clutch plate in question being pressed against the rotating drive plate. Clutch K1 is jo j oined via a spli spline ne connection connection to input shaft 1 and thereby transfers the torque for gears 1,3,5 and 7 to output shaft 1. Clutch K2 is jo j oined via a spli spline ne connection connection to input shaft 2 and thereby transfers trans fers the the torque for gears gears 2,4,6 and R to output shaft 2 and 3.
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Mehhatroonika Rõhu akumulaator Hüdrauliline pump
N438
N435
N440
N434
N439
N436
N433
N437 V401
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 5/17
Key N433
Valve Valve 1 in part gearbox 1
Gear pos pos itioner itio ner valve 1/3 1/ 3
N434
Valve Valve 2 in part gearbox 1
Gear pos pos itioner itio ner valve 5/7 5/ 7
N435
Valve Valve 3 in part gearbox 1
Clutch positioner osit ioner valve K1
N436
Valve Valve 4 in part gearbox 1
Part Pa rt gearbox press press ure regulator regulat or
N437
Valve Valve 1 in part gearbox 2
Gear pos pos itioner itio ner valve 2/4 2/ 4
N438
Valve Valve 2 in part gearbox 2
Gear pos pos itioner itio ner valve 6/R 6/ R
N439
Valve Valve 3 in part gearbox 2
Clutch positioner osit ioner valve K2
N440
Valve Valve 4 in part gearbox 2
Part Pa rt gearbox press press ure regulator regulat or
V401
Hy draulic pump motor
Valv Val ves are actuated actuated with it h a PWM PWM signal s ignal
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Hüdraulik Hüdraulik a skeem Hüdropumba Hüdropumba mootor mootor V401
Filter
Rõhu piiramise v entiil Rõhu akumulaator Käigu Käigu kasti rõhuandur rõhuandur G270
Pearõhu kanalid
Tagasiv Tagasiv oolu klapid
hüdropump
käigukasti os arõhud arõhud
N436
N440
KS Reguleeritud Reguleeritud õli v ool
N 433
N 434
N435
N 437 N 438
N 439
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 6/17
The hydraulic system The hydraulic pump motor V401 is actuated by the control unit and drives the hydraulic pump thereafter. Oil pressure build-up occurs to the pressure pressure accumulator and in the main main pressure pressure channels up to the part gearbox pressure regulators. The gearbox hydraulic pressure sender G270 passes on the pressure in the pressure accumulator and the main pressure channels (up to the part gearbox pressure regulator regulat ors s ) to the control unit. If pressure falls falls below below 40 bar, the control unit actuates the hydraulic pump motor V401. If pressure reaches 60 bar, the motor is switched off. In the event of signal failure from the hydraulic pressure sender, the hydraulic pump runs on indefinitely. The pressure limiting valve then assures hydraulic pressure to avoid avoid component c omponent damage. damage.
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Rõhukanalid mehhatroonika plokis
5
2 4
9 8
6
3
10 11 7
6
1
Osarõhu kanal
Reguleeritud Reguleeritud v ooluga õlikanal
Pea rõhukanal
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 7/17
Colour coding of the channels from the mechatronics for the individual gear and clutch actuators Colour definition of channels
VSQ/TT
1.
Gree n
= Main pressure channel
2.
Dark yellow
= Clutch 1
3.
Lighter yello ellow w
= Clutch 2
4.
White
= Part gearbox oil pressure for gear positioner 1/3
5.
Gre y
= Regulat Regulate ed volum volumetric etric flow flow for gear pos pos itioner 1/3
6.
Dark brown
= Part gearbox pressure for gear positioner 2/4
7.
Light brown
= Regulated Regulated volumetric volumetric flow flow for gear posi positione tionerr 2/4 2/4
8.
Dark bl ue
= Part gearbox oil pressure for gear positioner 5/7
9.
Light bl ue
= Regulated Regulated volumetric volumetric flow flow for gear posi positione tionerr 5/7 5/7
10. Dark red
= Part gearbox pressure for gear positioner 6/R
11. Ligh Lightt red
= Regulat Regulate ed volum volumetric etric flow flow for gear pos pos itioner 6/R
7
Hüdraul Hüdrauliikapumba kapumba moo moo tor tor V401
Püsimagnetitega rootor
Staator
Solenoid
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 8/17
The hydraulic hy draulic pump motor V401
This is a brushless direct current motor. The rotor comprises 6 pairs of permanent magnets. The stator comprises 6 pairs of solenoids. A rotatin rotating g magnetic magnetic field is gener generated ated in the sta st ator coils throug through h actuation by the control unit of the individual electromagnetic terminal pairs. This rotating magnetic magnetic field is is followed by by the rotor rotor and and this causes a rotating movement.
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Rõhu akum akumu u laato aato r / õli filte filter r Rõhu akumulaator
õlifilter
Möödav oolu kuulklapp
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 9/17
The pressure accumulator With ignition "on" the pressure accumulator is charged with oil from a hydraul hy draulic ic pressure press ure of 20 bar. The The working pressure is between 40 and 60 bar.
The oil filt filte e r The filter is located behind the hydraulic pump. The oil flows through the filter filter onc onc e oil temperature temperature is > - 5°C. 5°C. If the oil temperature temperature is < 5°C, the oil is too thick and cannot flow through the filter walls. A ball within the filter is pushed back, thereby opening the bypass. The oil c an now mak mak e its its way way via the by pass pass to t o the main press press ure channel.
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Elekt Elektro/hüdr ro/hüdraulilise aulilised d kompone ko mponendi ndid d Solenoid klapi plokk Paaki tagasi Reguleeritud v ooluga õlikanal õlikanal
Osarõhu kanal
ühiskanal
Kanal mis on ühenduses pea rõhukanaliga
N433
N436
N434
N435
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 10/17 10/17
Design of solenoid valve block The part gearbox pressure regulator N436 changes main pressure to part gearbox oil pressure. The part gearbox oil pressure is thereby channelled via a hole to the distribution rail. In the distribution rail the part gearbox oil pressure makes its way to the gear and clutch actuator valves. At the same time, the part gearbox oil pressure makes its way way via holes in the mechatronic mechatronic s blo bl ock to t o the part gearbox gearbox pressure channels. Two channels per part gearbox are connected to the front pis pis ton c hamber of the gear actuators actuators . This This mean m eans s tha t hatt part part gearbox oil pressure can be built up in front of the gear actuator piston. A different c hannel of the part part gearbox gearbox leads to the clutch safety valve (KS). There is part gearbox oil pressure here, too.
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Elekt Elektro/hüdr ro/hüdraulilise aulilised d kompone ko mponendi ndid d Käigukasti Käigukasti osarõh osarõhu u reg regu uleerk lee rklapp lapp N436/440 N436/440
Tagasi õlipaaki Osarõhu kanalisse Pea rõhukanalist
kolb
Magnet südamik pool
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 11/17 11/17
The part gearbox pressure regulator N436 If the part gearbox pressure regulator is actuated by the control unit with wit h a PW PW M s ignal, the con c ontrol trol plunger pl unger moves moves upwards, thereb t hereby y opening up the path for connection of the distribution rail (in the solenoid valve block). This is where the part gearbox oil pressure is built up. The part gearbox oil pressure is determined by the current strength set at the solenoid valve. The axiom here is: the more current received by the solenoid, the higher the part gearbox oil pressure.
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Elekt Elektro/hüdr ro/hüdraulilise aulilised d kompone ko mponendi ndid d Käiguvahetus ja sidurilülitusventiil
Tagasi õlipaaki Reguleeritud Reguleeritud õli v ool käiguv ahetussüsteemile ahetussüsteemile v õi sidurilülitusele
kontrollkolb
Käigukasti osarõhukanalist osarõhukanalist
pool
Magnet südamik
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 12/17 12/17
Gear actu a ctua a tor valve For activation of the solenoid by the gear actuator valve, a PWM signal is used by the control unit. The current moves the control plunger upwards and the path to the the channel channel of the gear ac ac tuator is opened. The current strength determines what position the control plunger adopts and thereby the volumetric flow imparted on the gear actuator. The regulated volumetric flow flows in the rear piston chamber of the gear actuator. From the regulated volumetric flow behind the plunger of the gear actuator, any position required by the gear actuator can be set. Clutch positioner valve For activ act ivati ation on of the s olenoid by by the clutch positioner positioner valv valve, e, a PWM signal is used by the control unit. The current moves the control plunger upwards upwards and the t he path to th t he channel of the clut c lutc c h positioner positi oner is is opened. The current strength determines what position the control plunger adopts and thereby the volumetric flow imparted on the clutch positioner. The plunger presses against the engaging lever and the clutch is pressed against the drive plate. In contrast to gear actuator valves, relieving the load on the clutch actuator is also achieved through activation of the control plunger. If contamination causes the control plunger to become jammed, the volume is built-up by the clutch safety valve (KS). If this fault occurs, the affected clutch no longer works and the part gearbox is isolated.
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Käiguvahetuse operatsioon 1-3 1-3 käigu aktuaator aktuaator neutraalas eutraalasendis endis
N 436 N 433 Kolv i taga kamber
Kolv i ees kamber
käiguv käiguv ahetuskolb ahetuskolb
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 13/17 13/17
The gear actuators 1-3 in neutral position When the gear actuator is in neutral position, the plunger is located in a state of equilibrium (different surfaces) in the front and rear piston chamber as a result of different pressures. The gear actuator valve N433 is energised by the control unit and frees the path to the rear piston chamber. Through regulated inlet and outlet of the very low volumetri olum etric c flow in the rear pis pis ton chamber, the gear actu act uator plunger is held in neutral position against part gearbox pressure of the front chamber
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Käiguvahetuse operatsioon 1-3 käigu aktuaator, 1 käik on sisse lülitatud
N 436 N 433 Kolv i taga kamber
Kolv i ees kamber
käiguv käiguv ahetuskolb ahetuskolb
Serv ice Training Training 02.200 02.2008 • VSQ/TT • 14/17 14/17
The gear actuators 1-3; 1st gear selected select ed When 1st gear is selected, the gear actuator valve N433 is supplied with wit h more power by by the control unit. unit. In this way way , the volum volumetric etric flow in the rear piston chamber is increased. The pressure in the rear piston chamber can be raised up to the pressure of the front chamber. This causes an excess in force (different surfaces) resulting in movement of the gear actuator plunger in the direction of out. The fluid that is forced out of the front chamber is used to fill the rear chamber. 1st gear is engaged by the selector fork. Control/measurement of the position of the plunger/selector fork occurs in both situ sit uatio ati ons by means of magnets on the t he s elector form and travel sensors of the control unit.
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Serv ice Training Training 02.200 02.2008 • VSQ/TT • 15/17 15/17
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