Direct-shift gearbox
Automotive transmissions |
---|
Manual |
Automatic / Semi-automatic |
A direct-shift gearbox (DSG,
In simple terms, a DSG automates two separate "manual" gearboxes (and clutches) contained within one housing and working as one unit.
Overview
Transverse DSG
At the time of launch in 2003,
The first DSG transaxle that went into production for the Volkswagen Group mainstream marques had six forward speeds (and one reverse)[5][6] and used wet/submerged multi-plate clutch packs[2] (Volkswagen Group internal code: DQ250, parts code prefix: 02E).[6][7] It has been paired to engines with up to 350 N⋅m (260 lb⋅ft) of torque.[5][6] The two-wheel-drive version weighs 93 kg (205 lb). It is manufactured at Volkswagen Group's Kassel plant,[2] with a daily production output of 1,500 units.[5]
At the start of 2008, another world-first
In September 2010, VW launched a new seven-speed DSG built to support up to 600 N⋅m (440 lb⋅ft), the DQ500.[12]
Audi longitudinal DSG
In late 2008, an all-new seven-speed longitudinal
This was initially available in their
List of DSG variants
Name | Orientation | Ratios | Max. torque (N·m) | Clutch type | Comments |
---|---|---|---|---|---|
DQ200 | Transverse | 7 | 250 | Dry | 7-speed DSG transmission with dry clutch, most found on VAG-cars from 2007 till present day. With engine capacity between 1.0–1.9-litre. (Max torque 250Nm) |
DQ200e | Transverse | 7 | Dry | 7-speed DSG transmission with dry clutch, found on the Volkswagen Jetta 1.4 TSI Hybrid. | |
DQ250 | Transverse | 6 | 400 | Wet | 6-speed DSG transmission with wet clutch, most found on VAG-cars from 2003 till present day. |
DQ380[19] | Transverse | 7 | 420 | Wet | 7-speed DSG transmission with wet clutch, used in the Golf 7 GTI and Audi S3. Production started in 2015, widespread in China. This transmission is a smaller version of the DQ500, which can be found on the Audi RS3 & Audi Q3 2.0TFSI/TDI engines. |
DQ381 | Transverse | 7 | 420-430 | Wet | In 2017 an improvement of DQ380 was derived as the DQ381(also known as 0GC), is used in many new vehicles with MQB platform like Arteon. DQ381 has an all wheel drive variant as DQ381-7A, the front drive variant is called DQ381-7F.[20][21] |
DQ400e | Transverse | 6 | 400 | Wet | 6-speed DSG transmission with wet clutch used in the plug-in hybrid Passat GTE , and the equivalent e-tron versions of the Audi A3 and Audi Q3. The electric motor is included in the DSG assembly. There are a total of 3 clutches on this DSG.
|
DQ500 | Transverse | 7 | 600 | Wet | 7-speed DSG transmission with wet clutch, mostly found on Transporters 2009–2013, VW Tiguan 2.0TDI 4motion, but also used in the Audi RS3 or VW Passat B8 BiTDI. Also standard on Audi Q3 series with 2.0TFSI/TDI engines. |
DQ511 | Transverse | 10 | 550 | Wet | The DQ511 was a planned 10-speed DSG transmission. The project was cancelled citing cost and complexity issues.[22] |
DL382 | Longitudinal | 7 | 500[23] | Wet | 7-speed DSG transmission with wet clutch. Used in the Audi A4/A5/A6/Q5 and Volkswagen Phideon. Production started in 2015 with a 400Nm capacity, both front wheel drive variant DL382-7F and all wheel drive variant DL382-7Q are provided. The Quattro Ultra all wheel drive version DL382-7A is introduced with Q5(typ FY).[24] Starting with Audi A6/A7(typ 4K), the high torque variant(up to 500Nm) named as DL382+ is introduced. 0CK and 0DN are codenames for DL382-7F, 0CL is for DL382-7Q, 0CJ and 0DP are for DL382-7A and 0HL is for DL382+-7A.[25][26] |
DL501 | Longitudinal | 7 | 600 | Wet | 7-speed DSG transmission with wet clutch. (Audi S-tronic) |
DL800 | Longitudinal | 7 | Wet | 7-speed DSG transmission with wet clutch. Rarely used, only in the second generation Audi R8 (2015–present) and the Lamborghini Huracan. |
Operational introduction
The
The variant of DSG fitted to
DSG controls
The direct-shift gearbox uses a floor-mounted
P
P position of the floor-mounted gear shift lever means that the transmission is set in
N
N position of the floor-mounted shift lever means that the transmission is in
D mode
Whilst the motor vehicle is stationary and in neutral (N), the
Once the vehicle has completed the shift to second gear, the first gear is immediately de-selected, and third gear is pre-selected.[2][3] Once the time comes to shift into 3rd, the second clutch disengages and the first clutch re-engages.[2] This sequence repeats through the gear changes.
Downshifting is similar to up-shifting but in reverse order. At 600 milliseconds downshifting is necessarily slower, due to the engine's
The actual shift points are determined by the DSG's transmission ECU, which controls a hydro-mechanical unit.[2] The transmission ECU, combined with the hydro-mechanical unit, are collectively called a mechatronics[2] unit or module. Because the DSG's ECU uses fuzzy logic, the operation of the DSG is said to be adaptive;[dubious ] that is, the DSG will "learn" how the user drives the car, and will progressively tailor the shift points accordingly to suit the habits of the driver.[citation needed]
In the vehicle instrument display, between the speedometer and tachometer, the available shift-lever positions are shown, the current position of the shift-lever is highlighted (emboldened), and the current gear ratio in use is also displayed as a number.
Under "normal", progressive and linear
When the floor-mounted gear selector lever is in position D, the DSG works in fully automatic mode,[3][4] with emphasis placed on gear shifts programmed to deliver maximum fuel economy.[3][9] That means that shifts will change up and down very early in the rev-range. As an example, on the Volkswagen Golf Mk5 GTI, sixth gear will be engaged around 52 km/h (32 mph), when initially using the DSG transmission with the default ECU adaptation; although with an "aggressive" or "sporty" driving style, the adaptive shift pattern will increase the vehicle speed at which sixth gear engages.
S mode
The floor selector lever also has an S position.
S is highlighted in the instrument display, and like D mode, the currently used gear ratio is also displayed as a number.
R
R position of the floor-mounted shift lever means that the transmission is in reverse. This functions in a similar way to D, but there is just one reverse gear. When selected, R is highlighted in the instrument display.
Manual mode
Additionally, the floor shift lever also has another plane of operation, for manual
In most (VW) applications, the readout in the instrument display changes to 6 5 4 3 2 1, and just like the automatic modes, the currently used gear ratio is highlighted or emboldened. In other versions (e.g., on the Audi TT) the display shows just M followed by the gear currently selected; e.g., M1, M2, etc.
To change up a gear, the lever is pushed forward (against a spring pressure) towards the +, and to change down, the lever is pulled rearward towards the −. The DSG transmission can now be operated with the gear changes being (primarily) determined by the driver. This method of operation is commonly called
Current variants of the DSG will still downshift to the lowest possible gear ratio when the
Paddle shifters
Initially[
These operate in an identical manner as the floor mounted shift lever when it is placed across the gate in manual mode. The paddle shifters have two distinct advantages: the driver can safely keep both hands on the steering wheel when using the Manual/tiptronic mode; and the driver can temporarily manually override either of the automatic programmes (D or S),[9] and gain instant manual control of the DSG transmission[9] (within the above described constraints).
If the paddle-shift activated manual override of one of the automatic modes (D or S) is used intermittently the DSG transmission will default back to the previously selected automatic mode after a predetermined duration of inactivity of the paddles, or when the vehicle becomes stationary. Alternatively, should the driver wish to immediately revert to fully automatic control, this can be done by activating and holding the + paddle[9] for at least two seconds.
Advantages and disadvantages
Advantages
- Better fuel economy[2][5] (up to 15% improvement) than conventional planetary geared automatic transmission (due to lower parasitic losses from oil churning)[4] and for some models with manual transmissions;[2]
- No loss of torque through the transmission from the engine to the driving wheels during up-shifts;[2][4]
- Short up-shift time when shifting to a gear the alternate gear shaft has preselected;
- Smooth gear-shift operations;[4]
- Consistent down-shift time of 600 milliseconds, regardless of throttle or operational mode;
Disadvantages
- The clutch pack mechanisms have a limited lifespan;
- Marginally worse mechanical efficiency compared to a conventional manual transmission, especially on wet-clutch variants due to electronics and hydraulic systems;[4]
- Expensive specialist transmission fluids/lubricants with dedicated additives are required, which need regular changes;[14][15]
- Relatively expensive to manufacture,[citation needed] and therefore increases new vehicle purchase price;
- Relatively lengthy shift time when shifting to a gear ratio which the transmission control unit did not anticipate (around 1100 ms, depending on the situation);[27]
- Torque handling capability constraints impose a limit on after-market engine tuning modifications (though many tuners and users may exceed the official torque limits notwithstanding); (Later variants have been fitted to more powerful cars, such as the 300 bhp/350 Nm VW R36 and the 272 bhp/350 Nm Audi TTS.)
- Heavier than a comparable Getrag conventional manual transmission (75 kg (165 lb) vs. 47.5 kg (105 lb));
Applications
Volkswagen Group vehicles with the DSG gearbox include:[7]
Audi
After originally using the DSG moniker, Audi subsequently renamed their direct-shift gearbox to S tronic.
- Audi TT
- Audi A1
- Audi A3
- Audi S3
- Audi A4 (B8)[6][13]
- Audi A4 (B9)
- Audi S4 (B8)[6][13]
- Audi S5 (B8)[6][13]
- Audi A5
- Audi A6
- Audi S6 (C7)
- Audi A7
- Audi A8 (D4)
- Audi Q2
- Audi Q3
- Audi Q5[6][13]
- Audi R8 facelift
Bugatti
- Ricardo[28]rather than Borg Warner)
- Bugatti Chiron[29]
Lamborghini
- Lamborghini Huracan
SEAT
Škoda
- Škoda Fabia
- Škoda Kodiaq
- Škoda Karoq (in Australia it replaced with 8-speed sourced from Aisin)
- Škoda Kamiq (except China market)
- Škoda Octavia
- Škoda Rapid (2012)
- Škoda Roomster
- Škoda Superb (MK2 & MK3)
- Škoda Yeti
- Škoda Scala
- Škoda Kushaq
- Škoda Slavia
Volkswagen
- Volkswagen Vento
- Volkswagen Santana
- Volkswagen Bora (China)
- Volkswagen Polo (paired with 6-speed TC automatic in some markets)
- Volkswagen Virtus
- Volkswagen Golf, GTI, GTD, GTE, TDI, R32, R[2][5]
- Volkswagen Jetta (TDI and GLI)
- Volkswagen Eos
- Volkswagen Touran[5]
- Volkswagen New Beetle
- Volkswagen Lamando
- Passat (NMS)(China & US first generation)
- Volkswagen CC
- Volkswagen Arteon (In the US, MY22+ only)
- Volkswagen Sharan
- Volkswagen Viloran
- Volkswagen Scirocco
- Volkswagen T-Cross
- Volkswagen T-Roc
- Volkswagen Taigun
- Volkswagen Taos (China FWD & US AWD)
- Volkswagen Tayron
- Volkswagen Tiguan (except US market)
- Volkswagen Teramont(China)
Volkswagen Commercial Vehicles
- Volkswagen Caddy car-derived van
- Volkswagen Transporter (T5 & T6)
Problems and recalls of DSG-equipped vehicles
The 7-speed DQ200 and 6-speed DQ250 gearboxes sometimes suffer from power-loss (gear disengaging) due to
United States
In August 2009, Volkswagen of America issued two recalls of DSG-equipped vehicles. The first involved 13,500 vehicles,[31] and was to address unplanned shifts to the neutral gear,[31] while the second involved similar problems (by then attributed to faulty temperature sensors) and applied to 53,300 vehicles.[31][32][33] These recalls arose as a result of investigations carried out by the US National Highway Traffic Safety Administration (NHTSA),[34] where owners reported to the NHTSA a loss of power whilst driving.[31] This investigation preliminary found only 2008 and 2009 model year vehicles as being affected.[31][34]
Australia
In November 2009, Volkswagen recalled certain Golf, Jetta, EOS, Passat & Caddy models equipped with 6-speed DQ250 DSG transmission because the gearbox may read the clutch temperature incorrectly, which leads to clutch protection mode, causing a loss of power.[35]
China
Since 2009 there have been widespread concerns from Chinese consumers particularly among the online community, who expressed that Volkswagen has failed to respond to complaints about defects in its DSG-equipped vehicles. Typical issues associated with 6-speed DSG include abnormal noise and inability to change gear; while issues associated with 7-speed DSG include abnormal noise, excessive shift shock, abnormal increase in engine RPM, flashing gear indicator on the dashboard as well as inability to shift to even-numbered gears.[citation needed] In March 2012 China's quality watchdog the General Administration of Quality Supervision, Inspection and Quarantine (AQSIQ) said that it had been in contact with Volkswagen (China) and urged the carmaker to probe the issues.[36][37] In a survey held by Gasgoo.com (China) of 2,937 industry experts and insiders, 83% of respondents believed that the carmaker should consider a full vehicle recall.[38] In March 2012 Volkswagen Group China admitted that there could be an issue in its seven-speed DSG gearboxes that may affect approximately 500,000 vehicles from its various subsidiaries in China.[39] A software upgrade has since been offered for the affected vehicles in an attempt to repair the problem.
According to 163.com - one of China's most popular web portals - in March 2012 about a quarter of the complaints about problems found in cars in China's automotive market were made against DSG-equipped vehicles manufactured by Volkswagen.[40] The top five models that dominate those complaints were:
- Volkswagen Magotan- 6%
- Volkswagen Bora - 5.3%
- Volkswagen Sagitar- 5.3%
- Volkswagen Touareg - 4.7%
- Volkswagen Golf - 4%
Would be worth noting that Touareg has never been fitted with a DSG transmission.
On 15 March 2013,
Sweden
VW Sweden stopped selling the Passat EcoFuel DSG as a taxi after many cars had problems with the 7 speed DSG gearbox. They instead offered the Touran EcoFuel DSG, which uses an updated version of the same DSG gearbox.[42]
Japan
The recall has been extended to Japan with 91,000 (VW and Audi using the same DSG) being recalled.[43]
Malaysia
13 days after the Singapore recall, Volkswagen Malaysia also announced a recall for the 7-speed DSG. No official statement was released by the company, but it was stated that a total of 3,962 were involved in the unit recall exercise - units produced between June 2010 and June 2011, with affected vehicles being Golf, Polo, Scirocco, Cross Touran, Passat and Jetta models equipped with the transmission.[44]
Australian recall
15 October 2019, Australia recall of DSG 7-speed gearboxes. Due to a production fault, over time a crack in the transmissions pressure accumulator can occur. If the pressure accumulator cracks, oil and pressure is lost in the hydraulic system of the gearbox. As a result, the transmission of engine power via the gearbox is interrupted. The experience of this symptom would be comparable to depressing the clutch in a vehicle fitted with a manual transmission. This could increase the likelihood of an accident affecting the occupants of the vehicle and other road users.[45]
See also
- List of ZF transmissions
- List of Aisin transmissions
- List of GM transmissions
- List of Ford transmissions
- Automated manual transmission
References
- ^ Volkswagen Service Training Manual 308 - 02E 6-speed DSG
- ^ a b c d e f g h i j k l m n o p q r s t u v w x y z aa ab ac ad ae af ag ah ai aj ak al "Volkswagen DSG - World's first dual-clutch gearbox in a production car". Volkswagen-Media-Services.com (Press release). Volkswagen Group / Volkswagen AG. 22 November 2002. Archived from the original on 24 May 2006. Retrieved 30 October 2009.
- ^ a b c d e f g h i j k l m "Twin Clutch / Direct Shift Gearbox (DSG) - What it is, how it works". Cars.About.com. Archived from the original on 7 July 2011. Retrieved 27 October 2009.
- ^ a b c d e f g h i j k l m n "How the Dual Clutch Transmission Works". DCTfacts.com. The Lubrizol Corporation. 2009. Archived from the original on 17 September 2009. Retrieved 27 October 2009.
- ^ a b c d e f g h i j k l m n o "The 7-speed DSG - the intelligent automatic gearbox from Volkswagen". VolkswagenAG.com. Volkswagen Group / Volkswagen AG. 21 January 2008. Archived from the original on 16 December 2010. Retrieved 3 November 2009.
- ^ a b c d e f g h i j k l m n "Volkswagen Group extends reach of dual clutch transmissions". DCTfacts.com. The Lubrizol Corporation. 8 May 2009. Archived from the original on 4 November 2009. Retrieved 27 October 2009.
- ^ a b c d e ETKA[clarification needed]
- ^ Volkswagen Service Training Manual 390 - 0AM 7-speed DSG
- ^ a b c d e f g h i j k l m "Golf Plus on the Road". DCTfacts.com. The Lubrizol Corporation. 2009. Archived from the original on 7 October 2011. Retrieved 28 October 2009.
- ^ "LuK Dual Dry Clutch 7-Speed DSG Gearbox in volume production at Volkswagen". LuKclutch.com. Schaeffler Group USA Inc., BÜHL, GERMANY. 13 February 2008. Retrieved 27 October 2009. [dead link]
- ^ "7-Speed DSG Gearbox < Technical Glossary < Innovation & Technology < Volkswagen International". Archived from the original on 17 September 2014. Retrieved 25 July 2014.
- ^ "Volkswagen Group DSG: The New DQ500". Archived from the original on 25 September 2013. Retrieved 28 April 2013.
- ^ a b c d e f g h i j k l "Inside Audi's premium DCT". DCTfacts.com. The Lubrizol Corporation. 8 May 2009. Archived from the original on 12 October 2009. Retrieved 27 October 2009.
- ^ a b "Special Transmissions Need Special Lubricants". DCTfacts.com. The Lubrizol Corporation. 2009. Archived from the original on 6 April 2009. Retrieved 28 October 2009.
- ^ a b "Special Transmissions Need Special Lubricants". DCTFacts.com. Archived from the original on 25 March 2011. Retrieved 15 May 2011.
- ^ "ZF 7-speed dual clutch transmission". ZF.com. ZF Friedrichshafen AG. Archived from the original on 27 November 2011. Retrieved 28 October 2009.
- ^ "Top 911 moves to industry-standard shift controls". DCTfacts.com. The Lubrizol Corporation. 24 September 2009. Archived from the original on 16 October 2009. Retrieved 27 October 2009.
- ^ "Porsche Joins the DCT Set". DCTfacts.com. The Lubrizol Corporation. Archived from the original on 1 October 2009. Retrieved 28 October 2009.
- ^ "DQ380". auto.sina.com.cn. Retrieved 26 November 2014.
- ^ "VAG SSP 556 - The development goal for the 7-speed dual-clutch gearbox 0GC - Pdf Online Download". ProCarManuals.com. 30 March 2018. Retrieved 30 August 2019.
- ^ "VAG SSP 557 - The Arteon - Pdf Online Download". ProCarManuals.com. 30 March 2018. Retrieved 30 August 2019.
- ^ "VW confirms its 10-Speed dual-clutch transmission is dead". Motor Authority. Retrieved 30 August 2019.
- ^ "Фотоотчеты по ремонту Ауди А6, A7 - документация для Audi A6, A7 (4A)". vwts.ru (in Russian). Retrieved 27 March 2019.
- ^ "VAG SSP 657 - Audi Q5 (type FY) - Pdf Online Download". ProCarManuals.com. 30 March 2018. Retrieved 30 August 2019.
- ^ "erWin Online | Audi of America | Document properties". erwin.audiusa.com. Retrieved 30 August 2019.
- ^ "Ремонт Ауди А6, A7 своими руками: документация, фотоотчеты для Audi A6, A7 (4A)". vwts.ru (in Russian). Retrieved 30 August 2019.
- ^ "How Dual-Clutch Transmissions Work". AutoEvolution.com. SoftNews NET. 31 March 2009. Retrieved 30 October 2009.
- ^ "Ricardo Extends DCT Production for Open-top Bugatti". DCTfacts.com. The Lubrizol Corporation. 16 January 2009. Archived from the original on 27 February 2009. Retrieved 28 October 2009.
- ^ "Bugatti Chiron Trims & Specs".
- ^ "Volkswagen in damage limitation mode after recalls". The Australian. 15 June 2013.
- ^ a b c d e Jensen, Christopher (21 August 2009). "VW DSG Transmission Problem Leads to Recall". wheels.blogs.nytimes.com. The New York Times Company. Retrieved 30 November 2009.
- ^ Chang, Richard S. (28 August 2009). "VW Has More Problems With Its DSG Transmission". wheels.blogs.nytimes.com. The New York Times Company. Retrieved 30 November 2009.
- ^ "Volkswagen will repair DSG transmissions on 53,300 vehicles". Blog.CarAndDriver.com. Hachette Filipacchi Media U.S., Inc. 28 August 2009. Archived from the original on 19 July 2011. Retrieved 27 October 2009.
- ^ a b "ODI Resume - Volkswagen of America, Inc., 2008-2009 Volkswagen EOS, GTI, Jetta and R32 with DSG transmission" (PDF). Archived from the original (PDF) on 21 July 2011., National Highway Traffic Safety Administration, Retrieved 30 November 2009. The direct shift gearbox can malfunction at any speed and cause the vehicle to lose motive power suddenly and without warning
- ^ "Volkswagen—Volkswagen Golf, Jetta, EOS, Passat & Caddy Vehicles". 3 November 2009.
- ^ "VW urged to probe DSG defects, recall possible". China Daily. Retrieved 5 April 2012.
- ^ "VW urged to probe DSG defects, recall possible". just-auto.com. 22 March 2012. Retrieved 5 April 2012.
- ^ "Analysis: Industry viewpoints on VW's Chinese DSG gearbox controversy". Gasgoo. Archived from the original on 17 September 2016. Retrieved 5 April 2012.
- ^ "VW issues software upgrade to resolve gearbox problems, shies away from recall". Gasgoo. Archived from the original on 17 March 2012. Retrieved 5 April 2012.
- ^ "大众DSG投诉居首 3月投诉平台数据分析" (in Chinese). 163.com. Retrieved 6 April 2012.
- ^ "315曝光大众汽车DSG问题 大众中国回应" (in Chinese). qq.com. Retrieved 17 March 2013.
- ^ "Volkswagen Passat slut som taxi – DSG-lådan är problemet | Konsument | Teknikens Värld". Archived from the original on 29 March 2013. Retrieved 29 December 2012. - - Volkswagen Passat slut som taxi
- ^ "Volkswagen recall extended". drive.com.au. Fairfax Media. 13 May 2013. Archived from the original on 8 June 2013. Retrieved 13 May 2013.
- Asiaone. 12 May 2013. Archived from the originalon 25 June 2013. Retrieved 12 May 2013.
- ^ Volkswagen Group Australia — Volkswagen Golf MY2009-2015, Jetta MY2009-2015, Beetle MY2013-2015, Passat MY2010-2015, Polo MY2010-2015 & Caddy MY2011-2015 15 October 2019 www.productsafety.gov.au, accessed 29 December 2019
External links
- Dual Clutch Transmission - DCT Facts (not implemented yet)
Official links
- Volkswagen AG corporate website Archived 9 January 2011 at the Wayback Machine
Independent links
- Pictures and diagrams of DQ250 DSG at WorldCarFans.com.
- Reviews, videos, and explanation of DSG transmission
- First Drive: Audi TT 3.2 DSG review at VWvortex.com.
- European interest in dual clutch technology shifts up a gear, an informative article from Just-Auto.com.
- Computer-controlled Meccano model of a DSG Transmission by Alan Wenbourne of the South East London Meccano Club (SELMEC).
- Video of Alan Wenbourne's Meccano DSG in operation at YouTube.com.