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Volkswagen
The 7-speed DSG
To the Point
Key Aspects
Mechatronics Page 12
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technolog y. This and other engineering modifications led to
significant improvements to the DSG’s efficiency. The result:
Further reduced fuel consumption and emissions values, even
greater convenience and driving fun.
The 122 PS TSI in the Golf consumes just 5.9 liters/100 km with DSG. A record
• Since the 7-speed DSG can now also serve on smaller engines,
another jump in volume can be expected for DSG. In the final
months of 2007, the DSG share in the Golf class – even without
7-speed DSG – already rose to above nine percent. The year’s
average for the new Golf Variant came in at over ten percent.
On the Golf Plus the average for 2007 was greater than twelve
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percent. The Jetta had a DSG share of over 13 percent, and the
Eos over 14 percent. 24 percent of all Touran buyers chose
a dual-clutch transmission in the past year. It was about
22 percent on the Passat sedan and over 28 on the Passat Variant.
The trend toward automatics – when they have DSG – is therefore
clearly evident.
Before production start the new DSG covered two million test kilometers
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Interesting Figures from the DSG World
• 0.4 liters fuel per 100 kilometers fuel savings on Golf TSI
(122 PS) plus 7-speed DSG compared to identically powered
counterpart with 6-speed manual transmission
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• 2004: 6-speed DSG is used in combination with a turbodiesel
for the first time (on Golf TDI and Touran TDI with 105 PS and
140 PS, respectively)
• 2004: new Golf GTI offers a TSI paired with DSG for the first
time
• 2007: new Golf TSI with 122 PS and 7-speed DSG already places
2nd in Environmental Automobile List of the Verkehrsclub
Deutschland (VCD; “German Travel Club”) for the compact
class
• 2007: Golf GT Sport with 170 PS strong TSI plus 6-speed DSG
wins Technological Innovation of the Year award in Barcelona
• 2007: at the end of this year series production was started for
the 7-speed DSG
• 2008: new Golf TSI with 122 PS and 7-speed DSG earns “Yellow
Angel 2008” award by ADAC in “Innovation and Environment”
category
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The 7-speed DSG Key Aspects
The intelligent automatic from Volkswagen
New dual clutch provides for even greater efficiency
7-speed DSG was designed for engines produced in high-volume at Volkswagen
Up to 20 percent lower fuel consumption compared to conventional converter
automatics
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7-speed DSG for high production volume engines
The dual multi-plate clutch of the 6-speed DSG runs with oil
cooling. On the new 7-speed DSG a dry clutch has now been
implemented for the first time. This leads to a whole series of
advantages; in sum they are expressed as a significant gain in
efficiency. On the new DSG it was possible to eliminate a suction
filter, an oil cooler and pressurized oil lines in the transmission
case, for example, since oil is no longer needed to cool the plates.
What remains is the “normal” transmission oil for lubricating
and cooling the gears and bearings. The bottom line here is that
eliminating clutch cooling lowered oil volume from 6.5 liters in
the 6-speed DSG to 1.7 liters in the 7-speed DSG.
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Two DSG systems that complement one another
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spaced overall, as well as an overdrive. This seventh gear with
a long gear ratio has a positive effect on fuel economy, emissions
and low-noise comfort.
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Dual clutch
Drive shafts
The two drive shafts are arranged centrally on a single axis. Their
design assumes a key function. Both drive shafts are located,
as described, on a common axis. The outer driveshaft II was
designed as a hollow shaft, in which driveshaft I is integrated as a
solid shaft. The two shafts are mounted concentrically, one below
the other, on needle bearings.
Assigned to drive shaft I are the odd gears (1, 3, 5 and 7), while the
even gears (2, 4, and 6) and reverse gear reside on drive shaft II.
The distribution of the “1” and “R” gears permits quick changes
between forward and reverse in parking maneuvers, simply by
controlling two clutches. The clutches are controlled by hydraulics,
and solenoid valves regulate the contact pressures of the two
clutches. The solenoid valves are directly connected to a mecha-
tronics module that coordinates everything.
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Mechatronics
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• The high purity of the hydraulic oil enables the use of so-called
cartridge valves with very small gap dimensions. This significantly
reduces leakage quantities, and use of an electrically-driven
pump is economical.
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