7-käiguline DSG

7-käiguline DSG käigukast 0AM

Serv ice Training

VSQ/T T 1
 Tehnilised andmed

Tehnilised andmed

Serv ice Training

02.2008 • VSQ/TT • 2/17

Technical data
Weight: 70 kg including clutch
Torque: max. 250 Nm
Clutch: 2 x dry-plate clutches
Gear stages: 7 x forward, 1 x reverse
Operating modes: automatic/tip mode
Oil volume and specification
Gearbox: 1.7 litre gear oil: - G 052 171-
Mechatronics: 1 litre central hydraulic / power steering fluid
- G 004 000-
Housing: Aluminium

VSQ/T T 2
 Käigukasti skeem

Väljund v õll 2 Väljund v õll 3

Käigukasti osa 2 Sisend v õll 2

R
6 4 2
K2
v eoketas
Diff erentsiaal
Kahemassiga hooratas

Mootori moment
K1
7 5 3 1

Sisend v õll 1
Käigukasti osa 1 F414_002

Väljund v õll 1

Serv ice Training

02.2008 • VSQ/TT • 3/17

Gearbox diagram
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 to input shaft 1. Input shaft 1 rotates. 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
shaft 1 and output shaft 1. Output shaft 1 rotates and 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 based on the same principle.

VSQ/T T 3
 Topeltsidur

Topelt kuiv sidur

sidur K2 surv elaager K1

surv elaager K2
sidur K1

v eoketas

Serv ice Training

02.2008 • VSQ/TT • 4/17

The double dry-plate clutch

The engaging lever with engagement bearings is pressed against the

disk springs by the clutch actuators, which results in the clutch plate in
question being pressed against the rotating drive plate.

Clutch K1 is joined via a spline connection to input shaft 1 and thereby

transfers the torque for gears 1,3,5 and 7 to output shaft 1.

Clutch K2 is joined via a spline connection to input shaft 2 and thereby

transfers the torque for gears 2,4,6 and R to output shaft 2 and 3.

VSQ/T T 4
 Mehhatroonika

Rõhu akumulaator

Hüdrauliline pump

N438
N435

N440
N434

N439
N436

N433 N437

V401

Serv ice Training

02.2008 • VSQ/TT • 5/17

Key

N433 Valve 1 in part gearbox 1 Gear positioner valve 1/3

N434 Valve 2 in part gearbox 1 Gear positioner valve 5/7
N435 Valve 3 in part gearbox 1 Clutch positioner valve K1
N436 Valve 4 in part gearbox 1 Part gearbox pressure regulator

N437 Valve 1 in part gearbox 2 Gear positioner valve 2/4

N438 Valve 2 in part gearbox 2 Gear positioner valve 6/R
N439 Valve 3 in part gearbox 2 Clutch positioner valve K2
N440 Valve 4 in part gearbox 2 Part gearbox pressure regulator

V401 Hydraulic pump motor

Valves are actuated with a PWM signal

VSQ/T T 5
 Hüdraulika skeem

Filter Rõhu piiramise v entiil

Hüdropumba mootor V401 Rõhu akumulaator

Käigukasti rõhuandur G270

Pearõhu kanalid
hüdropump Tagasiv oolu klapid

N436 käigukasti osarõhud N440

KS

Reguleeritud õli v ool

N433 N434 N435 N437 N438 N439

Serv ice Training

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 accumulator and in the main 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
regulators) to the control unit. If pressure falls 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 component damage.

VSQ/T T 6
 Rõhukanalid mehhatroonika plokis

5
2

4
9
8 6
3
10
11
7 6

Osarõhu kanal Reguleeritud v ooluga Pea rõhukanal

õlikanal

Serv ice Training

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
1. Green = Main pressure channel
2. Dark yellow = Clutch 1
3. Lighter yellow = Clutch 2
4. White = Part gearbox oil pressure for gear positioner 1/3
5. Grey = Regulated volumetric flow for gear positioner 1/3
6. Dark brown = Part gearbox pressure for gear positioner 2/4
7. Light brown = Regulated volumetric flow for gear positioner 2/4
8. Dark blue = Part gearbox oil pressure for gear positioner 5/7
9. Light blue = Regulated volumetric flow for gear positioner 5/7
10. Dark red = Part gearbox pressure for gear positioner 6/R
11. Light red = Regulated volumetric flow for gear positioner 6/R

VSQ/T T 7
 Hüdraulikapumba mootor V401

Püsimagnetitega
rootor

Solenoid
Staator

Serv ice Training

02.2008 • VSQ/TT • 8/17

The hydraulic 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 rotating magnetic field is generated in the stator coils through
actuation by the control unit of the individual electromagnetic terminal
pairs. This rotating magnetic field is followed by the rotor and this
causes a rotating movement.

VSQ/T T 8
 Rõhu akumulaator / õli filter

Rõhu akumulaator õlifilter

Mööd av oolu
kuulklapp

Serv ice Training

02.2008 • VSQ/TT • 9/17

The pressure accumulator

With ignition "on" the pressure accumulator is charged with oil from a
hydraulic pressure of 20 bar. The working pressure is between 40 and
60 bar.

The oil filter

The filter is located behind the hydraulic pump. The oil flows through
the filter once oil temperature is > - 5°C. If the oil 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
can now make its way via the bypass to the main pressure channel.

VSQ/T T 9
 Elektro/hüdraulilised komponendid

Solenoid klapi plokk

Paaki tagasi

Reguleeritud
v ooluga õlikanal

Osarõhu kanal ühiskanal

Kanal mis on
ühenduses pea
rõhukanaliga

N433 N436 N434 N435

Serv ice Training

02.2008 • VSQ/TT • 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 via holes in the mechatronics block to the part gearbox
pressure channels. Two channels per part gearbox are connected to
the front piston chamber of the gear actuators. This means that part
gearbox oil pressure can be built up in front of the gear actuator
piston. A different channel of the part gearbox leads to the clutch
safety valve (KS). There is part gearbox oil pressure here, too.

VSQ/T T 10
 Elektro/hüdraulilised komponendid

Käigukasti osarõhu reguleerklapp N436/440

Tagasi õlipaaki

Osarõhu kanalisse

Pea rõhukanalist
kolb

Magn et südamik
pool

Serv ice Training

02.2008 • VSQ/TT • 11/17

The part gearbox pressure regulator N436

If the part gearbox pressure regulator is actuated by the control unit

with a PWM signal, the control plunger moves upwards, thereby
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.

VSQ/T T 11
 Elektro/hüdraulilised komponendid

Käiguvahetus ja sidurilülitusventiil

Tagasi õlipaaki
Reguleeritud õli v ool
käiguv ahetussüsteemile v õi
sidurilülitusele kontrollkolb
Käigukasti osarõhukanalist

pool
Magn et südamik

Serv ice Training

02.2008 • VSQ/TT • 12/17

Gear actuator 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 channel of the gear actuator 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 activation of the solenoid by the clutch positioner valve, a PWM
signal is used by the control unit. The current moves the control
plunger upwards and the path to the channel of the clutch positioner 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.

VSQ/T T 12
 Käiguvahetuse operatsioon

1-3 käigu aktuaator neutraalasendis

N 436

N 433

Kolv i taga kamber Kolv i ees kamber

käiguv ahetuskolb

Serv ice Training

02.2008 • VSQ/TT • 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
volumetric flow in the rear piston chamber, the gear actuator plunger is
held in neutral position against part gearbox pressure of the front
chamber

VSQ/T T 13
 Käiguvahetuse operatsioon

1-3 käigu aktuaator, 1 käik on sisse lülitatud

N 436

N 433

Kolv i taga kamber Kolv i ees kamber

käiguv ahetuskolb

Serv ice Training

02.2008 • VSQ/TT • 14/17

The gear actuators 1-3; 1st gear selected

When 1st gear is selected, the gear actuator valve N433 is supplied
with more power by the control unit. In this way, the volumetric 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 situations by means of magnets on the selector form
and travel sensors of the control unit.

VSQ/T T 14
 Serv ice Training
02.2008 • VSQ/TT • 15/17

VSQ/T T 15