[car home Technology] powershift, in the impression of most people, is just equivalent to a swordsman with high kung fu in martial arts novels (such as seeking defeat alone? )-The evaluation we can give is: fast, fast, very fast. Moreover, this kind of transmission is direct enough and efficient enough, and it is like a master who never drags his feet … but why is it fast? Why is it efficient? What is its control principle? Is it really advanced? Want to know the answer? You don’t have to go to Baidu. car home has already opened powershift’s coat for you here-ladies and gentlemen, look for the answers you want in front of the naked transmission.

> > > Special note: 1. This paper only dissembles the DSG gearbox objectively, and does not comment on the phenomenon.
2. Regarding the topic of stability and fault that users are concerned about, we will explain it for you in the following follow-up articles. There is a notice at the end of the article. Please leave a message and participate in the discussion if you have any questions or faults about the dual clutch gearbox!
As usual, first of all, briefly introduce the protagonist of this "dedication": Volkswagen DQ200 dual-clutch gearbox-the first Volkswagen DSG gearbox made in China.
Basic information of Volkswagen DQ200 seven-speed dry dual-clutch gearbox |
model |
0AM |
Maximum transmission torque |
250 nm |
Number of forward gears/reverse gears |
7 /1 |
weight |
About 70 kilograms |
Matching engine and vehicle type |
Match the 1.4TSI and 1.6L engines of Volkswagen EA111 series. And Volkswagen EA888 series 1.8TSI engine. It has been mounted on sagitar, Golf, Ming Rui, LaVida, Magotan, Haorui, Bora, Volkswagen CC, New Passat, New Magotan and other models. |
● Get familiar with DQ200 gearbox quickly? Manual gearbox? Dual clutch gearbox?
Before we begin, we need to form an awareness of the dual-clutch gearbox in our consciousness. If you still don’t know what the gearbox is and how the basic manual gearbox works, we have prepared the following aperitif wine for you, please taste it first.

After understanding the structure of the manual gearbox, it is much simpler for us to understand the dual-clutch gearbox. In principle, the dual-clutch gearbox is equivalent to the combination of two manual gearboxes, one controls the odd gear, the other controls the even gear, and the reverse gear is queued according to the situation (in the DQ200 7-speed dual-clutch gearbox, the reverse gear is regarded as a group with the even gear). Then, one set can be added to the combination of these two manual gearboxes. Hong Gong, a well-known Volkswagen engineer in the media circle, used "two manual boxes and one set of automatic dialing" to vividly compare the principle of dual-clutch gearbox. The following video will help you to understand our metaphor more intuitively, and also help you to face the various parts that will be disassembled from DQ200 more calmly.
"『DQ200 gearbox principle demonstration video-in order to save your time, it is suggested thatAfter 1 minute and 12 seconds,Start watching "
With regard to the origin and evolution history of the concept of "dual clutch", we also give it to you as an appetizer. Please click the link below to see the ups and downs of the dual clutch so far.

● Actual disassembly of DQ200 transmission: three modules-two "powerful" and one "calculated"
Metaphor is metaphor. When we really put DQ200 in front of you, you can’t really see a product that is directly combined with "two manual gearboxes and one controller". The previous section is only for everyone to understand the principle of dual-clutch gearbox.

Judging from the actual structure of the gearbox, the main number of members of DQ200 powershift is still "three" (of course not MT+MT+ controller …). These three modules have different division of labor, and two of them are only responsible for "hard work". They are dual clutch modules and gearbox parts, and all they have to do is to transmit power, commonly known as "force". The third part is the "source of wisdom" of the dual-clutch gearbox-the electromechanical control module, but in fact it is both mental and physical-it can be said that it is both a director and an actor. What are the specific tasks and characteristics of these three modules? We interpret it by disassembling it.
● Dual clutch module: I have a foreign ID card!
Let’s get to know the dual clutch module with German ID on DQ200. Since powershift took his last name, you can imagine how important this guy is.

"The dual clutch module is provided by the Luk brand of Schaeffler, Germany."

The dual clutch module is simply two sets of clutches+one shell. We call the clutch near one end of the engine K1 clutch, and the clutch behind it K2 clutch. The two sets of clutches K1 and K2 have their own independent driven parts (friction plate+driven plate+shock absorber+driven hub), pressing mechanism (diaphragm spring, pressure plate) and operating mechanism (only the operating arm is mentioned here).





The double clutch housing, the driving disc in the middle of the housing, and the butterfly diaphragm springs and pressure plates of K1 and K2 are all "best friends" of the engine, and there is no relative rotation between them. The double clutch housing is connected with the engine flywheel and rotates synchronously with the engine, and these components are called "driving parts".



The diaphragm spring and pressure plate which rotate together with the clutch housing play an important role. Under the lever action of the control arm, the sleeve is pressed to deform the diaphragm spring, and the resulting deformation pushes (or pulls) the pressure plate to press the friction plate. At this time, the driven plate and the aforementioned driving part become a whole. With the synchronous rotation of the engine, after the power is obtained from the clutch, the driven plate relies on the internal spline to transfer the power to the input shaft, and the power from the engine enters the gearbox.


● What you don’t know about DQ200(1)
-The working principle of the clutch is the same as that of the manual gearbox, but it works in the opposite way!

Speaking of butterfly diaphragm spring, I have to say that this DQ200 dry dual clutch is very interesting in control mode and principle. It is consistent with the familiar manual gearbox principle, which also relies on extrusion and friction to realize the continuous transmission of power, and also uses the lever principle to squeeze the sleeve to deform the diaphragm spring. However, the diaphragm spring works in the opposite way to the diaphragm spring in the manual transmission clutch (see the dynamic diagram above). In the single-chip clutch structure of manual transmission, when the diaphragm spring is squeezed, the clutch pressure plate will be released and the power transmission will be interrupted; In DQ200 gearbox, the function of diaphragm spring when it is squeezed is actually to press the clutch to turn on the power! To put it bluntly, the clutch of the manual gearbox is-You give an external force, it separates,The clutch of this DQ200 dual-clutch gearbox is just the opposite.You give an external force, it will engage!The "disengaging bearing" and "disengaging lever" in the traditional clutch should be renamed as "engaging" XX here. …
● Gear box: double MT combined body
After the power enters the gearbox from the input shaft, it will begin to travel between gears. The gear camp in the box is very easy to divide-like two sets of manual gearboxes-two input shafts and two output shafts, and then a set of parking locking mechanism and a differential to transmit power to the wheel axle are added. In this way, you will find that the dual-clutch gearbox is actually just a few more shafts than the traditional manual gearbox. As we have previewed before, the shifting principle of DQ200 and manual gearbox is completely consistent, and the shifting fork pushes the engaging gear sleeve to complete the combination or separation of gears (shifting gears).

The two input shafts are respectively connected with the K1 clutch and the K2 clutch, and the internal and external coupling mode is adopted. The first input shaft is equipped with a 1357th gear, and the second input shaft is equipped with a 246R gear. When the two clutches work alternately, the power can be connected between the odd gear and the even gear. Take a closer look at the input shaft, and you will find another interesting thing. On the first input shaft, the gears corresponding to the 1357th gear are independent, while the second input shaft corresponding to the 246R gear has only two gears. The 4th gear and the 6th gear share one input shaft gear, and the 2nd gear and the R gear (reverse gear) share one input shaft gear. Perhaps the purpose of this design is to ensure that the hollow second input shaft can have enough strength and ensure the gearbox.






● What you don’t know about DQ200 gearbox (2)
-What’s the difference between the "N" gear (neutral gear) of the dual clutch gearbox and the manual gearbox?
Many netizens want to know the difference between the "N" gear of the dual clutch gearbox and the neutral gear of the manual gearbox. Take the DQ200 gearbox we disassembled as an example. Its logic in the "N" gear is indeed different from the "neutral" of our usual manual gearbox. Simply put,The "neutral" of the dual clutch gearbox is equivalent to the state that the manual gearbox is "engaged in 1st gear and engaged"., so that the speed will be faster when the power is engaged. Moreover, in the D-range mode, when the brake is stepped on for a long time, the clutch will also be automatically disconnected, and the gear engaging sleeve is still engaged with the 1st gear.

In addition to various shafts and gears, the gearbox body also has a part that we can’t ignore-the parking control module, that is, the "P" gear control mechanism of our vehicle. The parking gear is integrated on the third output shaft, coaxial with the reverse gear, and it is the only gear with internal splines (synchronized with the output shaft).



The parking control mechanism is the only one physically connected with the gear lever on the DQ200 gearbox (all other controls are transmitted by electrical signals). When we put the gear lever into the "P" gear, the gear lever is controlled by the cable, and the connecting ball pin is pulled to make the pawl buckle the parking gear, thus locking the output shaft and achieving the purpose of parking locking.
● Electromechanical control module, with developed "six limbs" and not simple mind.

The hardest part of the three is naturally the electromechanical control module, which is "both output and calculation". This way of working is simply a typical "IT migrant worker".

From the structural point of view, its composition is not complicated. The sensor, arithmetic/control chip, hydraulic unit and actuator are just four pieces of content, which is also a simple number. The electromechanical control module relies on these components to complete the whole process of obtaining information-judgment/decision-making-execution. Among them, the hydraulic pump and pressure storage tank composed of gear pump are the source of all power for the electromechanical control module, and if human organs are used as an analogy, this is the heart.





We humans move through four limbs. The electromechanical control module of DQ200 has six limbs, which control the operating arms of K1 and K2 clutches respectively, and the other four limbs are used to control the shift fork. Four independent fork control levers control five forks (six gears and reverse gears are two forks sharing a fork control lever), and it is the existence of independent control levers that makes it possible to engage adjacent gears in advance.



The "brain" that gives action instructions to limbs is provided by Continental, Germany. This brain judges the driving state of the vehicle and the driver’s intention through the engine speed sensor, the output shaft speed sensor and the operation made by the driver on the gearbox control lever, and shares a series of information on the CANBUS bus, such as vehicle speed, wheel speed, accelerator pedal position, steering angle sensor, lateral acceleration sensor and so on, and makes a response. Sensors located at the fork and clutch actuator always remind the German brain of the clutch that the gearbox is currently working and the gear that is currently combined. At the same time, according to the oil temperature sensor and oil pressure sensor in the electromechanical control module, whether the working state of the gearbox is normal or not can be monitored in time. We can imagine that this information processing ability is hopeful to challenge the popular dual-core smart phone …
● What you don’t know about DQ200 gearbox (3)
-even without a double clutch, it can be fast!
The reason why the dual clutch gearbox is fast enough is not only because it is as simple as a "dual clutch module", but also largely due to its independent shift control lever. Do you know what "independence" means? This means that even if there is no double clutch, since DQ200 adopts the design that the interval gears share a joint sleeve (as mentioned above), the joint sleeves of adjacent gears can operate independently, and theoretically, "the joint sleeves of one gear can be disengaged while the joint sleeves of adjacent gears are engaged!" Do you know what is the core system of Lamborghini’s ISR gearbox (the gearbox with a shift time of 50 milliseconds)? In fact, it is a number of forks that can be controlled independently!


"The reason why Lamborghini’s ISR gearbox dares to challenge the serial gearboxes of the previous supercars.
It is also because it adopts an independently controlled shift fork.
(This paragraph is purely for discussion, and fans are welcome to speak enthusiastically.) The effect of this independent control is more flexible than that of the mechanical multi-fork synchronous action mode relying on the "shift drum" of the sequential gearbox, especially in the case of "trip stop" (except for odd-numbered trip stop …), while the shift drum mechanism can quickly switch between adjacent gears by relying on the servo motor with quick response, but when multiple gears are shifted up or down (for example,
● DQ200(4 you don’t know (4)
-the gearbox needs to use two kinds of oil at the same time!

Most automatic gearboxes and even dual-clutch gearboxes only use one kind of oil, which not only needs to realize the functions of lubrication, heat dissipation and torque transmission, but also needs to provide the hydraulic pressure required by hydraulic control components. DQ200 dual-clutch gearbox adopts independent dual-oil circuit design, and different oils are applied in the two oil circuits. In the gearbox, the gear oil of model G052171 is used, which is consistent with the gear oil used in the domestic Volkswagen MQ250 manual gearbox, while the hydraulic oil of model G004000 is used in the electromechanical control module. The two oils can better play their own functions in their independent oil circuit circulation, so that the gearbox has better low-temperature working characteristics.

Moreover, the total oil consumption of DQ200 is only 2.7L (1.7L of gear oil and 1L of hydraulic oil), which is nearly half of that of traditional automatic gearbox and wet dual-clutch gearbox. Needless to say, DQ200 is a maintenance-free design, even if it needs maintenance later, it has obvious advantages in cost. (It is said that the oil consumption of DQ250 wet dual clutch gearbox is more than 6L, and the total oil consumption of DQ200 is less than half.)
● DQ200(5 you don’t know (5)
-What’s the difference between DQ200 (7-speed dry dual clutch) and DQ250(6-speed wet dual clutch)?

I believe everyone knows the most obvious difference between DQ200 and DQ250, that is, the difference between "wet and dry" clutches. DQ250 uses a wet clutch, and the control method of the clutch is completely different. DQ200 relies on hydraulic pressure to push the control arm and presses the clutch plate by the diaphragm spring, while the clutch engagement of DQ250 is completely controlled by hydraulic pressure. DQ250 designed with a wet clutch uses a single oil, because of its large consumption. Therefore, the oil tank is designed, and it has pressure oil filter, oil cooler and oil pump driven by crankshaft power, which DQ200 does not have.

In addition, due to the different number of forward gears, the 7-speed DQ200 has three output shafts, the reverse gear and the parking gear alone occupy one output shaft, while the DQ250 has only two, and the parking gear of DQ250 is integrated on the differential.
Summary:
After reading the disassembly article of DQ200, I believe everyone has a deeper understanding and cognition of this 7-speed dry dual-clutch gearbox.Personally, the dual clutch gearbox is not complicated in principle or structure, and the structure based on manual gearbox is the fundamental reason for its high transmission efficiency and low fuel consumption.The design idea of DQ200 dual oil circuit and dual oil is one of its highlights. The two independent oils have more advantages in functional adaptability, and the total oil consumption of 2.7L is also a figure worth showing off.
Of course, all advanced and fresh technologies always need to face people’s doubts and challenges, and our users still have various questions about "dual clutch". In the next article, we will answer the hot issues of gearbox reliability, price, maintenance and so on that are concerned by the majority of riders, and present more "DQ200 dual clutch gearbox you don’t know" for you. Please pay attention to our later content! (Text/car home Fan Xintu/car home Liu Wei Liu Yuhui)
Extended reading:

● Automobile technology is difficult to understand? Car design is too far away? Who said that? These contents can also be very interesting!

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