bluemotion technology.docx

(1)

VOLKSWAGEN BLUEMOTION TECHNOLOGIES

ABSTRACT

Human activities are affecting the environment much more and so that every automation company is busy to make its Human activities are affecting the environment much more and so that every automation company is busy to make its products

products and and projects projects very very efficient efficient and and involving involving many many important important steps steps to to achieve achieve this this target. target. And And Blue Blue motionmotion Technology is one of them that is used by Volks Wagen group of industries and it tries to decrease the impact of human Technology is one of them that is used by Volks Wagen group of industries and it tries to decrease the impact of human activity on the environment. Blue motion Technology based cars are known as most cleanest cars and very much activity on the environment. Blue motion Technology based cars are known as most cleanest cars and very much Eco-friendly in the world. [More...] Volkswagen group of industry is not depending on the old or space age technology. They friendly in the world. [More...] Volkswagen group of industry is not depending on the old or space age technology. They are making the car engines more efficient by including the electronic circuitry and by modifying some basic cycle parts of are making the car engines more efficient by including the electronic circuitry and by modifying some basic cycle parts of the car engine. By using blue motion technology the car engine gets various useful features like TDI, TSI, DSG, automatic the car engine. By using blue motion technology the car engine gets various useful features like TDI, TSI, DSG, automatic start/stop, Recuperation, usage of taller gear ratios, better aerodynamics etc.The products made by using both blue motion start/stop, Recuperation, usage of taller gear ratios, better aerodynamics etc.The products made by using both blue motion technology and electronic circuitry, are very much efficient and reliable rather than other products.

(2)

1. 1. INTRODUCTION

INTRODUCTION

Today the world is become more and more polluted with harmful gases and pollutants like NOx, SOx, HC, Today the world is become more and more polluted with harmful gases and pollutants like NOx, SOx, HC, CO

CO22, CO... to name a few. The main cause of the atmospheric pollution is our very own automobiles which now, CO... to name a few. The main cause of the atmospheric pollution is our very own automobiles which now

have become an integral part of our lives. At this moment replacing all the automobiles with some other have become an integral part of our lives. At this moment replacing all the automobiles with some other alternative is simply not feasible. Due to the increasing pressure fro

alternative is simply not feasible. Due to the increasing pressure fro

m the government and other NGO‟s the

automobile manufacturers are feeling the pressure which is motivating them to come with some very good ideas automobile manufacturers are feeling the pressure which is motivating them to come with some very good ideas to make our future greener, cleaner

to make our future greener, cleaner and much more efficient tan it is todaand much more efficient tan it is today.y.

The adverse affects that atmospheric pollutants have on humans are: Carbon Monoxide (CO)

–

reduces the reduces the

blood‟s ability to carry oxygen, ag

blood‟s ability to carry oxygen, aggravates lung and heart

gravates lung and heart disease, and causes headaches,

disease, and causes headaches, fatigue, and dizziness.

fatigue, and dizziness.

Sulfur Dioxides (SOx)

–

when combined with water vapor in the air become the major contributor to acid rain. when combined with water vapor in the air become the major contributor to acid rain. Nitrogen

Nitrogen Oxides Oxides (NOx)(NOx)

–

cause the yellowish-brown haze over dirty cities, and when combined with oxygen cause the yellowish-brown haze over dirty cities, and when combined with oxygen becomes a poisonous gas that can dama

becomes a poisonous gas that can damage lung tissue. Hydrocarbons (HC) are a group of pollutants that react toge lung tissue. Hydrocarbons (HC) are a group of pollutants that react to form ozone (O3), some HCs cause cancer and others can irritate mucous membranes. Ozone (O3) is the white form ozone (O3), some HCs cause cancer and others can irritate mucous membranes. Ozone (O3) is the white haze or smog seen over many cities. Ozone can irritate the respiratory system, decrease lung function, and haze or smog seen over many cities. Ozone can irritate the respiratory system, decrease lung function, and aggravate chronic lung diseases (such as asthma). Carbon Dioxide (CO2), although naturally occurring, can aggravate chronic lung diseases (such as asthma). Carbon Dioxide (CO2), although naturally occurring, can cause problems. In large quantities it allows more sunlight to enter the atmosphere than can escape

cause problems. In large quantities it allows more sunlight to enter the atmosphere than can escape

–

trapping trapping

excess heat that can lead to the “greenhouse effect” and cause global warming.

The first idea was to use a hybrid system; generally an electric hybrid is preferred over other kinds of hybrid The first idea was to use a hybrid system; generally an electric hybrid is preferred over other kinds of hybrid due to its feasibility in the compact dimensions of a car. But there is a problem with hybrid electric vehicle due to its feasibility in the compact dimensions of a car. But there is a problem with hybrid electric vehicle (HEV). The weakest links are the batteries which stores the electric energy to be used by the electric motor. (HEV). The weakest links are the batteries which stores the electric energy to be used by the electric motor. They are naturally heavy and quick acceleration and deceleration can severely affect the life of the batteries They are naturally heavy and quick acceleration and deceleration can severely affect the life of the batteries moreover the mining of nickel is a highly polluting process. This is why VolksWagen, which is one of the moreover the mining of nickel is a highly polluting process. This is why VolksWagen, which is one of the biggest automakers of

biggest automakers of the world, has the world, has preferred to go preferred to go without hybrid systems. without hybrid systems. The strategy of The strategy of VolksWagen is toVolksWagen is to

take the conventional internal combustion engine and make them as efficient as it‟s possible so that the

environmental impact of these cars will be greatly reduced. environmental impact of these cars will be greatly reduced.

BlueMotion is a trade name (developed externally by UK's Origin Brand Consultants) for fuel-efficient BlueMotion is a trade name (developed externally by UK's Origin Brand Consultants) for fuel-efficient automobile models from the Volkswagen Group. Volkswagen introduced the name in 2006 on the Mk4 Polo automobile models from the Volkswagen Group. Volkswagen introduced the name in 2006 on the Mk4 Polo

(3)

Škoda Fabia and Superb, where the technology is ca

lled Greenline. BlueMotion versions of the Golf and lled Greenline. BlueMotion versions of the Golf and TouranTouran were released in 2008. The

were released in 2008. The name refers to VW's corporate colour, blue, and name refers to VW's corporate colour, blue, and echoes DaimlerChrysler's BlueTec.echoes DaimlerChrysler's BlueTec. BlueMotion Volkswagens use existing technology to improve on the standard engine/vehicle. Currently, BlueMotion Volkswagens use existing technology to improve on the standard engine/vehicle. Currently, Volkswagen Group focuses in three areas of improvement:

Volkswagen Group focuses in three areas of improvement:



 ENGINE:ENGINE: 

 Revised engine mapping, and including diesel particulate filters help the fuel consumption andRevised engine mapping, and including diesel particulate filters help the fuel consumption and

lower NOx levels. lower NOx levels.



 TRANSMISSION:TRANSMISSION: 

 On the Polo, Golf and Passat the last two gear ratios are longer than on standard TurbochargedOn the Polo, Golf and Passat the last two gear ratios are longer than on standard Turbocharged

Direct Injection (TDI) engine gearboxes. Direct Injection (TDI) engine gearboxes.



 AERODYNAMICS:AERODYNAMICS: 

 On the Polo, Golf and Passat, Volkswagen have lowered the suspension, redesigned the spoilers,On the Polo, Golf and Passat, Volkswagen have lowered the suspension, redesigned the spoilers,

and performed additional enhancements underneath each car - so the air is channeled better giving and performed additional enhancements underneath each car - so the air is channeled better giving less drag which produces better fuel consumption.

less drag which produces better fuel consumption.

Why the name bluemotion? Blue - the Volkswagen colour - symbolises the elements water and air, while Why the name bluemotion? Blue - the Volkswagen colour - symbolises the elements water and air, while Motion represents a move forwards towards the future. BlueMotion Technologies have one very important aim Motion represents a move forwards towards the future. BlueMotion Technologies have one very important aim that is to reduce the impact of ca

that is to reduce the impact of cars on the environment for future generations.rs on the environment for future generations.

Bluemotion cars are not only cleaner, more efficient cars but also offer greater performance. The result is an Bluemotion cars are not only cleaner, more efficient cars but also offer greater performance. The result is an impressive range of refinements and innovations that save fuel and cut CO2 emissions. All the technologies impressive range of refinements and innovations that save fuel and cut CO2 emissions. All the technologies have been grouped together under the badge of BlueMotion Technologies. So the environmental technologies of have been grouped together under the badge of BlueMotion Technologies. So the environmental technologies of today are meeting the driving challenges of tomorrow. At the heart of BlueMotion Technologies are advanced today are meeting the driving challenges of tomorrow. At the heart of BlueMotion Technologies are advanced TDI & TSI engines and DSG dual-clutch gearbox.

TDI & TSI engines and DSG dual-clutch gearbox.

Volkswagen has not only made the car more efficient and eco-friendly but it has made the whole manufacturing Volkswagen has not only made the car more efficient and eco-friendly but it has made the whole manufacturing process

process a a lot lot more more cleaner cleaner and and greener greener making making use use of of modern modern highly highly fuel fuel efficient efficient boilers boilers and and furnaces.furnaces. Preaparing a life cycle assessment(LCA) is a method of understanding the amount of resources going into a car. Preaparing a life cycle assessment(LCA) is a method of understanding the amount of resources going into a car. Volkswagen has many years of experience with Life Cycle Assessments for product and process optimisation. Volkswagen has many years of experience with Life Cycle Assessments for product and process optimisation. They have even assumed a leading role in implementing and publishing life cycle inventories of complete They have even assumed a leading role in implementing and publishing life cycle inventories of complete vehicles. For instance, in 1996 they were the first car manufacturer in the world to prepare a Life Cycle vehicles. For instance, in 1996 they were the first car manufacturer in the world to prepare a Life Cycle Inventory study (for the Golf III) and publish it [Schweimer and Schuckert 1996]. Since then they have drawn Inventory study (for the Golf III) and publish it [Schweimer and Schuckert 1996]. Since then they have drawn

(4)

up Life Cycle Assessments for other cars and also published some of the results [Schweimer 1998; Schweimer up Life Cycle Assessments for other cars and also published some of the results [Schweimer 1998; Schweimer et al. 1999; Schweimer and Levin 2000; Schweimer and Roßberg 2001].

et al. 1999; Schweimer and Levin 2000; Schweimer and Roßberg 2001]. These LCAs

These LCAs

primarily describe and identify environmental hot spots“ in

primarily describe and identify environmental hot spots“ in the life cycle of a ca

the life cycle of a car. Since then they

r. Since then they

have broadened the assessments to include production processes as well as fuel production and recycling have broadened the assessments to include production processes as well as fuel production and recycling processes

processes [Bossdorf-Zimmer [Bossdorf-Zimmer et et al. al. 2005; 2005; Krinke Krinke et et al. al. 2005b]. 2005b]. Since Since 2007, 2007, they they have have been been usuingusuing environmental commendations to inform customers and the public about the environmental properties of their environmental commendations to inform customers and the public about the environmental properties of their vehicles [Volkswagen AG 2007a, Volkswagen AG 2007b, Volkswagen AG 2008].

vehicles [Volkswagen AG 2007a, Volkswagen AG 2007b, Volkswagen AG 2008].

Volkswagen is also making long-term investments in further developing and optimising Life Cycle Assessment Volkswagen is also making long-term investments in further developing and optimising Life Cycle Assessment methods. Thanks to their intensive research they have succeeded in considerably reducing the workload methods. Thanks to their intensive research they have succeeded in considerably reducing the workload involved in preparing Life Cycle Inventories. Their research resulted in the development of the VW slimLCI involved in preparing Life Cycle Inventories. Their research resulted in the development of the VW slimLCI interface system [Koffler et al. 2007]: this interface not only significantly cuts the workload involved in interface system [Koffler et al. 2007]: this interface not only significantly cuts the workload involved in preparing Life Cycle Assessments of complete vehicles by automating the process, but also f

preparing Life Cycle Assessments of complete vehicles by automating the process, but also further improves theurther improves the consistency and quality of the LCA models produced. This represents substantial progress, since preparing a consistency and quality of the LCA models produced. This represents substantial progress, since preparing a complete LCA for a vehicle involves registering thousands of components, together with any related upstream complete LCA for a vehicle involves registering thousands of components, together with any related upstream supply chains and processes. Fig. 1 shows the variety of parts involved in an entire vehicle taking the Golf V as supply chains and processes. Fig. 1 shows the variety of parts involved in an entire vehicle taking the Golf V as an example. All these data has helped Volkswagen to improve the manufacturing process and to reduce the use an example. All these data has helped Volkswagen to improve the manufacturing process and to reduce the use of conventional fossil fuels in the manufacturing of its cars. Hence the idea of greener cars doesent only starts at of conventional fossil fuels in the manufacturing of its cars. Hence the idea of greener cars doesent only starts at the car but it starts from the whole process of manufacturing it.

(5)

Fig. 1: Fig. 1: Dismantling study of the Golf V

Dismantling study of the Golf V

2. 2. TDI (TURBOCHARGED DIRECT INJECTION)

TDI (TURBOCHARGED DIRECT INJECTION)

TDI identifies all the VW advanced diesel engines using direct injection and a turbocharger. TDI engines are TDI identifies all the VW advanced diesel engines using direct injection and a turbocharger. TDI engines are economical and smooth with high levels of torque (pulling power) and good energy efficiency. Fuel needs economical and smooth with high levels of torque (pulling power) and good energy efficiency. Fuel needs oxygen to burn and the engine has to be supplied with huge quantities of air to be effective. This problem is oxygen to burn and the engine has to be supplied with huge quantities of air to be effective. This problem is solved

solved using using a a bigger bigger engine engine - - or or by by using using a a turbocharger turbocharger - - as as in in the the TDI. TDI. Driven Driven by by the the exhaust exhaust gases, gases, itit squeezes

squeezes air morair more e tightly tightly into into the cylinders. the cylinders. The air The air is then is then cooled (cool cooled (cool air takes air takes up less up less space than space than hot airhot air)) and diesel is injected directly into the cylinders at very high pressure through a nozzle.

and diesel is injected directly into the cylinders at very high pressure through a nozzle.

It‟s this intensive

mixing

mixing of of highly highly atomised atomised fuel fuel with with the the compressed compressed air air that that leads leads to to better, better, more more efficient efficient combustion.combustion. Makng

Makng the the driving driving experience experience quiet quiet and and refined refined because because effective effective sound sound insulation insulation keeps keeps noise noise to to aa minimum,

minimum, while while hydraulic hydraulic engine mounts engine mounts ensure ensure smooth, smooth, low-vibration low-vibration running. The running. The great advantage great advantage of of TDITDI engines is that they are very powerful, even at low revs, and economical across the entire speed range. This engines is that they are very powerful, even at low revs, and economical across the entire speed range. This efficiency

efficiency also also means means that that one one save save on on fuel fuel costs costs and and emit emit less less CO2, CO2, so so helping helping to to minimise minimise his/herhis/her impact

impact on on the the environment.environment.

2.1

2.1 The TechnologyThe Technology

The engine uses direct injection, where a fuel injector sprays atomised fuel directly into the main combustion The engine uses direct injection, where a fuel injector sprays atomised fuel directly into the main combustion chamber of each cylinder, rather than the pre-combustion chamber prevalent in older diesels which used indirect chamber of each cylinder, rather than the pre-combustion chamber prevalent in older diesels which used indirect

(6)

injection. The engine is coupled with a turbocharger to increase the amount of air going into the engine injection. The engine is coupled with a turbocharger to increase the amount of air going into the engine cylinders, and an intercooler to lower the temperature (and therefore increase the density) of the air from the cylinders, and an intercooler to lower the temperature (and therefore increase the density) of the air from the turbo, thereby increasing the amount of fuel that can be injected and combusted. These, in combination, allow turbo, thereby increasing the amount of fuel that can be injected and combusted. These, in combination, allow for

for greater greater engine engine performance performance (from (from a a more more complete complete combustion combustion process process compared compared to to indirect indirect injection),injection), while

while also also decreasing decreasing emissions emissions and and providing providing more more torque torque than than its its petrol petrol engined engined counterpart. counterpart. SimilarSimilar technology

technology has has been been used used by by other other companies companies but but "TDI" "TDI" refers refers to to these these Volkswagen Volkswagen Group Group engines.engines. Normally-aspirated

Normally-aspirated engines engines (those (those without without a a turbocharger) turbocharger) made made by by Volkswagen Volkswagen Group Group use use the the labellabel Suction

Suction Diesel Diesel Injection Injection (SDI). (SDI). The The reduced reduced material material volume volume of of the the direct direct injection injection diesel diesel engine engine reducesreduces heat

heat losses, losses, and and thereby thereby increases increases engine engine efficiency, efficiency, at at the the expense expense of of increased increased combustion combustion noise. noise. A A directdirect injection engine is also easier to start when cold,

injection engine is also easier to start when cold, due to more efficient placing and usadue to more efficient placing and usage of glowplugs.ge of glowplugs.

The PD(Pumpe-Düse) design was a reaction to the development of common rail fuel injection by The PD(Pumpe-Düse) design was a reaction to the development of common rail fuel injection by competitors

competitors - - an attempt an attempt by Volkswagen by Volkswagen Group to creGroup to create an iate an in-house technology of n-house technology of comparable performancecomparable performance that would not require any royalties to be paid. While Pumpe-Düse engines had a significantly higher injection that would not require any royalties to be paid. While Pumpe-Düse engines had a significantly higher injection pressure than older engines, they were not a match

pressure than older engines, they were not a match with the very with the very latest common rail, and weren't able to controllatest common rail, and weren't able to control injection timing as precisely (a major factor in improving emissions). New engines appearing in 2009 model injection timing as precisely (a major factor in improving emissions). New engines appearing in 2009 model year

year Volkswagens Volkswagens are are using using the the common-rail common-rail technique technique with with piezoelectric injectors.piezoelectric injectors. Fuel:

Fuel: TDI TDI engines, engines, like like most most diesel diesel engines, engines, can can run run on on petrodiesel petrodiesel or or B5, B5, B20, B20, or or B99 B99 biodiesel biodiesel subject subject toto manufacturers' prior approval. In fuel efficiency, and clean emissions when run on biodiesel or when converted manufacturers' prior approval. In fuel efficiency, and clean emissions when run on biodiesel or when converted vegetable

vegetable oil oil (which (which should Nshould NOT OT be be used used on ton the he later later PD PD engines engines without without prior prior conversion, conversion, since since irreparableirreparable damage will result), TDI engines are among the best on the market. This is often overlooked because they damage will result), TDI engines are among the best on the market. This is often overlooked because they do not drive on petrol. A 2007 Volkswagen Jetta 1.9L TDI with 5-speed manual, for example, achieves 5.2 do not drive on petrol. A 2007 Volkswagen Jetta 1.9L TDI with 5-speed manual, for example, achieves 5.2 L/100 km (54 mpg UK or 45 mpg US) on the European combined-cycle test while a DSG automatic reaches 5.9 L/100 km (54 mpg UK or 45 mpg US) on the European combined-cycle test while a DSG automatic reaches 5.9 L/100 km (48 mpg UK or 40 m

L/100 km (48 mpg UK or 40 mpg US). Newer TDI engines, with higpg US). Newer TDI engines, with higher injection pressures, arher injection pressures, are less e less forgivingforgiving about poor-quality

about poor-quality fuel than their 1980s ancesfuel than their 1980s ancestors. VW has recetors. VW has recently permitted mixes up tntly permitted mixes up to B20, and haso B20, and has recommended B5

recommended B5 be used in be used in place of place of 100% petroleum-based diesel 100% petroleum-based diesel because of biodiesel'because of biodiesel's s improved improved lubricatinglubricating properties. No.

properties. No. 2 diesel 2 diesel fuel fuel is is recommended recommended since since it has it has a higher a higher cetane numbecetane number r than No. than No. 1 1 fuel and fuel and hashas lower

lower viscosity viscosity (better (better ability ability to to flow) flow) than than heavier heavier fuel fuel oils. oils. Some Some owners owners in in North North America, America, where where cetanecetane levels

levels are are generally generally poor poor (as (as low low as as 40), 40), use use additives additives or or premium premium diesel diesel to to get get cetane cetane numbers numbers closer closer toto the standard levels found in the European market (at least 51) where the engine is designed.

(7)

Improved cetane reduce

Improved cetane reduces emissions while improving s emissions while improving performance and performance and may increase fuel may increase fuel economy. economy. NewNew low-sulfur petroleum-only diesel recipes cause seals to shrink and can cause fuel pump failures in TDI engines; low-sulfur petroleum-only diesel recipes cause seals to shrink and can cause fuel pump failures in TDI engines; biodiesel blends are reported to prevent that failure.

biodiesel blends are reported to prevent that failure.

2.2 The Turbocharger 2.2 The Turbocharger

To boost

To boost power power output and output and torque, torque, VW fitted VW fitted their TDI their TDI engines engines with exwith exhaust turbochargers haust turbochargers featuringfeaturing variable turbine geometry. They compress the air required for combustion, letting the engine draw in more air variable turbine geometry. They compress the air required for combustion, letting the engine draw in more air while its displacement and revs stay the same. A turbocharger is powered by the energy in the exhaust gas. It while its displacement and revs stay the same. A turbocharger is powered by the energy in the exhaust gas. It has two connected turbines. The turbine wheel in the exhaust stream drives the intake compressor, which sucks has two connected turbines. The turbine wheel in the exhaust stream drives the intake compressor, which sucks in air through the intake system. The compressed air is cooled by a charge air cooler before entering the in air through the intake system. The compressed air is cooled by a charge air cooler before entering the combustion chamber. Because cool air is denser than hot air, more oxygen can be fed into the cylinder boosting combustion chamber. Because cool air is denser than hot air, more oxygen can be fed into the cylinder boosting the efficiency of the combustion process.

the efficiency of the combustion process.

Overcoming turbo lag: The main disadvantage of a turbocharger is that it needs a certain gas pressure to work Overcoming turbo lag: The main disadvantage of a turbocharger is that it needs a certain gas pressure to work which are only available when engine revs are high enough. To avoid 'turbo lag' a delay in available power which are only available when engine revs are high enough. To avoid 'turbo lag' a delay in available power -the turbocharger needs to be able to control -the exhaust pressure at low engine revs.

the turbocharger needs to be able to control the exhaust pressure at low engine revs.

A variable turbine geometry (VTG) turbocharger does this with a system of mechanical guide vanes. These A variable turbine geometry (VTG) turbocharger does this with a system of mechanical guide vanes. These vanes move to adjust the cross-section area to maximise the air flow into the exhaust turbine. Thus at lower vanes move to adjust the cross-section area to maximise the air flow into the exhaust turbine. Thus at lower speeds, a higher flow can be maintained, increasing the pressure to the compressor and therefore increasing speeds, a higher flow can be maintained, increasing the pressure to the compressor and therefore increasing power output.

power output.

2.3

2.3 Volkswagen’sVolkswagen’s Injection SystemsInjection Systems

They are one of the leaders in developing advanced efficient diesel engines with lower emissions. Their They are one of the leaders in developing advanced efficient diesel engines with lower emissions. Their innovative engines are progressively meeting the new EU 5 standard, ahead of legislation. Their range of three innovative engines are progressively meeting the new EU 5 standard, ahead of legislation. Their range of three to ten-cylinder turbodiesel engines are based on u

to ten-cylinder turbodiesel engines are based on u nit injector systems, and common rail injection.nit injector systems, and common rail injection. Table 1: Comparison between different VW engines.

Table 1: Comparison between different VW engines.

VW Polo 1.6 VW Polo 1.6 TDI TDI VW Polo 1.6 TDI VW Polo 1.6 TDI BlueMotion Technology BlueMotion Technology VW Polo 1.4 MPI VW Polo 1.4 MPI DSG DSG Engine

Engine capacity capacity [cm3] [cm3] 1598 1598 1598 1598 13901390 Output

Output [kW] [kW] 55 55 66 66 6363

Gearbox

(8)

How How injection injection works? works? The The pressure pressure atat which the which the diesel is diesel is injected

injected into into the the cylinder cylinder is is the the key key factor factor in in diesel diesel direct direct injection. injection. The The fuel fuel has has to to mix mix swiftly swiftly with with thethe compressed air in the cylinder. The higher the pressure, the more finely the diesel is atomised for an intensive compressed air in the cylinder. The higher the pressure, the more finely the diesel is atomised for an intensive mixing of the fuel and air particles. This, in turn, leads to better and more efficient combustion process. The mixing of the fuel and air particles. This, in turn, leads to better and more efficient combustion process. The energy from the fuel is used more effectively and emissions are reduced. We use various injection stages within energy from the fuel is used more effectively and emissions are reduced. We use various injection stages within one power stroke - referred to as multiple injections. Depending on the engine design, revs and load, modern one power stroke - referred to as multiple injections. Depending on the engine design, revs and load, modern diesel engines use a pilot or double pilot injection and a main injection. Pilot injection achieves smooth diesel engines use a pilot or double pilot injection and a main injection. Pilot injection achieves smooth combustion,

combustion, ensuring ensuring that that the the extremely high extremely high pressures pressures necessary necessary for for combustion combustion to to take take place aplace are re reachedreached more gradually. This significantly reduces combustion noise and

more gradually. This significantly reduces combustion noise and cuts emissions.cuts emissions.

Piezo crystal injectors. To control the injection process precisely and cut fuel consumption and emissions Piezo crystal injectors. To control the injection process precisely and cut fuel consumption and emissions significantly,

significantly, they use they use piezo inline piezo inline injectors iinjectors instead of nstead of solenoid valves. solenoid valves. They are They are lighter and lighter and respond respond twice twice asas fast.

fast. This enables the injector valve tThis enables the injector valve to switch five times faso switch five times faster to meter the fter to meter the fuel and control the injection curveuel and control the injection curve far more precisely, resulting in a smoother, quieter and more efficient combustion process. A post injection far more precisely, resulting in a smoother, quieter and more efficient combustion process. A post injection phase is

phase is also possible also possible with this with this type of type of injector, which injector, which helps the helps the exhaust exhaust emissions system to emissions system to be more be more efficientefficient and

and results results in in lower lower emissions.emissions. Common

Common rail rail - - third-generationthird-generation diesel

diesel direct direct injection. injection. CommonCommon rail

rail is is the the latest latest diesel diesel engineengine technology

technology and and is is used used in in many many VWVW vehicles

vehicles already. already. The The common common railrail system

system stores stores the the injection injection pressurepressure in

in a a high-pressure high-pressure fuel fuel reservoirreservoir

Fuel

Fuel Diesel Diesel Diesel Diesel Petrol Petrol (Super)(Super) Fuel consumption [l/100 km]

Fuel consumption [l/100 km] (urban/overland/combined)

(urban/overland/combined) (5.1/3.6/4.2) (5.1/3.6/4.2) (4.6/3.2/3.7) (4.6/3.2/3.7) (7.7/4.7/5.8(7.7/4.7/5.8)) Emission

Emission class class Euro Euro 5 5 Euro Euro 5 5 Euro Euro 55 CO

CO22emissions; emissions; combined combined [g/km] [g/km] 109 109 96 96 135135

Maximum

Maximum speed speed [km/h] [km/h] 170 170 180 180 177177 Acceleration

Acceleration 0-100 0-100 km/h km/h [s [s ] ] 13.9 13.9 11.5 11.5 11.911.9 Kerb

(9)

system the generation of pressure and the fuel injection p

system the generation of pressure and the fuel injection p rocesses are separate.rocesses are separate.

Figure 2: Comparison between the TDI and normal diesel engine. Figure 2: Comparison between the TDI and normal diesel engine.

Lines connect all the cylinder injectors to the common rail in parallel, ensuring they all have an uninterrupted Lines connect all the cylinder injectors to the common rail in parallel, ensuring they all have an uninterrupted supply of constant pressure. The injection quantity and

supply of constant pressure. The injection quantity and timing are controlled using solenoid valves.timing are controlled using solenoid valves.

The advantage of common rail is that fuel can be delivered at higher pressure, giving better mixing with air for The advantage of common rail is that fuel can be delivered at higher pressure, giving better mixing with air for a more efficient and cleaner combustion. This gives higher performance combined with improved fuel a more efficient and cleaner combustion. This gives higher performance combined with improved fuel consumption.

consumption.

The ever-higher injection pressures that make diesel engines cleaner and more efficient than before place big The ever-higher injection pressures that make diesel engines cleaner and more efficient than before place big demands on the common rail system. Their latest generation of diesel engines reaches injection pressures as demands on the common rail system. Their latest generation of diesel engines reaches injection pressures as high as 1,800 bars. For this reason the

high as 1,800 bars. For this reason the y make the rail themselves, and they make the rail themselves, and they are the first car maker to do soy are the first car maker to do so..

2.4 Diesel Particulate Filters (DPF) 2.4 Diesel Particulate Filters (DPF)

The main problem with diesel engine is the amount of soot emission. This is why diesel particulate filter is an The main problem with diesel engine is the amount of soot emission. This is why diesel particulate filter is an integral

integral part part of of any any diesel diesel engine. engine. The The diesel diesel particulate particulate filter: filter: Legislation Legislation is is continually continually driving driving carcar manufacturers

manufacturers to to produce produce cleaner cleaner and and more more environmentally environmentally friendly friendly vehicles. vehicles. Their Their advanced advanced dieseldiesel engines meet this challenge and are cleaner than ever before. One important factor is their diesel particulate engines meet this challenge and are cleaner than ever before. One important factor is their diesel particulate

(10)

filters (DPF), which are very effective in cutting particulate emissions, trapping even the finest soot particles filters (DPF), which are very effective in cutting particulate emissions, trapping even the finest soot particles that are produced as the engine burns diesel fuel.

that are produced as the engine burns diesel fuel. The

The latest generation latest generation of filterof filters operate s operate without additives. without additives. This makes This makes them maintenance-free for them maintenance-free for anan exceptionally long time: an initial inspection is usually carried out only after 150,000 km. The filter's lifespan is exceptionally long time: an initial inspection is usually carried out only after 150,000 km. The filter's lifespan is dependent on factors such as fuel qualit

dependent on factors such as fuel quality, driving style, use and oil consumption.y, driving style, use and oil consumption.

3. 3. TSI (REVOLUTIONARY PETROL ENGINE)

TSI (REVOLUTIONARY PETROL ENGINE)

What is TSI? TSI is VW‟s pioneering tec

hnology for petrol engines. TSI engines are compact, high-poweredhnology for petrol engines. TSI engines are compact, high-powered and use less fuel. TSI technology blends the best of their TDI diesel and FSI (Direct Injection) engines. One can and use less fuel. TSI technology blends the best of their TDI diesel and FSI (Direct Injection) engines. One can enjoy excellent drivability and outstanding fuel economy. Acceleration is instant, whichever gear one is using. enjoy excellent drivability and outstanding fuel economy. Acceleration is instant, whichever gear one is using. So overtaking is safer and one can power smoothly up hills with no delay. TSI technology is available on an So overtaking is safer and one can power smoothly up hills with no delay. TSI technology is available on an increasing number of

increasing number of

VW‟s

cars, from Golf to Passat. cars, from Golf to Passat.

As responsible car makers VW wanted to make its petrol engines even cleaner and more efficient, while still As responsible car makers VW wanted to make its petrol engines even cleaner and more efficient, while still being

being fun fun to to drive. drive. Their Their aim aim was was to to create create engines engines that that used used less less fuel fuel and and produced produced lower lower CO2 CO2 emissionsemissions without

without sacrificing sacrificing power. power. The The solution solution their their engineers engineers came came up up with wwith was boas both th elegant elegant and and ingenious: ingenious: anan engine

engine that that combines combines petrol petrol direct direct injection injection with with twinchargingtwincharging

–

a turbocharger and a supercharger working a turbocharger and a supercharger working together. The TSI engine was born. Volkswagen is the only car manufacturer in the world to offer an engine together. The TSI engine was born. Volkswagen is the only car manufacturer in the world to offer an engine with this feature. The effect is to combine the benefits of both petrol and diesel power units: smooth and quiet with this feature. The effect is to combine the benefits of both petrol and diesel power units: smooth and quiet on the road, TSI delivers high torque - pulling power - throughout the acceleration range with no turbo lag. The on the road, TSI delivers high torque - pulling power - throughout the acceleration range with no turbo lag. The successful TSI formula combines a number of different elements:

successful TSI formula combines a number of different elements:

3.1 Smaller Engines 3.1 Smaller Engines

At the heart of TSI

At the heart of TSI is a smaller engine. is a smaller engine. It's more effIt's more efficient, as there is less icient, as there is less power loss resulting frpower loss resulting from friction. om friction. It'sIt's also lighter, so the engine has less weight to shift in the car. Direct petrol injection with charging. Direct petrol also lighter, so the engine has less weight to shift in the car. Direct petrol injection with charging. Direct petrol injection

injection is is combined combined with with a a turbocharger turbocharger or or with with a a turbocharger turbocharger and and a a supercharger supercharger working working in in tandem.tandem. This enhances the engine's combustion efficiency so the TSI engine power output is much higher than that of This enhances the engine's combustion efficiency so the TSI engine power output is much higher than that of conventional, naturally aspirated engines.

conventional, naturally aspirated engines. Hunting down every gram:

(11)

concept is also based on the stronger TSIs, it was possible to reduce weight by about 600 grams with a concept is also based on the stronger TSIs, it was possible to reduce weight by about 600 grams with a structure-optimized design. The Volkswagen engineers also reconfigured the intake port. Based on the large structure-optimized design. The Volkswagen engineers also reconfigured the intake port. Based on the large TSI, it was further developed with the goal of achieving a level of swirl or tumble that would not require charge TSI, it was further developed with the goal of achieving a level of swirl or tumble that would not require charge movement flaps, as already mentioned. In addition, the new intake port was modified substantially. The movement flaps, as already mentioned. In addition, the new intake port was modified substantially. The advantage: In broad sections of the engine's operating range, it was possible to achieve quicker and even more advantage: In broad sections of the engine's operating range, it was possible to achieve quicker and even more efficient combustion with better fuel economy and a smoother engine characteristic. Valves on the TSI are efficient combustion with better fuel economy and a smoother engine characteristic. Valves on the TSI are actuated by two camshafts also further optimized with inlet-side adjustment. Various modifications enabled actuated by two camshafts also further optimized with inlet-side adjustment. Various modifications enabled weight savings here too: The camshafts each weigh 304 grams less. Every gram counts. That is why even the weight savings here too: The camshafts each weigh 304 grams less. Every gram counts. That is why even the cylinder head cover is 150 grams lighter. Overall, the 90-kW TSI is 14,000 grams, or 14 kilograms, lighter than cylinder head cover is 150 grams lighter. Overall, the 90-kW TSI is 14,000 grams, or 14 kilograms, lighter than a TSI with 125 kW.

a TSI with 125 kW.

3.2 Twincharging 3.2 Twincharging

On the TSI 1.4 160PS the engine-driven supercharger operates at lower revs, with the turbocharger - powered On the TSI 1.4 160PS the engine-driven supercharger operates at lower revs, with the turbocharger - powered by

by the the exhaust exhaust gases gases - - joining joining in in as as engine engine speed speed rises. rises. The The supercharger supercharger is is powered powered via via a a belt belt drive drive directlydirectly from the crankshaft. This provides maximum pulling power on demand, even at very low engine speeds. TSI from the crankshaft. This provides maximum pulling power on demand, even at very low engine speeds. TSI engines are designed to deliver maximum torque from engine speeds as low as 1500 or 1750 rpm. And that has engines are designed to deliver maximum torque from engine speeds as low as 1500 or 1750 rpm. And that has the twin benefit of not only increasing

the twin benefit of not only increasing your driving pleasure but also cutting fuel consumption.your driving pleasure but also cutting fuel consumption.

The turbochargers are compact and therefore weight-optimized in design too. In keeping with the overall The turbochargers are compact and therefore weight-optimized in design too. In keeping with the overall concept, the best dynamics and lowest fuel consumption were top priorities. The very quickly responding concept, the best dynamics and lowest fuel consumption were top priorities. The very quickly responding turbocharger and the very narrow intake and exhaust cams, together with intake camshaft adjuster, are also turbocharger and the very narrow intake and exhaust cams, together with intake camshaft adjuster, are also responsible for making 80 percent of the 200 Newton-meter maximum torque available at a low 1,250 rpm. The responsible for making 80 percent of the 200 Newton-meter maximum torque available at a low 1,250 rpm. The refined flow optimization of the integral exhaust manifold and a very carefully optimized exhaust turbine also refined flow optimization of the integral exhaust manifold and a very carefully optimized exhaust turbine also deliver excellent, low-loss charger operation, even at high speeds. The maximum speed of the turbocharger is deliver excellent, low-loss charger operation, even at high speeds. The maximum speed of the turbocharger is 220,000 rpm. Integrated directly in the compr

220,000 rpm. Integrated directly in the compressor housing of the charger is the electrically-controlled essor housing of the charger is the electrically-controlled divert-airdivert-air valve. Its advantage compared to a pneumatic valve: Its construction is more compact and less complex. In valve. Its advantage compared to a pneumatic valve: Its construction is more compact and less complex. In addition, it produces significantly shorter switching response times, so that the turbocharger always operates addition, it produces significantly shorter switching response times, so that the turbocharger always operates optimally, even with abrupt throttle adjustments. An electrically-controlled divert-air valve was introduced for optimally, even with abrupt throttle adjustments. An electrically-controlled divert-air valve was introduced for the first time on the turbo engine on the current Golf GTI.

the first time on the turbo engine on the current Golf GTI.

An innovation on the new TSI is its water-flow intercooler, which is positioned right in the intake port. It is part An innovation on the new TSI is its water-flow intercooler, which is positioned right in the intake port. It is part of a low-temperature circulation loop that is independent of engine cooling. The advantage here: The charge air of a low-temperature circulation loop that is independent of engine cooling. The advantage here: The charge air system exhibits a lower volume than in conventional approaches that use a front intercooler. Numerically system exhibits a lower volume than in conventional approaches that use a front intercooler. Numerically speaking, it was possible to reduce the volume from about 11.0 to 4.8 liters. This significantly shortens the time speaking, it was possible to reduce the volume from about 11.0 to 4.8 liters. This significantly shortens the time

(12)

required to reach a charge pressure of 1,800 millibar in the intake port. The results: Improved dynamics due to required to reach a charge pressure of 1,800 millibar in the intake port. The results: Improved dynamics due to minimal delays in filling the combustion chamber to its maximum. And the driver of a Volkswagen equipped minimal delays in filling the combustion chamber to its maximum. And the driver of a Volkswagen equipped with the 122-PS TSI can ex

with the 122-PS TSI can experience this dynamic gain.perience this dynamic gain.

Latest developments: They never stopped refining their TSI technology. Some of their latest ideas for the 1.4 Latest developments: They never stopped refining their TSI technology. Some of their latest ideas for the 1.4 122 PS

122 PS include: More ways to sinclude: More ways to save weight. These range from a ligave weight. These range from a lightened cylinder head cover and a weighthtened cylinder head cover and a weight saving per camshaft to the refined design of the cylinder head itself. A new injector with six fuel bores for saving per camshaft to the refined design of the cylinder head itself. A new injector with six fuel bores for electronic direct injection helps achieve this. The injector jets have been realigned to give more efficient electronic direct injection helps achieve this. The injector jets have been realigned to give more efficient distribution of the fuel mixture in the combustion chamber.

distribution of the fuel mixture in the combustion chamber.

Supercharger boosts pressure at low end: To increase torque at low engine speeds, engine developers selected a Supercharger boosts pressure at low end: To increase torque at low engine speeds, engine developers selected a supercharger that is mechanically-driven by a belt. This charger is based on the Roots principle. A special supercharger that is mechanically-driven by a belt. This charger is based on the Roots principle. A special feature of the supercharger being used is its internal gearing stage located in front of the synchronization gear feature of the supercharger being used is its internal gearing stage located in front of the synchronization gear pair, which enables high supercharger boost performance at low engine speeds.

pair, which enables high supercharger boost performance at low engine speeds.

Turbocharger kicks in at the upper end: At higher engine speeds the turbocharger (with wastegate control) kicks Turbocharger kicks in at the upper end: At higher engine speeds the turbocharger (with wastegate control) kicks in. The supercharger and turbocharger are arranged in series here. The supercharger is actuated by a magnetic in. The supercharger and turbocharger are arranged in series here. The supercharger is actuated by a magnetic clutch integrated in a module within the water pump. A control flap ensures that the necessary fresh air is clutch integrated in a module within the water pump. A control flap ensures that the necessary fresh air is supplied to the turbocharger or supercharger for the given operating point. In pure turbocharger operation the supplied to the turbocharger or supercharger for the given operating point. In pure turbocharger operation the control flap is open. The air then takes the route of conventional turbo engines, via the front intercooler and control flap is open. The air then takes the route of conventional turbo engines, via the front intercooler and throttle valve and into the intake port. The maximum charge pressure of the twincharger is approx. 2.5 bar at throttle valve and into the intake port. The maximum charge pressure of the twincharger is approx. 2.5 bar at 1,500 rpm. Only in the lower speed range below 2,400 rpm is the supercharger needed to generate the necessary 1,500 rpm. Only in the lower speed range below 2,400 rpm is the supercharger needed to generate the necessary charge pressure. The turbocharger is designed for optimal efficiency in the upper performance range, and it also charge pressure. The turbocharger is designed for optimal efficiency in the upper performance range, and it also supplies sufficient charge pressure in the middle speed range.

supplies sufficient charge pressure in the middle speed range.

3.3 Charge-Air Intercooling 3.3 Charge-Air Intercooling

The turbocharger has a water-cooled intercooler with a low-temperature circuit independent of the engine The turbocharger has a water-cooled intercooler with a low-temperature circuit independent of the engine cooling

cooling system. Asystem. As a s a result we'result we've cut ve cut the volume the volume of of the charge the charge air air system by system by more more than than half, half, allowing allowing a a highhigh charge

charge pressure pressure to to build build up up much much more more quickly. quickly. This This gives gives improved improved dynamics dynamics because ibecause it t reduces reduces the the time time itit takes to achieve maximum charge in the

takes to achieve maximum charge in the combustion chambers.combustion chambers.

The first car in the world to have TSI on board was the Golf GT. The 125 kW / 170 PS power and 240 The first car in the world to have TSI on board was the Golf GT. The 125 kW / 170 PS power and 240

(13)

Newton-km/h it has reached its top speed. Standard equipment on the Golf GT includes a six-speed transmission, but km/h it has reached its top speed. Standard equipment on the Golf GT includes a six-speed transmission, but available as an option on

available as an option on this Volkswagen too is the technically unique DSG this Volkswagen too is the technically unique DSG dual clutch transmission.dual clutch transmission.

Meanwhile, the large TSIs paired with DSG are not just reserved for the Golf; the engine and transmission are Meanwhile, the large TSIs paired with DSG are not just reserved for the Golf; the engine and transmission are available today on the Golf Plus, Golf Variant, Jetta and Touran too. Representing the technical foundation of available today on the Golf Plus, Golf Variant, Jetta and Touran too. Representing the technical foundation of the TSI on the new, small TSI with 90 kW, for example is a 1,390 cm

the TSI on the new, small TSI with 90 kW, for example is a 1,390 cm33 displacement four-cylinder engine, displacement four-cylinder engine, whose dynamics, in the case of the

whose dynamics, in the case of the GT, match those of a GT, match those of a 2.5-liter naturally aspirated engine.2.5-liter naturally aspirated engine.

The TSI already develops its maximum torque at 1,750 rpm, which is then constantly in reserve up to 4,500 The TSI already develops its maximum torque at 1,750 rpm, which is then constantly in reserve up to 4,500 rpm. The second TSI is the engine version debuting in 2006 on the Golf, Jetta and Touran with 103 kW / 140 rpm. The second TSI is the engine version debuting in 2006 on the Golf, Jetta and Touran with 103 kW / 140 PS. TSI stands for a

PS. TSI stands for a new type of downsizing: For new type of downsizing: For less displacement, less fuel consumption, lower less displacement, less fuel consumption, lower emissions, yetemissions, yet more power, more torque and more driving fun. The 140-PS TSI develops 220 Newton-meter torque at a low more power, more torque and more driving fun. The 140-PS TSI develops 220 Newton-meter torque at a low 1,500 rpm and holds this value constant up to 4,000 rpm. To ensure that driving fun is not spoiled when 1,500 rpm and holds this value constant up to 4,000 rpm. To ensure that driving fun is not spoiled when refueling, all TSI engines are designed to operate

refueling, all TSI engines are designed to operate with economical, super 95 ROZ fuel.with economical, super 95 ROZ fuel.

3.4 Advanced Injection Technology 3.4 Advanced Injection Technology

Electronic direct injection is marked by a newly developed high-pressure injection valve with six fuel spray Electronic direct injection is marked by a newly developed high-pressure injection valve with six fuel spray holes. Background: A multi-hole high-pressure injection valve of this type was first used on the large TSI holes. Background: A multi-hole high-pressure injection valve of this type was first used on the large TSI engines. However, on the small TSI the spray behavior was significantly modified. The fuel mixture is engines. However, on the small TSI the spray behavior was significantly modified. The fuel mixture is distributed more efficiently in the combustion chamber thanks to a new design of the six injection jets adapted distributed more efficiently in the combustion chamber thanks to a new design of the six injection jets adapted to the specific needs of this engine. This enabled ignition timing adjustment, and one result was significantly to the specific needs of this engine. This enabled ignition timing adjustment, and one result was significantly lower HC emissions (hydrocarbons). The injector itself is arranged on the intake side between the intake port lower HC emissions (hydrocarbons). The injector itself is arranged on the intake side between the intake port and the cylinder head gasket

and the cylinder head gasket level; the maximum injection pressure is 110 blevel; the maximum injection pressure is 110 bar.ar.

4. 4. DIRECT SHIFT GEARBOX (DSG)

DIRECT SHIFT GEARBOX (DSG)

Their acclaimed Direct Shift Gearbox (DSG) has two clutches with electronically controlled gear selection. Their acclaimed Direct Shift Gearbox (DSG) has two clutches with electronically controlled gear selection. DSG gives: Fast, smooth gear changes; lively handling with unbroken acceleration; Safer driving with the DSG gives: Fast, smooth gear changes; lively handling with unbroken acceleration; Safer driving with the power

power to to get get you you out out of of tricky tricky situations; situations; Improved Improved fuel fuel economy, economy, even even compared compared to to a a manual manual gearbox, gearbox, forfor many of their new

7-many of their new 7-

speed DSG „boxes.

4.1

4.1 WorkingWorking

DSG is a groundbreaking 'two-in-one' concept. Available in 6-speed and 7-speed versions, it's totally unlike a DSG is a groundbreaking 'two-in-one' concept. Available in 6-speed and 7-speed versions, it's totally unlike a conventional automatic

conventional automatic transmission. transmission. Twin electronically Twin electronically controlled shafts controlled shafts manage gear manage gear selection, alwaysselection, always anticipating your next shift.

(14)

while the second shaft puts the next gear on 'standby'. As the gearbox changes to second, the second shaft is while the second shaft puts the next gear on 'standby'. As the gearbox changes to second, the second shaft is engaged and the original shaft reaches third. As you shift upwards the sequence continues in a series of engaged and the original shaft reaches third. As you shift upwards the sequence continues in a series of seamless moves.

seamless moves. Because

Because power power is is simply simply switched switched from from one one shaft shaft to to another, another, not not only only are are gearshifts gearshifts silky silky smooth, smooth, butbut they

they are are also also very very fast: fast: each each change change takes takes less less than than four-hundredths four-hundredths of of a a second. second. The The DSG DSG gearbox gearbox gives gives aa choice of two driving programmes:

choice of two driving programmes: normal and sport. normal and sport. In sport mode, the DSG leaves it longer to shiIn sport mode, the DSG leaves it longer to shift up theft up the gears. And if one wants to take over, he/she can control the DSG manually. Nudge the Tiptronic gearlever gears. And if one wants to take over, he/she can control the DSG manually. Nudge the Tiptronic gearlever forwards or backwards to change gear, or use the paddle shifts mounted on the steering wheel: left for down, forwards or backwards to change gear, or use the paddle shifts mounted on the steering wheel: left for down, right for up. Both DSG gearboxes are application-specific. The 6-speed is paired with high torque engines (up right for up. Both DSG gearboxes are application-specific. The 6-speed is paired with high torque engines (up to 350 Nm) while the 7-speed variant is more effective in combination with smaller engines and torque outputs to 350 Nm) while the 7-speed variant is more effective in combination with smaller engines and torque outputs of up to 250 Nm.

of up to 250 Nm.

4.2 The Technology 4.2 The Technology::

The 6 speed DSG gearbox is made up of two independent gearbox units. With dual-clutch technology - two The 6 speed DSG gearbox is made up of two independent gearbox units. With dual-clutch technology - two clutches in a common housing - both gearboxes are connected under load to the engine in turn, depending on clutches in a common housing - both gearboxes are connected under load to the engine in turn, depending on the current gear, via two drive shafts. Clutch 1 serves the first gearbox unit with 1st, 3rd, 5th 7th and reverse the current gear, via two drive shafts. Clutch 1 serves the first gearbox unit with 1st, 3rd, 5th 7th and reverse gear and clutch 2 the second gearbox unit with 2nd, 4th and 6th gear. An output shaft that applies the torque to gear and clutch 2 the second gearbox unit with 2nd, 4th and 6th gear. An output shaft that applies the torque to the

the driven driven wheels wheels via via the the differential differential gear gear is is assigned assigned to to each each gearbox gearbox unit. unit. Thanks Thanks to to the the dual-clutch dual-clutch designdesign the

the DSG DSG is is more more efficient efficient than than conventional conventional automatic automatic transmission. transmission. This This efficiency, efficiency, together together with with its its lowlow weight and intelligent control, means that DSG can achieve the same, and in some instances better, fuel weight and intelligent control, means that DSG can achieve the same, and in some instances better, fuel consumption, than a manual gearbox or even lower, depending on the style of driving.

consumption, than a manual gearbox or even lower, depending on the style of driving.

4.3 Mechatronics 4.3 Mechatronics

Electronics

Electronics and and mechanics mechanics in in one one unit. unit. Clutches Clutches and and gearbox gearbox units units are are operated operated hydraulically hydraulically by by thethe gearbox

gearbox mechatronics mechatronics (a (a combination combination of of mechanics mechanics and and electronics) helectronics) housed oused in in the the DSG. DSG. The The electronicelectronic transmission control unit, sensors and hydraulic control unit form one compact unit.

(15)

The control unit does the thinking for you, using information such as engine speed, road speed, and accelerator The control unit does the thinking for you, using information such as engine speed, road speed, and accelerator position

position and and driving driving mode mode to to select select the the optimum optimum gear gear and and to to determine determine the the ideal ideal shift shift point. point. The The hydraulichydraulic control unit then

control unit then implements the shift commands in implements the shift commands in a sequence of a sequence of precisely co-ordinated actprecisely co-ordinated actions.ions. Figure 3. Schematic diagram of a 7 speed DSG gearbox.

Figure 3. Schematic diagram of a 7 speed DSG gearbox.

Split-second Split-second gear changes: gear changes: When one When one gear is gear is engaged, engaged, another gear another gear is always is always preselected. preselected. Within four Within four hundredths of hundredths of a second after a second after the system the system detects a gear detects a gear change it change it opens one clutch and closes the other. The mechatronics unit ensures that this takes place fast and to a level of opens one clutch and closes the other. The mechatronics unit ensures that this takes place fast and to a level of accuracy that would not be possible in a manual transmission. The change of gear is imperceptible to the driver accuracy that would not be possible in a manual transmission. The change of gear is imperceptible to the driver who is merely conscious of the uninterrupted power.

who is merely conscious of the uninterrupted power.

4.4 DSG 7-Speed Gearbox 4.4 DSG 7-Speed Gearbox

The new

The new 7-speed DSG gearbox 7-speed DSG gearbox is a is a world firsworld first. What t. What makes it makes it so innovative so innovative is its is its pair of pair of dry dry clutches clutches whichwhich

have dispensed with the need for the oil bath of conventional „wet‟ clutches.

They have been designedThey have been designed to improve fuel efficiency and driving agility further. The clutches' dry, organic-bonded friction linings need no to improve fuel efficiency and driving agility further. The clutches' dry, organic-bonded friction linings need no cooling. The gearbox is also very compact and requires less power for the gear selection and clutch servo cooling. The gearbox is also very compact and requires less power for the gear selection and clutch servo system.

system. Ideal Ideal for for motorway motorway driving. driving. Adopting Adopting 7 7 speeds speeds meant meant our our engineers engineers could could lower lower 1st 1st gear gear toto improve

improve acceleration acceleration from standstfrom standstill and ill and raise 7th raise 7th gear to gear to act as act as an overdrive an overdrive function, ideal function, ideal for motorwayfor motorway driving. This can save fuel, cut emissions, and

driving. This can save fuel, cut emissions, and means the car runs even more quietly.means the car runs even more quietly. Table 2: Comparison between different automatic gearboxes Table 2: Comparison between different automatic gearboxes

(16)

Figure

Figure 4. 4. DualDual

clutch. clutch. The The

recently developed dual clutch is one of the most radical developments which helped make the DSG such a recently developed dual clutch is one of the most radical developments which helped make the DSG such a ground breaking innovation. Being a dry clutch its not only better in terms of performance but is much lighter ground breaking innovation. Being a dry clutch its not only better in terms of performance but is much lighter than its earlier counterpart. Figure 4 shows a cutaway diagram of the dual clutch used in the 7 speed DSG than its earlier counterpart. Figure 4 shows a cutaway diagram of the dual clutch used in the 7 speed DSG gearbox. Besides core power train and drivetrain components Volkswagen has also made improvement in other gearbox. Besides core power train and drivetrain components Volkswagen has also made improvement in other peripheral equipments

peripheral equipments related to related to the car the car as explained as explained below. Inorder below. Inorder to make to make the car the car better not better not only in only in the fieldthe field of performance but also helping it become

of performance but also helping it become more eco friendly.more eco friendly.

5. 5. AUTOMATIC START/STOP

AUTOMATIC START/STOP

Driving in towns involves a lot of stopping and starting, waiting in queues or at traffic lights. And while Driving in towns involves a lot of stopping and starting, waiting in queues or at traffic lights. And while the engine is ticking over

the engine is ticking over

, it‟s

using fuel using fuel

. . VW‟s

VW‟s efficient

efficient Start/Stop

Start/Stop technology,

technology, introduced

introduced on

on the

the Passat

Passat

BlueMotion,

BlueMotion, stops stops this this waste, waste, cutting cutting CO2 CO2 emissions emissions and and saving saving fuel. fuel. The The Start/Stop Start/Stop system system means means that that thethe car

car can can virtually virtually stop stop its its engine engine by by itself. itself. It It works works through through the the clutch, clutch, so so when when the the car car come come to to a a standstill,standstill, one

one has has to to just select just select neutral gear, neutral gear, release the release the clutch and clutch and the engthe engine switches oine switches off with ff with a a Start/StopStart/Stop symbol appearing on the dashboard. When he/she wants to move off again he/she has to simply dip the clutch, symbol appearing on the dashboard. When he/she wants to move off again he/she has to simply dip the clutch,

Automatic

Automatic Transmissions

Transmissions

Torque

Torque converter

converter transmission

transmission

6-speed

6-speed DSG

DSG 7-speed

7-speed DSG

DSG

Number of g

Number of gears ears 6 6 6 6 77

Max.

Max. torque torque 320 320 Nm Nm 350Nm 350Nm 250Nm250Nm Clutch

Clutch - - Wet Wet DryDry

Transmissio

Transmission n oil oil volume volume 5.8l 5.8l 6.5l 6.5l 1.7l1.7l Weight

Weight 85Kg 85Kg 93Kg 93Kg 77Kg77Kg

Consumption

Consumption advantage advantage baseline baseline -0.3 l/100 -0.3 l/100 km km -0.8 -0.8 l/100 l/100 kmkm Efficiency