The DQ200 mechatronic unit is a complex assembly that integrates both mechanical and electronic components to control the transmission’s operation.
Transmission Control Unit (TCU)
The TCU is the electronic brain of the transmission. It controls gear shifts, clutch engagement, and other functions by processing data from various sensors and executing pre-programmed logic.
Hydraulic Valve Body
The valve body houses a network of channels and passages along with multiple solenoids and valves. It directs hydraulic fluid to various parts of the transmission to manage gear selection and clutch operation.
Solenoids
These are electromechanical valves that control the flow of hydraulic fluid within the valve body. Each solenoid is activated by the TCU to engage or disengage specific transmission components.
Pressure Sensors
These sensors monitor hydraulic pressure within the transmission. They provide real-time data to the TCU, which uses this information to make adjustments to ensure proper transmission operation.
Temperature Sensors
Temperature sensors measure the temperature of the transmission fluid. The TCU uses this data to regulate transmission behavior, such as cooling requirements and shift timing.
Clutch Actuators
The clutch actuators are mechanisms that physically engage and disengage the clutches within the transmission. They are controlled by the TCU via the hydraulic system.
Gear Position Sensors
These sensors detect the current gear position and send this information to the TCU. This ensures that the TCU is aware of which gear is engaged at any given time.
Hydraulic Pump
The hydraulic pump generates the necessary pressure to circulate the hydraulic fluid through the transmission system. It is essential for maintaining the required pressure levels for clutch and gear operation.
Accumulator
The accumulator stores hydraulic pressure that can be released when needed to ensure smooth and consistent operation, particularly during gear shifts. It helps to maintain pressure stability within the system. Otomatec is the world’s largest DSG 7 / DQ200 Accumulator/Reinforced Accumulator manufacturer.
Wiring Harness
The wiring harness is a network of wires and connectors that link all the electronic components of the mechatronic unit, allowing communication between the TCU and the various sensors, solenoids, and actuators.
Dual Clutch Pack
While not strictly a part of the mechatronic unit, the dual clutch pack is closely integrated with it. It consists of two separate clutches that manage odd and even gear sets, enabling seamless gear shifts.
Speed Sensors
These sensors measure the rotational speed of the transmission shafts and provide data to the TCU for precise control of gear shifts and clutch engagement.
Oil Pressure Regulator
This component helps regulate the pressure of the hydraulic fluid within the transmission, ensuring consistent operation and preventing pressure spikes that could damage the system.
Sealing Rings and Gaskets
These components ensure that the hydraulic fluid stays contained within the transmission system, preventing leaks that could lead to loss of pressure and transmission failure.
Control Pistons
Control pistons are used to apply pressure to various clutches or gears within the transmission. They are actuated by hydraulic pressure controlled by the valve body.
Filters
Filters within the transmission help remove contaminants from the hydraulic fluid, ensuring that the system operates smoothly and preventing damage to delicate components.