ec_dsg_background.pdf

The DSG Dual-Clutch Gearbox

Environmental Commendation –

Background Report

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Summary ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. 4

1 Shift up to environmental protection ...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ...... 5

1.1.. The.DSG.dual-clutch.gearbox ... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. ... 5

1.2.. Wet.or.dry ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . 6

2 Life Cycle Assessments for ecological product evaluation and optimisation ... .. . .. .. . .. .. . .. . 7

2.1.. Life.Cycle.Inventory.–.LCI ... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. ... 8

2.2.. Life.Cycle.Impact.Assessment.–.LCIA... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . 9

2.3.. Evaluation ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . 9

2.4.. Implementation.at.Volkswagen... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .10

3 The automatic transmissions assessed ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . 12

3.1.. Aim.and.target.group.of.the.assessment ... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. ..12

3.2.. Function.and.functional.unit.of.the.vehicle.systems.assessed ... .. .... .. .... .. .... .. .... .. .... .. ..12

3.3.. Scope.of.assessment ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . 13

3.4.. Environmental.Impact.Assessment ........ ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... . 15

3.5.. Basis.of.data.and.data.quality... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .. 16

4 Model assumptions and findings of the Life Cycle Assessment ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . 18

5 Results of the Life Cycle Assessment ...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... .... 20

5.1.. Material.composition.. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. 20

5.2.. Results.of.the.Life.Cycle.Inventory...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... .....21

5.3.. Comparison.of.Life.Cycle.Impacts ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .22

6 Technologies for the future ...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... .... 24

7 Conclusion ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . 26

8 Validation ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. 27

Glossary ... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. 28

Bibliography.and.list.of.sources...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....30

List.of.abbreviations... .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . 32

List.of.figures ... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. .... .. . 33

List.of.tables ........ ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... 33

Appendix.. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. 34

Introduction

Volkswagen develops environmentally friendly technologies that help reduce CO 2

emissions and makes them available throughout the product range. That way, all our

customers benefit from our development work. Our technologies reduce the carbon

dioxide emissions of the vehicle f leet and play a key role in making vehicles more

environmentally compatible. The DSG dual-clutch gearbox, designed to replace

conventional automatic transmissions with torque converters, is a case in point. DSG

gearboxes are to be available with almost all the petrol and diesel engine options in the

new Golf range and are considerably more efficient than conventional automatic

transmissions. Innovations of this type make our models better and improve their

environmental compatibility in particular.

Volkswagen uses environmental commendations to document the environmental

progress of its vehicles and technologies compared to their predecessors. Our en-

vironmental commendations provide our customers, shareholders and other stake-

holders inside and outside the company with detailed information about how we are

making our products and production processes more environmentally compatible and

what we have achieved in this respect. The DSG dual-clutch gearbox is the first Volks-

wagen technolog y to receive an environmental commendation. Our first vehicle

environmental commendations, for the Passat and the Golf, were very well received

both by the public and by the media.

The environmental commendations are based on the results of a detailed Life Cycle

Assessment (LCA) in accordance with ISO 14040/44, which has been verified by inde-

pendent experts, in this case from TÜV NORD. Volkswagen already has a long tradition

in this ield: we have been analysing our cars and their individual components for more

than ten years, using Life Cycle Assessments to enhance their environmental compati-

bility. As part of an integrated product policy, the LCA considers not only individual

environmental aspects such as the driving emissions of a vehicle, but the entire product

life cycle. This means that all the processes from the production and use of a gearbox

right through to disposal are considered in the analysis, “from cradle to grave”.

Summary

This environmental commendation compares current Volkswagen DSG dual-

clutch gearboxes (6- and 7-speed) with conventional torque converter automatic

transmissions. We have assessed the emissions caused by the gearbox not only

during use but over its entire life cycle, from production to disposal.

As in the case of the Golf and Passat, the DSG gearboxes show improvements, in

some cases significant, in all the environmental impact categories. The greatest

advances have been made in the areas of global warming potential (greenhouse

effect), acidification and photochemical ozone (summer smog) creation poten-

tial. In other respects, such as water and soil eutrophication and ozone depletion,

the changeover from conventional automatic transmissions to DSG gearboxes

has little impact. It emerged that these improvements were primarily due to

reduced fuel consumption and the resultant drop in driving emissions and

reduction in environmental impact at the fuel production stage. The reduction in

fuel consumption, in turn, is the direct result of the intelligent gearbox manage-

ment and high efficiency of the DSG gearbox.

1 Shift up to environmental protection

Shift up to environmental protection

Volkswagen develops environmentally friendly technologies that help reduce CO 2 emis-

sions. Our TDI and TSI engines, millions of which have been produced, are examples of

environmentally compatible innovation. However, the fuel consumption and CO 2 emissi-

ons of a vehicle are not only determined by its engine. Volkswagen is committed to

tapping all the opportunities for reducing fuel consumption and making technologies

even more climate-compatible in the future. Our especially frugal BlueMotion models

already meet these targets today. Our Powertrain and Fuel Strategy describes the technolo-

gies being pursued by Volkswagen with a view to implementing a long-term changeover to

sustainable fuels and powertrains. Biofuels are just as much a part of this strategy as the

fuel cell or electric propulsion systems.

Powertrain and Fuel Strategy of the Volkswagen Group

Electricity

Electrotraction

Renewable

Hydrogen (Regenerative)

Fuel Cell

SunFuel®

CCS®

Natural Gas

SynFuel

Hybrid

Diesel Fuel

Gasoline / CNG

Oil

TDI®/ TSI®/ DSG®

Fig. 1: Powertrain and Fuel Strategy of the Volkswagen Group

The DSG dual-clutch gearbox

The DSG intelligent automatic transmission developed by Volkswagen is also an

integral part of this strategy for the future. In 2002, Volkswagen presented the irst dual-

clutch gearbox intended for series production, the 6-speed DSG. The dual-clutch prin-

ciple ensures higher efficiency and lower fuel consumption than a conventional auto-

matic transmission. In addition, it also makes for greater comfort and driving pleasure.

In the meantime, Volkswagen has introduced a second dual-clutch gearbox, the 7-speed

DSG, which is even more economical and will be used in the future on high-volume

models with power outputs up to 125 kW and torque values up to 250 Nm.

Since the DSG dual-clutch gearbox was first launched, more than a million units have

been sold, resulting in a new boom in automatic transmissions at Volkswagen. The pro-

portion of new vehicles equipped with automatic transmissions has risen dramatical-

ly, from 5 to 10 percent with conventional transmissions to as much as 30 percent

with the DSG. With the new 7-speed DSG, even more customers will automatically

shift up to environmental protection.

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