Chronic Mechatronic
Mechatronics engineering, also known as mechatronics, is a branch of engineering that focuses on the integration of mechanical, electrical, electronic and software engineering. Originally the definition was just a combination of “mechanics” and “electronics” but has now been broadened since the 1980’s and 90’s with the increase use of microprocessors. The mechatronic term now includes the use of robotics and telecommunications in its design and application.
Mechatronic systems now play a large part in automobile functions. ABS braking systems use this design. A mechatronic engineering design has been used for the Direct Shift Gearbox (DSG) which is fitted to many German car models. The DSG was designed by BorgWarner, an American company that has produced automotive parts for over 140 years.
The Volkswagen Audi Group (VAG) have adopted the mechatronic component design unit into its DSG gearboxes that are fitted to many Audi, Seat, Skoda and VW models to date. Some model variants are labelled with the S Tronic name, such as the Lamborghini Huracan that employs a DSG. BMW call this type of gearbox on their models, the Dual Clutch Transmission or DCT. Porsche’s dual clutch transmission is the Porsche “Doppelkupplungsgetriebe” or PDK.
The DSG automates two separate manual type gearboxes and associated independent clutches. All components are housed into one unit. No torque convertor is required as in the conventional automatic transmission. The gear shift times are faster which aids the performance on the sportier models such as the Golf GTi and Audi S3 where it is normally installed in.
Starting around 2008, problems began occurring with DSG gearboxes. The symptoms were power loss and unplanned shifts. Common component failures materialized with the motor and high-pressure pump on the DSG mechatronic unit. The high pressure pump becomes subject to working too much due to pressure leaks which then overheats and burns out.
Owner recognition that the DSG is failing include, sudden loss of power – a problem with mechatronic unit, abrupt gearshifts, failure to select gears, mechanical sounding noises and excessive vibration. On later models, the vehicle will automatically go into limp mode. Some owners have reported the engine stalling at low speed.
Owners have been faced with large bills of up to £7000 depending on the model of car. In some cases, the DSG gearbox has been known to fail on models such as the Audi S3 with only 22k miles on it. If the vehicle has been serviced and maintained at a main dealership, they have been known to reduce the bill with a goodwill payment contribution. Alternative gearboxes in other models in vehicle manufacturers line-up, such as the robust German derived ZF gearbox have been known to withstand many hundred of thousands of miles of motoring. The Japanese derived Aisin gearbox which also has proven longevity, is ironically fitted to many VAG models, usually in their non performance variants though.
Problems have been reported with BMW’s DCT and Porsche’s PDK, but there appears to be more complaints with VAG’s DSG. This could be relative to the number of models the Volkswagen Audi Group produce. However, car buyers who are aware of potential problems with DSG gearboxes, may be influenced in their choice of purchase and opt for a marque and model that does not have this fitted. This is surely not good for say the VAG and will dent sales. It’s a problem that exists, and really needs a better long term solution to instil confidence in running these cars. ©