Analysis of Engagement Probability for Dog Clutch Geometry Parameters in Heavy-Duty Automated Mechanical Transmissions.

This study presents a simulation-based approach to estimate the dog clutch engagement probability maps under different vehicle operating conditions. The developed probability function incorporates multiple critical parameters including initial speed differential between engaging components, application of countershaft brake, number of tooth in dog clutch, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyze engagement dynamics and produce detailed probability maps at different vehicle speeds. The present work effectively outlines optimal operational zones for successful engagement while identifying critical regions prone to tooth clash and engagement failure. The effect of tooth geometry on engagement probability has been investigated to study its effect on the optimal mismatch speeds. The resulting engagement maps serve as valuable diagnostic tools for identifying potential system limitations, such as inadequate actuation forces or excessive speed differentials during shifting operations. Additionally, these simulations provide a cost-effective method for validating design innovations before physical prototyping, substantially reducing development time and resource expenditure.