Dog Clutch Engagement Probability Simulation for 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, dog tooth quantity, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyse engagement dynamics and produce detailed probability maps at different vehicle speeds, effectively outlining 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 using simulation model results. 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.