Browse Topic: Dual clutch transmissions

Items (111)
Evaluating the impact of software changes on fuel consumption and emissions is a critical aspect of transmission development. To evaluate the trade-offs between performance improvements and potential negative effects on efficiency, a forward-looking Software-in-the-Loop (SiL) simulation has been developed. Unlike backward calculations that derive fuel consumption based solely on cycle speed and engine speed, this approach executes complete driving cycles as the Worldwide Harmonized Light-Duty Vehicle Test Cycle (WLTC) within a detailed SiL environment. By considering all relevant influencing factors in a dynamic simulation, the method provides a more accurate assessment of fuel consumption and emission differences between two versions of the transmission software. The significant contribution of this work lies in the high-fidelity integration of a real virtual Transmission Control Unit (vTCU) software within a comprehensive, validated forward-looking SiL environment. This approach enables precise delta comparisons that capture transient dynamic interactions, facilitating early, reliable software testing and validation.
Kengne Dzegou, Thierry JuniorSchober, FlorianRebesberger, RonHenze, Roman
The torque transfer response to rider throttle operation contributes to vehicle control in motorcycles equipped with a DCT (Dual Clutch Transmission). The clutch response is a key parameter to enhance torque transfer response. We have developed three new ECU (Electric Control Unit) control methods to enhance the clutch response on the DCT. The DCT clutch transfers torque by controlling the contact force between the clutch discs and the clutch plates. It is desirable to measure the hydraulic pressure value directly from the clutch piston chamber to control the contact force. However, since the clutch piston is a rotating body, it is impractical to place a hydraulic pressure sensor on it. Therefore, the hydraulic pressure sensor is placed along the clutch control oil line at the existing DCT system. Consequently, when oil flows in the oil line, pressure loss in the oil line causes a deviation between the hydraulic pressure sensor value and the clutch piston chamber pressure value, which limits the enhancement of clutch response. To enhance clutch response, we have studied the estimation of the hydraulic pressure value in the clutch piston chamber using the existing hydraulic pressure sensor value at the oil line. This estimation is based on the reaction force characteristics of the clutch piston and Bernoulli’s principle. By using the estimated hydraulic pressure, half-clutch control can be identified, which allows the application of higher feedback gain to enhance clutch response. We also implement correction of clutch control oil viscosity fluctuations based on the hydraulic pressure variations of the clutch control oil. With these technologies applied, the clutch response time is reduced 45% as reference compared to the existing DCT clutch control. This also reduces torque transfer response time, ultimately allowing for smoother vehicle control.
Takahashi, Kosaku
This paper proposes an uneven pitch control for electric oil pumps. For the noise reduction of vane pumps, mechanical arrangements of uneven pitch vain angle are widely used. However, the tooth angle of gear-type pumps should be even mechanically. The proposed uneven pitch control provides similar effects of the mechanical uneven pitch arrangement by instantaneous motor torque controls of the electric oil pump which cannot have uneven pitch mechanically. The magnitude of motor torque for each pump tooth is determined by an uneven pitch formula which is widely used for mechanical vane pumps in previous study and patents. A formula for the shape of motor torque is proposed by analyzing pressure fluctuations of pump as a combination of trigonometric and exponential functions. The calibration factors for the magnitude and shape are adjusted by characteristics of pumps. The experimental results showed that noise reduction and dispersion effects of the proposed method.
Choi, ChinchulKim, Jongbeom
The two-wheeler industry features a diverse range of transmission systems catering to varied riding preferences and market demands. Manual transmissions offer direct gear control, favored by enthusiasts for its precision and customizable performance. Automatic transmissions simplify riding, especially in urban settings, eliminating manual gear shifts and reducing rider fatigue. Understanding the dynamics of transmission systems in the two-wheeler space is crucial for manufacturers, engineers, policymakers, and riders alike. It informs product development, regulatory compliance efforts, and market positioning initiatives in an increasingly competitive and innovation-driven industry landscape. DCT (Dual Clutch Transmission) and manual transmissions represent extremes in rider engagement, automation, and cost. While DCT offers seamless gear changes and convenience at a higher price point, manual transmissions provide direct control and a tactile experience with lower initial costs. Riders weigh these factors when choosing between technological innovation and traditional engagement. Between these two extremes, certain transmissions systems provide manual gear selection with automatic clutch operation, appealing to riders seeking control without the complexities of manual clutch manipulation like the E-Clutch. Continuously Variable Transmission (CVT) systems represent a notable innovation, offering seamless gear ratio adjustments and optimized engine output across riding conditions, enhancing ride quality and rider comfort, particularly in urban environments and have gained a lot of traction in the past decade. Each transmission system presents distinct advantages and challenges, influencing rider preferences and manufacturer strategies. Understanding the dynamics of transmission systems in the two-wheeler space is crucial for manufacturers, engineers, policymakers, and riders alike. It informs product development, regulatory compliance efforts, and market positioning initiatives in an increasingly competitive and innovation-driven industry landscape. The introduction of Semi-Automated Manual Transmission (SMT) stands as a bridge, blending the precision of automated gear shifts with the visceral engagement of manual control. SMT enables clutch less gear shifts, providing riders with a unique synthesis of technological innovation and the hands-on experience enthusiasts cherish. Beyond preserving the art of manual transmission, SMT addresses challenges associated with manual gear changes, mitigating issues like gear grinding and missed shifts. Positioned at the intersection of automated efficiency and the enduring appeal of manual engagement, SMT represents a blend of conventional mechanics and modern-day power electronics.
Kundu, Prantik
Unsuitable shift control strategies may increase the vehicle jerk and clutch wear. In order to improve the shift quality of electric vehicles (EVs) equipped with dual clutch transmission, this paper proposes an optimal shift control strategy based on linear quadratic regulator, in which weighting matrices are selected by using genetic algorithm (GA). The dynamics of the shift process of the dual clutch transmission is analyzed to establish the dynamic model of the driving system. In addition to the vehicle jerk, the friction work of clutch is also considered as one of the performance criteria and a new linear quadratic objective function is formulated. The optimal weighting matrices for obtaining a globally optimal solution are selected benefit from the global search capacity of genetic algorithm. The optimal target trajectories of the torque of the two clutches and motor are obtained by simulating the linear quadratic regulator (LQR). The dynamic model of the driving system including dry clutch is built and a controller is introduced to track the optimal target trajectories. The simulation results indicate that the optimal control strategy proposed in this paper can effectively reduce the vehicle jerk and friction work of clutch.
Zhou, ShuiTingWu, JinglaiZhang, Yunqing
Determining impact speeds is an important factor in any accident reconstruction. Event data recorders are now commonplace in on-road vehicles and provide an added tool for the accident reconstructionist. However, in low-speed collisions where impact severity is often important, event data recorders fail to record data as the minimum threshold for impact severity sometimes is not met. Alternatively, damage-based methods may be ineffective in quantifying the severity of the impact due to a lack of defined vehicle crush damage. These types of scenarios oftentimes present themselves as a bullet vehicle in the beginning processes of accelerating from a stop or when a stopped target vehicle is rear-ended from behind by the bullet vehicle. A specific subset of this scenario might entail the foot of the driver of the bullet vehicle coming off the brake pedal, allowing the bullet vehicle to “creep” forward at engine idle speeds and impacting the target vehicle resulting in no visible crush damage to either vehicle. Eighteen vehicles with conventional automatic transmissions were tested, which included sedans, sport utility vehicles (SUVs), pickup trucks, and vans. Two vehicles (one sedan, one wagon) equipped with dual-clutch transmissions (DCTs) and three vehicles (one sedan, one hatchback, and one wagon) equipped with continuously variable transmissions (CVTs) were also tested. These vehicles were allowed to accelerate at idle with the brake pedals released. Acceleration, speed, distance, and engine speed data were collected for multiple vehicles runs in both forward and reverse directions over level ground. The data resulting from this study were then compared/contrasted among the different drivetrains and also previously published literature to determine similarities and differences. Previous study data sets were also incorporated with the authors’ data to improve predicted vehicle speed.
Timbario, Thomas A.Stoner, JacobSheldon II, Stuart
This paper introduces one functional safety development solutions of Dual Clutch Transmission (DCT) equipped with Position 2 (P2) hybrid control system, which mainly includes the concept development stage (only for selected part), the system development stage (only for selected part), the hardware development stage (only for selected part) and the software development stage (only for selected part). It is carried out based on ISO 26262 standard and the selected system topology (details can be found in the paragraph). In the concept development stage of the DCT equipped with P2 hybrid control system, the hazard analysis and risk assessment of the item will be carried out based on the selected objects according to defined working condition. Especially the hybrid transmission control features are analyzed. And the safety goals will be summarized according to the evaluation results. The preliminary system architecture, functional safety requirements and concepts will be analyzed based on the obtained safety goals and selected objects. In the system development stage, the detailed system architecture, technical safety requirements and concepts will be analyzed based on the functional safety requirements with the help of the safety analysis tool. The system safety requirements for software and hardware will also be decomposed, and the decomposition strategy is described in detail.
Chen, JingjunYang, QingZhang, Kuankuan
This SAE Recommended Practice is intended as the definition of a standard test, which may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering its use. This SAE No. 2 friction test monitors the µ-v curve for a negative slope which can be used to evaluate a wet clutch system (WCS) anti-shudder performance and can be used for any wet driveline mechanism. WCS shudder is considered a clutch failure condition. The cause of shudder is consistent with glazing as the primary failure mode. It has been shown that a substantial loss of the wet friction material surface porosity leads to a glaze forming on the friction material surface. This process typically leading to a negative dµ/dv slope over time as addressed in SAE 2020-01-0560. This procedure includes evaluation friction characteristics of wet clutch stystem (WCS) at various specific pressures, speeds, and temperatures, and an extended durability duty cycle test to evaluate the WCS during which the µ-v curve is monitored for a negative slope—a condition indicating the potential for shudder. This procedure can be used to compare the shudder potential of various WCS combinations of friction material and lubricant. It is recommended that testing be conducted on an SAE No. 2 or similar machine. Also use the same machine for all tests when comparing results. The amount of aging has not been correlated to vehicle mileage or vehicle shudder and should only be used as an example of a test that results in a severe negative slope on the µ-v test. This procedure is designed for a standard SAE plate clutch pack with one friction plate and two steel plates, but can be modified for any WCS configuration. This procedure is built on the basis of SAE J2964, with modified test parameters and test procedure to evaluate a WCS aging stability and predict anti-shudder performance. This procedure is intended as a recommended practice for both suppliers and end users. The only variables selected by the supplier or user of the friction system are: Friction plate with friction material (lining): Specify friction material, lot or batch number, groove pattern, and lining thickness. Fluid: Specify fluid and lot or batch number. Reaction (separator) plates: Use SAE standard as inticated below. Specify plates material, thickness, and lot or batch number. These three variables must be clearly identified when reporting the results of this test. If any of the test parameters or system hardware as described in this document are changed—other than the friction material, test fluid, or reaction (separator) plates—the data may not be reported as being obtained using this document, but should be shown as a modified version of the procedure. The friction testing has a combination of modes, including short time continuous slip (C), ramp up and down speed sweeps (S), and static or breakaway slip (BA). The friction testing is done before break-in (BBI), after break-in (ABI), and after each aging test block (A). The general overview this test procedure is presented schematically in Figure 1. Reference the testing clutch geometric parameters are shown in Table 1. Various testing speeds, fluid temperatures, unit surface pressures, and slip timings are used during the different modes to simulate clutch operating conditions. The aging mode test parameters are selected to accelerate the WCS degradation response within the 120 hours total time. The obtained values of friction torque and resulting friction coefficient, friction coefficient slopes (gradients), fluid, and reaction plate temperatures allow comparison of the WCS wear resistance and resistance to aging. These parameters are utilized for evaluating the clutch anti-shudder performance. Details of the test modes operating conditions are presented in Section 5.
Automatic Transmission and Transaxle Committee
In order to achieve a good shifting quality of pure electric vehicle dual-clutch transmission, this paper adopts linear active disturbance rejection controller (LADRC) to control the shifting strategy. For the uncertainty of transmission dynamics model parameters and the existence of unknown disturbance effects, the linear expansion state observer (LESO) can be used to estimate and compensate the disturbance. The shift control process is converted into tracking the motor speed and clutch speed trajectory, and the linear feedback control law is used to control the motor torque and the solenoid valve current. The simulation and test results show that the control algorithm is effective and good shifting quality is guaranteed.
Dai, QinglinChen, YongHe, BoLinXiao, SenZhang, ZhongliWang, YiYin, Xuebing
In order to improve the safety of vehicles driving in mountainous areas and other curve roads, a DCT shift strategy for different drivers is designed in this article. First, the test road is digitized and an electronic map model is built based on particle filtering (PF) to achieve the optimal prediction of road conditions. Then, a driver’s intention recognition model is constructed based on principle component analysis (PCA) and Kohonen neural network (KohonenNN) to accommodate different driving intentions, and the appropriate downshift schedules are designed for different driver’s intentions. In addition, we propose the concept of the curve safety factor, and the current safety level is determined by vehicle speed and distance. By combining the earlier discussed concepts, the predictive curve shift strategy is presented. To determine the appropriate downshift schedule and make full use of the auxiliary engine brake to improve the vehicle’s braking efficiency, the strategy utilizes the driver’s intention as well as the vehicle’s current safety level. The simulation and real vehicle test results show that the predictive curve shift strategy can effectively reduce the braking distance and time compared with the traditional one.
Wu, GuangqiangLyu, ZhichaoWang, Chao
For vehicles equipped with dry dual clutch transmission, due to the diversity of starting conditions, it is a nontrivial task for control strategy to meet the requirements of all kinds of complex starting conditions, which is easy to cause large starting shock and serious clutch wear. Therefore, it is proposed in this paper an adaptive control strategy for complex starting conditions by adjusting two clutches to participate in the starting process at the same time. On the basis of establishing the transmission system model and clutch model, the starting conditions are identified in terms of starting speed, road adhesion and driver's intention, in which the driver's intention is identified by fuzzy reasoning model. Based on the identification of starting conditions and considering the safety principle, it is selected the appropriate starting gear and clutch combination mode, and adjusted the combination speed of the two clutches to carry out an adaptive control strategy. The Simulink simulation model is built, and the typical working conditions are selected for experimental verification. The results show that the control strategy can effectively reduce the starting shock, prolong the service life of the clutch and adapt to more starting conditions.
Guo, JunWu, JinglaiZhang, Yunqing
Dual Clutch Automatic Transmission (DCT) has the characteristics of light weight, fast shift speed and high transmission efficiency. Electric vehicles equipped with dual clutch transmission can effectively improve vehicle power performance and economy. Electro-hydraulic control system, as a key component of transmission, determines the quality of shift. In this paper, an electro - hydraulic control system is designed based on two - speed dry dual clutch transmission of electric vehicle. Firstly, the hydraulic components of the system were selected and calculated based on the vehicle parameters. Secondly, the electro-hydraulic control system of the dual clutch transmission was established according to the transmission control strategy and the matching hydraulic valve body assembly was designed. Then, the key components of the system were simulated to analyze their dynamic shift characteristics and response characteristics. Finally, through various tests, it is verified that the designed electro-hydraulic control system and transmission meet the design requirements. The results show that the electro-hydraulic control system can meet its working characteristics and shift requirements.
Zhang, ZeChen, YongLi, GuangxinTan, YanjunLin, XiaozheWang, Yougang
Shift fork is a key shifting element in manual and dual clutch transmission for smooth operations of gear shifting. One of the main criteria for robust design of shift fork is stiffness symmetry. Stiffness symmetry ensures straight movement of sleeve onto hub and thus helps in achieving good shift quality. Stiffness symmetry also ensures equal load distribution across two or three pads of shift fork while in operation. In this paper, we intend to demonstrate finite element simulation driven design process to improve stiffness symmetry of shift fork. Various parameters affecting stiffness symmetry are analyzed through design of experiment and selected best range for optimum design of shift fork. Output of this study will be useful for improving any design of shift fork to meet different targets of stiffness symmetry for all automobile suppliers and manufactures.
PRAYAGA, GIRIDHAR KRISHNAsahu, Deepak Kumar
Synchronizers are shifting elements in transmissions with power interruption, such as manual transmissions (MT) and automated manual transmissions (AMT). Synchronizers are also used in dual clutch transmissions (DCT) for shifting the preselected idler gear in the load-free branch of the transmission. Electric drive units (EDU) mainly consist of a two-stage transmission combined with a high-speed electric motor. Synchronizers realize the power flow from an idler gear to a gear shaft of the transmission. Automotive transmissions are usually operated with lubricating oils in order to minimize friction and wear of the mechanical components. Lubricating oil has a major influence on torque losses and on vibration behavior of transmission components. Torsional vibrations of mechanical components in transmissions lead to natural vibrations with high impact forces and thus to high radiated airborne sound levels. This occurs in particular when hard surfaces impact and the components have a high level of spring stiffness in addition to low damping properties. A drive torque that has a rotational irregularity leads to torsional vibrations of the components outside the power flow and is the starting point for transmission noises. Synchronizers have a function-related circumferential backlash in order to be able to shift the gear in a synchronized manner and therefore contribute to undesirable transmission noises. The aim of this work is to measure the vibrations of a synchronizer ring due to torsional vibration excitation while varying various parameters and to show the influences of the parameters. In particular, the lubricating oil has an influence on the torque losses and on the vibration behavior of a synchronizer. Lubricating oil with a low coefficient of friction due to its chemical structure leads to lower torque losses of the synchronizer and reduces the vibrations, which leads to a 1-2 dB(A) lower noise level of the transmission.
Baumann, AxelBertsche, Bernd
The degradation of the frictional characteristics of a wet clutch, which is repeatedly engaged throughout its entire life, alters the dynamic characteristics of the driveline system. It weakens the effect of control systems that use a fixed control strategy. To solve this problem, the cooperative effect of controllable parameters on the dynamic characteristics of the shift process throughout the full life cycle of the wet clutch was studied. First, an improved dynamic model of the driveline was established. The model considered the clutch’s frictional characteristics, time-varying mesh stiffness of the gears, and torque-coupling effect. Then, the dynamic characteristics of the driveline during the shifting process were analyzed. The model was validated with experimental data. Based on the model, the effect of a clutch’s frictional characteristics on the dynamic characteristics of the driveline was analyzed. To reduce the adverse effects caused by the degradation of the frictional characteristics and obtain an optimal control strategy for the different stages of the clutch life, a control strategy that controls the rising rate of on-coming clutch pressure and threshold of the micro-slip coordinately was proposed. The influence of these two controllable parameters on the dynamic characteristics of the driveline during the shift process throughout the entire life of a wet clutch was analyzed. The results showed that the side effects caused by the degradation of a clutch’s frictional characteristics on the driveline during the shifting process could be attenuated by controlling the rising rate of on-coming clutch pressure and threshold of the micro-slip coordinately.
Wang, DongyangHu, MinghuiQin, Datong
Shift quality is an important indicator to measure the performance of dual-clutch transmissions (DCT). To obtain optimal driving comfort and reduce the vehicle jerk as much as possible, this paper proposes an integrated gearshift controller to control the engine and the on-coming clutch in inertia phase. First of all, a dynamic model of DCT during gearshift is established. Key factors determining shift quality are analyzed. In order to reduce the vehicle jerk, a reference trajectory of the engine speed and the derivative of the desired torque transferred by the on-coming clutch in inertia phase are programmed respectively. A back-stepping sliding mode controller (BPSMC) is designed to make the actual engine speed track the reference trajectory and an incremental proportional-integrative (PI) controller is designed to make the actual clutch torque to track the desired clutch torque. At the end, simulation and experiment are carried out to validate the effectiveness of the proposed controller. Results show that the tracking error of engine speed is less than 10rad/s and the tracking error of the torque transferred by the on-coming clutch is less than 5Nm. Good tracking performance and driving comfort can be obtained using the proposed controller.
Tao, YichaoWu, Guangqiang
In order to improve the drivability of passenger cars with dual clutch transmission (DCT) and reveal the criteria for objective evaluation criteria and characteristic index and feature index division of vehicles under specific working conditions, a drivability evaluation system that integrates data-driven and the consistency between subjective and objective is proposed. At first, combined with the control principle and dynamics theory of specific working conditions, a quantitative index system of vehicle drivability is constructed, including three modules: data source, evaluation working conditions and objective indicators. Then, a novel intelligent drivability objective evaluation tools (I-DOET) is designed, including data acquisition, de-noising, working condition recognition, feature extraction and automatic scoring. What's more, aiming at the coupling problem of objective indicators in drivability evaluation, a method combining principle component analysis (PCA) and expert experience judgement is proposed to simplify the objective indicators. Finally, upshifting condition is taken as a case study, the subjective and objective consistency evaluation results are used to explore the reliability of objective drivability evaluation index and its classification criteria for passenger car with DCT. The real vehicle test results verify the scientific and effectiveness of the objective evaluation model which integrated data-driven and the consistency of subjective and objective, the importance of objective indicators are revealed which is used to provide theoretical and experimental basis for drivability adjustment and optimization. The integrated data-driven and the consistency of subjective and objective drivability evaluation model proposed in this research can be used as an important reference for drivability evaluation of passenger cars with DCT, and also provides a theoretical basis for drivability evaluation of heavy duty vehicles, new energy vehicles and autonomous vehicles.
Xia, JialeiGuo, XuexunZhou, WeiZhang, ChengcaiPei, XiaofeiYan, Jun
Suggestive Sound Design Based on Virtual Gears2020-01-15439/30/2020
With the electrification of vehicles, new questions and problems are rising in the field of NVH. The in-cabin noise was reduced significantly due to the new drive system. Additionally, the spectral composition of this noise changed dramatically. While the reduction of the in-cabin sound pressure levels is generally welcomed by customers and engineers alike, the predominantly high-pitched tonal sounds of the electrical drives are normally perceived with less enthusiasm. Active sound design can help both in masking those noises, or at the least embed them in new harmonic contexts so their annoyance can be reduced. A variety of research in the field of traffic psychology shows that acoustical feedback can alter the driving behavior. Based on this, our idea is, that if certain sounds induce specific reactions in drivers, a specifically designed active sound design could be used to influence said behavior. We aim to make the changes in the sound sufficiently subtle, so that the influencing only happens on a suggestive level, hence the name suggestive sound design. To investigate the potentials, and enable the development of a suggestive sound design, we created an interface between an electrical vehicle and a sound generator. With the sound generator we developed a sound that is based on the behavior of a dual clutch transmission. With this sound we want to further investigate the suggestivity - the ability to influence the driving behavior - of an active sound design and its potentials to improve traffic safety. The paper will focus on the definition of a suggestive sound design and how a particular manifestation based on virtual gears could be implemented. We discuss the current state of research and the development of a sound generator needed for further investigating a suggestive sound design. In the end we give an outlook on the planned experiments based on that sound generator.
Petersen, ManuelBehrendt, MatthiasHeizmann, LeonardAlbers, Albert
In-Depth PHEV Driveline Torsional Vibration Induced Vehicle NVH Response Study by Integrated CAE/Testing Methodology2020-01-15079/30/2020
In this paper, a 1-D refined driveline model in AMESIM was built up, for a P2.5 topology PHEV. The model includes detailed engine, damper, dual clutch transmission, differential, motor, half-shaft, wheel, body, suspension, powertrain mounting and powertrain rigid body, The objective of the simulation is to predict torsional vibration induced vehicle NVH response under different driving scenarios. Firstly, the torsional vibration modes were predicted, and the critical modes were identified. This enabled a good understanding of modal alignment, identification of countermeasures and provide feedback to other engineering teams in the early stages of vehicle development. Secondly, the holistic operational testing, which included a plenty of measurement points at various locations, partly intended for later model calibration, partly for extracting mandatory excitation input, and partly for the reference of next optimization stage, was implemented on vehicle chassis dyno in a hemi-anechoic chamber. As it was merely centered on torsional vibration induced scenarios, the intake system / exhaust system/engine radiation noise contribution was excluded by specific measures during the testing. Thirdly, the NTF/VTF from the mount / suspension attachment points to vehicle response points were measured on the trimmed body using hammer impact testing, to create structural TPA model, that way, each transfer path contribution to the response point could be predicted and overall response could be synthesized from all paths. Fourthly, the above-mentioned driveline model, combining the excitation on each cylinder due to gas pressure, inertial forces and motor average torque, was well calibrated to predict the critical rpm fluctuation / vibration / cabin noise and vibration. Finally, it was validated that CAE results correlated very well to measurement data for defined loadcase. This approach can be adapted to PHEV driveline/vehicle NVH development from the early stages of vehicle development as well as NVH tuning / refinement stage to expedite HEV/PHEV NVH developing process. This paper was a part of the whole study, including analyses of all loadcases corresponding to various driving scenarios followed by driveline design / calibration parameter sensitivity study to improve the torsional vibration induced vehicle NVH response.
Zhao, QianZhang, LiJia, JianningWu, LieZhuang, HuiminYu, HongzhiLu, ShouweiZhao, HonghuiPoduturu, AnilJain, SwejalCarter, Steven
Slip Speed and Drive Torque Planning of Multivariable Controller for an Electrified Vehicle with Dual Clutch Transmission125009/17/2020
Demand for electrified vehicles is increasing due to increased environmental pollution regulations and interest in highly efficient vehicles. According to these demands, research on electrified vehicles equipped with Dual Clutch Transmission (DCT) has been actively conducted for the purpose of improving energy efficiency of electrified powertrain, maximizing acceleration performance, and increasing maximum speed. However, since DCT requires clutch to clutch shifting, it is difficult to control drive torque and slip speed using two clutch actuators and a power source input. In order to solve this, a study on a multivariable shift controller has been conducted. However, this study chose a heuristic planning method to control the two outputs. However, since the slip speed and drive torque are coupled, it is necessary to tune the reference for every shift scenario, as well as create unnecessary control inputs or degrade shift control performance. Therefore, this study proposes a reference planning method considering powertrain dynamics. Specifically, by using the powertrain modeling of the electrified vehicle, a reference composed of power source input, slip speed, and drive torque can be constructed while satisfying dynamics. Using the proposed method, the slip speed is uniquely determined when the reduction ratio of the power source torque and the inertia phase time are predetermined. In order to verify the proposed planning method in this paper, an electrified powertrain simulator designed with a multivariable controller was constructed with MATLAB/SIMULINK. Afterwards, the heuristic reference planning method of the previous study and the method proposed in this paper were simulated in a vehicle composed of the same shift controller and powertrain. As a result, not only the reference automatically generated without tuning, but the energy consumption of the clutch actuator is reduced by about 10% in the control result with the same ride quality.
Kim, Dong-Hyun
Demand for electrified vehicles is increasing due to increased environmental pollution regulations and interest in highly efficient vehicles. According to these demands, research on electrified vehicles equipped with Dual Clutch Transmission (DCT) has been actively conducted for the purpose of improving energy efficiency of electrified powertrain, maximizing acceleration performance, and increasing maximum speed. However, since DCT requires clutch to clutch shifting, it is difficult to control drive torque and slip speed using two clutch actuators and a power source input. In order to solve this, a study on a multivariable shift controller has been conducted. However, this study chose a heuristic planning method to control the two outputs. However, since the slip speed and drive torque are coupled, it is necessary to tune the reference for every shift scenario, as well as create unnecessary control inputs or degrade shift control performance. Therefore, this study proposes a reference planning method considering powertrain dynamics. Specifically, by using the powertrain modeling of the electrified vehicle, a reference composed of power source input, slip speed, and drive torque can be constructed while satisfying dynamics. Using the proposed method, the slip speed is uniquely determined when the reduction ratio of the power source torque and the inertia phase time are predetermined. In order to verify the proposed planning method in this paper, an electrified powertrain simulator designed with a multivariable controller was constructed with MATLAB/SIMULINK. Afterwards, the heuristic reference planning method of the previous study and the method proposed in this paper were simulated in a vehicle composed of the same shift controller and powertrain. As a result, not only the reference automatically generated without tuning, but the energy consumption of the clutch actuator is reduced by about 10% in the control result with the same ride quality.
Kim, Dong-HyunChoi, Seibum
During the development of the Geely Hybrid System (GHS), which combines a 15T Miller engine with an Electric Motor (EM) integrated into a 7-speed Dual-Clutch Transmission (P2.5), several hybrid-specific Noise, Vibration, and Harshness (NVH) issues have been encountered. The technology used, the system features, and the hybrid operating modes are analyzed. Changes within driving modes and their transitions are among the new challenges faced by NVH and system engineers [1, 2, 3]. The lack of engine combustion noise masking during electric drive and hybrid mode brings new requirements for gear design and structural integrity. These requirements ensure the system is robust and insensitive to the excitation. Attachment points and its dynamic stiffness are important to prevent structure-borne frequency content of gear whine and EM magnetic noise being transmitted to the vehicle cabin via powertrain mounts. Idle speed selection has also become an important requirement to keep a suitable NVH comfort. This paper exposes the main challenges, root causes, and countermeasures applied during pure electric mode and combustion engine idle speed selection in order to create a competitive and refined hybrid propulsion system.
Garanto, Victor ManuelGeng, ZhirongHu, JunfengSu, HangPeng, GuominWang, Hao
To address the difficulties in modeling the starting process of dual-clutch transmission (DCT) vehicles and poor adaptability of vehicles in complex driving conditions, this article proposes a new modeling and control strategy for the DCT starting system based on data-driven autoregressive moving average exogenous (ARMAX) modeling. Firstly, the DCT starting process is considered equivalent to the time series-related ARMAX model, and a data-driven ARMAX model could be obtained using input-output data relating to the starting process; also, the effectiveness of the data-driven ARMAX modeling technique is verified using the starting test of a real vehicle. Secondly, a data-driven adaptive model predictive control (A-MPC) strategy, which synthetically considers driving intention and clutch engagement status, is proposed. Finally, in order to verify the proposed control strategy, simulation analysis is conducted in different intentions; the results show that the proposed control strategy could realize the starting control effectively, and reflect driving intention. Compared with model predictive control only considering driving intention, the proposed control strategy could improve starting performance in different intentions; also, compared with the conventional control method, the A-MPC can improve the starting performance.
Yang, YangWang, MengmengQin, DatongFeng, Jihao
This paper presents a feedback control strategy aimed to reduce noise and wear during gearshifts in conventional and hybrid Dual Clutch Transmissions (DCT and DCTH) and Automated Manual Transmissions (AMT). The control strategy is based on a new dog teeth position sensor developed by China Euro Vehicle Technology AB and existing speed sensors in the transmission. During gear shifting, noise is generated by impacts between the sleeve teeth and the idler gear dog teeth after speed synchronization. Besides noise, these impacts are also responsible for delaying the completion of shift and contribute to wear in the dog teeth, hence reducing the lifespan of the transmission. The presented control strategy controls speed synchronization such that the impact between sleeve and idler gear dog teeth, before the start of torque ramp up, is avoided. Since drag torque is an important factor in speed synchronization, this paper also contains an algorithm to identify friction torque coefficient in the transmission. The identification method ensures that the controller adapts to varying conditions without the need for offline calibration. The control strategy is developed for standard automatic gear shifting operations but minor adaptations in the algorithm also make it capable of handling gear shifts requested by the driver. The output signal of the control strategy is acceleration request on idler gear during speed synchronization. To make controller easier to implement and minimize shift time, the acceleration request only has two values, either maximum value or zero. The control strategy is designed in such a way that it can easily be integrated in the existing transmission control software. By applying the control strategy on a detailed simulation model, it is shown that the impacts during gear engagement are significantly reduced.
Piracha, Muddassar ZahidGrauers, AndersHellsing, Johan
The dual clutch transmission is one of the possible choices for electric vehicle drivelines. The basic principle and control mode of shifting of wet dual clutch transmission are introduced, and the dynamic process of shifting of wet double clutch transmission is studied. Combined with the dynamic model of the wet clutch engagement process, the difference between the dynamic characteristics of the dual clutch transmission modeling using the Coulomb friction model and the dual-clutch transmission model using the average flow model and the micro-convex contact theory is analyzed. The shift control strategy of the dual clutch transmission proposes a correction method to improve the shifting smoothness. Studies have shown that the torque response of the wet clutch has significant hysteresis, and the improved control algorithm can significantly improve the shifting smoothness of the wet dual clutch transmission. Based on the dynamic model of the wet clutch, the torque interruption of the shift control strategy of the dual clutch transmission is studied, and the method of improving the shift smoothness by the correction of the shift control strategy is proposed.
Lou, ZhenxiongDuan, YupengZhang, Yunqing
Using highly efficient powertrain is one of the most important and effective approaches to increase the driving distance of electric vehicles (EVs). In this paper, a novel two-speed dual-clutch transmission (DCT) is proposed. The transmission is comprised of two traditional friction clutches and two-stage planetary gear sets. One clutch connects the input sun gear and the other connects the input carrier. The Simulink models including an electric motor and two-speed DCT are established. Gearshift schedule based on fuzzy logic which reflects the driver’s intensions is adopted to improve the dynamic and economic performance of the novel transmission. The simulation model is built using MATLAB/Simulink® to validate the effectiveness of the proposed gearshift schedule compared with the conventional two-parameter gearshift schedule. Simulation results show that both the dynamic and economic performance of the novel DCT for EVs are improved with the proposed fuzzy logic gearshift schedule.
Zhang, HuanDu, HaipingLi, WeihuaWang, Yafei
Today, the contribution of the transportation sector on greenhouse gases is evident. The fast consumption of fossil fuels and its impact on the environment have given a strong impetus to the development of vehicles with better fuel economy. Hybrid electric vehicles fit into this context with different targets, starting from the reduction of emissions and fuel consumption, but also for performance and comfort enhancement. Lamborghini has recently invested in the development of a hybrid super sport car, due to performance and comfort reasons. Aventador series gearbox is an Independent Shift Rod gearbox with a single clutch and during gear shifts, as all the single clutch gearbox do, it generates a torque gap. To avoid the additional weight of a Dual Clutch Transmission, a 48V Electric Motor has been connected to the wheels, in a P3 configuration, to fill the torque gap, and to habilitate regenerative braking and electric boost functions. This paper discusses the usage of a control-oriented vehicle and powertrain model to analyze the performance of the first Lithium Ion Capacitor-based hybrid V12 by Automobili Lamborghini. The internal combustion engine, the gearbox, the LiC and the vehicle longitudinal dynamics models have been initially validated through the comparison with experimental data from chassis dynamometer testing, in addition to experimental results from specific components’ testing. As shown in the paper, the validated model has then been used to develop control strategies aimed at increasing comfort and performance, but also to expand the hybrid system capabilities by widening the LiC working range, and to study the possibility of implementing CO2 reduction-oriented control functions.
Franceschi, AlessandroCavina, NicoloParenti, RiccardoReggiani, MaurizioCorti, Enrico
The following schematic diagrams reflect various methods of illustrating automotive transmission arrangements. These have been developed to facilitate a clear understanding of the functional interrelations of the gearing, clutches, hydrodynamic drive unit, and other transmission components. Two variations of transmission diagrams are used: in neutral (clutches not applied), and in gear. For illustrative purposes, some typical transmissions are shown.
Automatic Transmission and Transaxle Committee
Dual Clutch Transmission Vibrations during Gear Shift: A Simulation-Based Approach for Clunking Noise Assessment2019-01-15536/5/2019
A novel methodology, for the assessment of Dual Clutch Transmission vibrations during gear shifts, is proposed in this paper. It is based on the capability to predict through numerical simulation a typical dynamic quantity used to objectively evaluate the vibrational behavior of a gearbox during experimental tests, i.e. the acceleration of a point on the external surface of the gearbox housing. To achieve this result, a two-step approach is proposed: an accurate simulation of the internal transmission dynamics and an offline uncoupled computation of the gearbox housing acceleration from the output of the simulation. The first step required the definition of a suitable nonlinear lumped parameter model of the car equipped with a DCT that was implemented in Amesim software. The second step, developed as a post processing tool in Matlab, is based on the knowledge of the inertance Frequency Response Functions (FRFs) between a single component of force applied in a bearing and a single component of acceleration in the measurement point. The indices used to assess the clunk severity are peak to peak amplitude and RMS of the gearbox housing acceleration. The effectiveness of this method is proven by comparing experimental and simulated trends of the clunk indices.
Galvagno, EnricoDimauro, LucaMari, GianlucaVelardocchia, MauroVella, Angelo Domenico
This paper explores the effects of maneuvering and gust loads on the drive system and flight dynamic response of a single main rotor helicopter equipped with a two speed dual clutch transmission. The authors demonstrate that performing upshifts during certain maneuvers can significantly reduce the transmitted clutch frictional torques and the resulting clutch pack temperature rise during gear changes. For example, compared with an upshift in level flight, performing a 8° pitch-up maneuver reduced peak clutch frictional power dissipation by 63% (from 455 Hp down to 169 Hp) and reduced total upshift time by 37% (from 5 seconds down to 3 seconds). This results in an 83% reduction in total heat energy dissipated by the clutch during the upshift. Since the design of the clutch pack mass is directly proportional to the heat dissipation requirements, this new (Maneuver Assisted Shifting) MAS technique could enable significant weight savings and clutch wear reduction in helicopter two-speed transmissions.
DeSmidt, HansSmith, EdwardSu, XiaowenBill, Robert
The purpose of this investigation is to present a control strategy and energy recovery potential for P2 parallel hybrid step gear automatic transmissions. The automatic transmission types considered for the investigation are rear wheel drive 8 speed dual clutch transmission and 8 speed planetary automatic equipped each equipped with an electric motor between the engine and transmission. The governing equations of clutch-to-clutch upshift controls are presented and are identical for each transmission type. Various strategies are explored for executing the upshift under a range of input torques, shift times and engine torque management approaches. The differences in energy recovery potential based upon control strategy is explored piecewise as well as through a DFSS study. On a comprehensive drive cycle consisting of FTP 75, US06 and HWFET test cycles, it is shown that upshift regen torque management can be equivalent to approximately 0.8% of the total fuel energy used. Additionally, it is shown that the utilization of the P2 electric motor is a further enabler to reduced shift times and improved shift quality at part throttle without compromise to net battery energy or fuel consumption.
Robinette, DarrellOrlando, Joshua
This paper presents a model based control strategy aimed to reduce noise and wear during gearshifts in conventional and hybrid Dual Clutch Transmissions (DCT and DCTH) and Automated Manual Transmissions (AMT). The control strategy is based on a newly developed dog teeth position sensor layout at China Euro Vehicle Technology AB (CEVT), a detailed simulation model for gear engagement and already existing speed sensors in the transmission. The details of dog teeth position sensor and simulation model are also presented in this paper. During gear shifting, noise is generated because of impacts between the sleeve teeth and the idler gear dog teeth after speed synchronization. Besides noise, these impacts are also responsible for delaying the completion of shift and contribute to wear in the dog teeth, hence reducing the lifespan of the transmission. The simulation model for gear engagement can simulate these impacts. Based on the simulation model and optimal control theory, an ideal dog teeth position trajectory is formulated that avoids the impact between sleeve and idler gear dog teeth, before the start of torque ramp up. The open loop strategy then controls the synchronization torque in the beginning of speed synchronization in such a way that the dog teeth position during shift follows the ideal dog teeth position trajectory. Since the control strategy is based on optimal control theory, its effect on speed synchronization time is minimal. The control strategy is designed in such a way that it can easily be applied in the existing transmission control software. By applying the control strategy on the simulation model, it is shown that the impacts during gear engagement are reduced.
Piracha, Muddassar ZahidGrauers, AndersBarrientos, EvaBudacs, HenriqueHellsing, Johan
A novel magnetorheological fluid dual clutch (MRFDC) for electric vehicle transmission is proposed in this article. The structure was based on the MR fluid clutch and traditional dual clutch equipped on internal combustion engine vehicle. Therefore the MRFDC combines the advantages of MR fluid clutch and dual clutch transmission (DCT) to achieve high control accuracy and fast response. The structure of MRFDC was designed by Unigraphics (UG) three-dimensional (3D) modeling software. Then, finite element analysis (FEA) for magnetic field was conducted by ANSYS under different applied currents from 0.1A to 1A with 0.1A space to obtain the relation between the applied current and magnetic field. In this article, Herschel-Bulkley model is used to predict the MR fluid behavior because of the high shear rate of MR fluid. Finally, output torque of MRFDC can be estimated by calculus with geometric dimensions of MRFDC structure and rheological properties of MR fluid dependent on the magnetic field generated by the applied current. Finally the relation between the applied current and output torque of the internal clutch and external clutch can be obtained, respectively. Simulation results show that the relation between the output torque and the applied current can be considered linear for internal clutch under 0-1.0A current excitation. While the applied current is below 0.3A, the relation for external clutch can also be considered as linear. Thus, it is easy to use linear control methods to achieve gear shift based on mathematical models of MRFDC by controlling the applied current through the coil of the dual clutch under the requirement of achieving the maximum driving torque.
Zhang, HuanDu, HaipingSun, ShuaishuaiLi, WeihuaWang, Yafei
This paper examines the effect of pulse-and-glide (PnG) driving strategies on the fuel efficiency when applied on parallel HEVs. Several PnG strategies are proposed, and these include the electrical, mechanical, and combined PnG strategies. The electrical PnG strategy denotes the hybrid powertrain control tactics in which the battery is charged or discharged according to the power demanded while maintaining the constant vehicle speed. On the other hand, the mechanical PnG strategy denotes the powertrain control tactics in which the vehicle accelerates or decelerates according to the power load while minimizing the battery usage. The combined PnG strategy involves both electrical and mechanical strategies to find a balanced point in between them. Here, a tradeoff relationship between the fuel efficiency and the vehicle drivability related to the tracking performance of the desired target speed is revealed. In the assessment of the feasibility of applying each of the formerly mentioned hybrid driving strategies, the causes of driveline heat loss are recorded and analyzed by their types. These include the engine heat loss, engine friction loss, motor loss, and the resistance loss. The motor loss includes all of the electrical energy loss induced in the powertrain electronics, and the resistance loss includes the loads acting on the vehicle such as the aerodynamic drag and rolling resistance. These factors are quantitatively analyzed for different driving strategies along with the related fuel efficiency in an integrated manner. The experimental validation is conducted using a real HEV equipped with a gasoline spark-ignition engine, transmission-mounted electric drive, and a 6-speed dual clutch transmission.
Eo, Jeong SooKim, Sung JaeOh, JiwonChung, Yeon KwangChang, Young Joon
A Guide to Handle Dry DCT (Dual Clutch Transmission) Motor2018-01-03934/3/2018
These days, the usage of Dual Clutch Transmission (DCT) system is increasing in the transmission systems according to Strategy Analytics [1]. The reason is mainly due to its quicker and smoother transition of gear shifting than conventional single clutched transmissions. Among two main types of DCTs, dry DCT is more beneficial in reducing fuel consumption than wet DCT due to the lack of hydraulic structure. However, dry DCT requires highly precise control due to its mechanical structure. Therefore, the main focus in this paper will be on dry DCT as the main idea of this paper was found during developing its particular control algorithm. Due to this reason, where DCT is mentioned later in this paper, it means “dry” type of DCT. When a conventional hydraulic automatic transmission with single clutch fails, the system simply locks at the third speed gear mechanically. However, the failure modes can vary numerously in DCT systems where several moving parts should be controlled simultaneously. However, in the authors’ opinion, the current criteria of failure mode detection are so broad that even a minor issue could drag the whole system down to the failure mode. This could unnecessarily cause inefficient fuel consumption and irregular gear transitions. This article is a part of Autron’s 7 speed DCT project. The microcontroller (MCU) used to control this system is Aurix TC275, Infineon 32bit Tricore.
Kim, JeehoonHan, SeonmiKim, HaramChoi, Seungman
The automotive vehicle market has seen an increase in the number of hybrid electric vehicles (HEVs), and forecasts predict additional growth. In HEVs, the hybrid drivetrain hardware can combine electric motor, clutches, gearbox, electro-hydraulics and the control unit. In HEV hardware the transmission fluid can be designed to be in contact with an integrated electric motor. One transmission type well-suited to such hybridization is the increasingly utilized dual clutch transmission (DCT), where a lubricating fluid is in contact with the complete motor assembly as well as the DCT driveline architecture. This includes its electrical components and therefore raises questions around the suitability of standard transmission fluids in such an application. This in turn drives the need for further understanding of fluid electrical properties in addition to the more usually studied engineering hardware electrical properties. New understanding around the properties of transmission fluids in electric fields has been gained. This knowledge has been used to design a fluid with the appropriate electrical characteristics coupled with those essential performance characteristics for a fluid required to lubricate a DCT unit. Such a fluid technology recently developed to be suitable for a hybrid electric DCT unit, an eDCT, is described, as well as some of the more fundamental investigations underpinning its development.
Gahagan, Michael P
This paper investigates the effect of the powertrain mounting system on the linear and nonlinear torsional dynamical behaviour of a transmission system. To this aim, two dynamic models, one with rigid mounts and the other with flexible mounts, are presented and compared: the first model considers only the torsional dynamics of transmission and driveline, while the second model includes also a 3 degrees-of-freedom powertrain block. The mechanical coupling and interaction between the powertrain block and transmission system is discussed and formulated. These models are then analyzed in terms of vibrational mode shapes, natural frequencies and Frequency Response Functions (FRFs); a sensitivity analysis of the main transmission parameters, e.g. the gear ratio, is also presented. From the comparison of the two simulated configurations (with and without powertrain mounts) both in time and frequency domain, a significant interaction between the two subsystems is noticed, particularly in the vehicle acceleration signal. Neglecting the powertrain mounts may lead to underestimating the real vibration level. A nonlinear model of a dual clutch transmission, including the main backlashes present along the transmission path (clutch spline, gear meshes, synchronizers), is coupled to the powertrain mounting system model. Finally, the effect of mount stiffness on transmission NVH during critical manoeuvres is shown.
Galvagno, EnricoGutierrez, PabloVelardocchia, MauroVigliani, Alessandro
An online and real-time Condition Prediction system, so-called lifetime monitoring system, was developed at the Institute for Mechatronic Systems in Mechanical Engineering (IMS) of the TU Darmstadt, which is intended for implementation in standard control units of series production cars. Without additional hardware and only based on sensors and signals already available in a standard car, the lifetime monitoring system aims at recording the load/usage profiles of transmission components in aggregated form and at estimating continuously their remaining useful life. For this purpose, the dynamic transmission input and output torques are acquired realistically through sensor fusion. In a further step, the lifetime monitoring system is used as an input-module for the introduction of innovative procedures to more load appropriate dimensioning, cost-efficient lightweight design, failure-free operation and predictive maintenance of transmissions. This is based on damage-oriented operating strategies (so-called eLIFE) and a paradigm shift in the design philosophy relying on a smart big data approach (so-called ecoLIFE3 design procedure). The paper will present the lifetime monitoring system by the example of two concrete application cases, namely a manual and a dual clutch transmission (DCT). Furthermore, the concepts of eLIFE and ecoLIFE3 will be introduced and the economic and ecologic potentials of the approach will be discussed and quantified on basis of a DCT.
Rinderknecht, StephanFietzek, RafaelFoulard, Stéphane
The reduction of CO2 emissions at vehicle level through the improvement of transmission efficiency represents the essential goal of transmission development engineers. New requirements, such as the recovery of the kinetic energy of the vehicle while coasting, the hybridization of drivetrains and autonomous driving, are challenges that can best be overcome with automatic transmissions. Dual clutch transmissions (DCT) with power-on-demand actuation systems offer a particularly efficient method of meeting the new requirements. However, many markets show vehicle applications with production volumes of less than 100.000 units per year. FEV’s new DCT family is conceived especially for customers in these markets. The re-use of proven subsystems which are already in series production results in a "business case" for applications with lower volumes also. This article introduces this transmission family.
Steinberg, IngoFreiholtz, DanHellenbroich, Gereon
An MIT student-inventor's clutchless hybrid transmission concept aims to provide high-performance vehicles an energy-saving attitude without compromise. The concept mechanism uses an electric motor to fill the acceleration lag that occurs when a driver releases the throttle and engages the clutch. A second electric motor is used for quickly speed-matching the gears during the shift since there is no mechanical means to speed up the next gear before engaging it.
Buchholz, Kami
Regenerative braking has been widely accepted as a feasible option to extend the mileage of electric vehicles (EVs) by recapturing the vehicle’s kinetic energy instead of dissipating it as heat during braking. The regenerative braking force provided by a generator is applied to the wheels in an entirely different manner compared to the traditional hydraulic-friction brake system. Drag torque and efficiency loss may be generated by transmitting the braking force from the motor, axles, differential and, specifically in this paper, a two-speed dual clutch transmission (DCT) to wheels. Additionally, motors in most battery EVs (BEVs) and hybrid electric vehicle (HEVs) are only connected to front or rear axle. Consequently, conventional hydraulic brake system is still necessary, but dynamic and supplement to motor brake, to meet particular brake requirement and keep vehicle stable and steerable during braking. Therefore, a complicated effect on the safety and performance of braking, mainly relating to tyre slips and locks, vehicle body bounces and braking distance will be applied by the blended brake system. In this paper, the brake energy recovery potentials of typical driving cycles are presented. Relevant critical limitations are introduced to define the available brake force distribution range for front and rear axles. Then the distribution strategies are compared and analyzed to achieve a satisfied balance between braking performance, driving comfort and energy recovery rate. Next, the required motor brake force is tuned, according to the response time and efficiency loss in transfer process which obtained in testing bench. At last, solutions for some special cases are proposed, for instance, motor brake torque interruption when downshifting occurs on long downhill. A credible conclusion is gained, through experimental validation of optimized brake force distribution strategy on a two-speed DCT based BEV testing rig, that the selected force distribution strategy help the blended brake system achieve a comfortable and safety braking during all driving conditions.
Ruan, JiagengWalker, PaulZhang, NongXu, Guangzhong
This paper presents a methodology for the assessment of the NVH (noise vibration and harshness) performance of Dual Clutch Transmissions (DCTs) depending on some transmission design parameters, e.g. torsional backlash in the synchronizers or clutch disc moment of inertia, during low speed maneuvers. A 21-DOFs nonlinear dynamic model of a C-segment passenger car equipped with a DCT is used to simulate the torsional behavior of the driveline and to estimate the forces at the bearings. The impacts between the teeth of two engaging components, e.g. gears and synchronizers, generate impulses in the forces, thus loading the bearings with force time-history characterized by rich frequency content. A broadband excitation is therefore applied to the gearbox case, generating noise and vibration issues. The metric used to assess the severity of a specific test and to compare, at least qualitatively, the NVH performance related to different design parameters sets, is based on the RMS (root-meansquare) value of each bearing force time-history. Variations from one test to another allow assessing the benefit introduced by specific design parameter modifications. Applications of the proposed methodology aimed at evaluating the effects of reducing the clutch discs moment of inertia, the synchronizers backlash and the internal backlash in the differential are presented. Finally the paper shows that results not only depend on the gearbox design but also on the specific maneuver chosen to excite the dynamic system under test: a clear trend may be seen in some cases while only negligible effects are observed in other conditions.
Galvagno, EnricoGuercioni, Guido RicardoVigliani, Alessandro
Dry dual clutch transmission (DCT) has played an important role in the high performance applications as well as low-cost market sectors in Asia, with a potential as the future mainstream transmission technology due to its high mechanical efficiency and driving comfort. Control system simplification and cost reduction has been critical in making dry DCT more competitive against other transmission technologies. Specifically, DCT clutch actuation system is a key component with a great potential for cost-saving as well as performance improvement. In this paper, a new motor driven clutch actuator with a force-aid lever has been proposed. A spring is added to assist clutch apply that can effectively reduce the motor size and energy consumption. The goal of this paper is to investigate the feasibility of this new clutch actuator, and the force-aid lever actuator's principle, physical structure design, and validation results are discussed in details. A prototyping of the proposed system is developed for the engagement of the clutch with a position-tracking controller. The advantages of the design and the performance of the control system developed are demonstrated through bench testing. It can be a promising low-cost clutch actuation system for a DCT transmission
Liu, FengyuChen, LiYao, JianZhang, JianlongYin, ChengliangLi, DongxuLee, ChunhaoHuang, Ying
Dual Clutch Transmissions (DCT) for passenger cars are being developed by OEMs and suppliers. The driving force is the improvement in fuel economy available from manual transmissions together with the comfort of automatic transmissions. A dry clutch system (dDCT) is currently the subject of research, development, and production implementation. One of the key issues in the development of a dDCT is clutch durability. In dry clutches with current linings, above a critical temperature, the friction system starts to suffer permanent damage. In addition, the clutch friction characteristics are a function of the clutch interface temperature. Because a reliable, low-cost temperature sensor is not available for this application, the clutch control engineers rely on a good thermal model to estimate the temperature of the clutches. A thermal model was developed for dry dual clutch transmissions to predict operating temperature of both pressure and center plates during all maneuvers. The model is intended to be used to a) prevent clutch plate over-heating during abusive driving scenarios such as hill holding or multiple GCVW launches in both forward and reverse on grades and b) estimate clutch friction characteristics for control purposes. It is a Simulink based model that is integrated into the transmission controller to notify drivers and take corrective actions in case of overheating. The model also predicts the initial conditions for the temperature of the clutches during engine startups. The thermal model was validated fully in a test cell environment as well as in vehicles using slip ring and telemetry hardware. The thermal model has seven states that include both bell housing air and skin temperatures. Other parameters that affect cooling performance of a dry DCT, such as ambient temperature, and engine coolant and transmission oil temperatures, are also taken into consideration.
Hebbale, KumaraswamySamie, FarzadKish, Jonathan
In this paper, a new algorithm for the off-line estimation of wet clutch friction parameters is proposed for automotive transmissions, motivated by the usefulness of such an algorithm for diagnosing the condition of the clutch and transmission fluid in service. We assume that clutch pressure is measured, which is the case in dual clutch transmissions (DCT). The estimation algorithm uses measured rotational speeds and estimated accelerations at the input and output sides of a clutch, measured clutch pressures, and a simplified dynamic model of clutch friction to estimate the viscous and contact components of clutch friction torque. Coefficient of friction data is generated using the contact friction torque. A Stribeck friction model is fit to the data, and parameters in the model are then calculated by applying linear least squares estimation. The proposed estimation algorithm is tested using the simulation of a powertrain utilizing a DCT, where the clutch friction model incorporates a realistic level of fluid film squeeze dynamics. The algorithm is evaluated under ‘noiseless’ and ‘noisy’ conditions. In the ‘noiseless’ case, clutch accelerations and pressure derivatives are obtained by differentiating stored clutch speed and pressure signals. In the ‘noisy’ case, white-Gaussian noise is introduced to the stored signals, with a noise-to-signal amplitude ratio of 10% for speed signals and 5% for pressure signals. The clutch accelerations and pressure derivatives are then estimated using a Kalman filter, and results are presented for both ‘noiseless’ and ‘noisy’ cases. In both cases, friction parameters are estimated within 10% of their respective simulated values, with the estimation accuracy being generally better for the ‘noiseless’ case.
Barr, MatthewSrinivasan, Krishnaswamy
During the last years mechatronic systems developed into one of the biggest drivers of innovation in the automotive industry. The start of production of systems like dual clutch transmission, lane departure warning systems and active suspensions proves this statement. These systems have an influence on the longitudinal, steering and vertical dynamics of the vehicle. That is why the interaction on vehicle level is crucial for an optimal result in the fields of efficiency, comfort, safety and dynamics. To optimize the interaction of mechatronic systems, in this paper a new test rig concept for a complete vehicle is presented. The so-called Car-in-the-Loop-concept is capable of realistically reproducing the loads, which act on the powertrain, the steering and the suspension during a test drive. The resulting advantages are the possibility to exactly reproduce test procedures, the independence from weather conditions and a minimization of the risk of human injuries during testing of safety functions. A prototype of this concept, which includes parts of the powertrain, the steering and the chassis corresponding to the left front side of a BMW Mini Countryman, was built at the lab of the Institute for Mechatronic Systems in Mechanical Engineering of the TU Darmstadt. A test rig shaft connects the wheelhub of the BMW Mini Countryman to actuators, which generate realistic loads corresponding to the current driving situation. To provide the needed adaptiveness for the steering and suspension movement constant velocity joints and ball-spline supported length compensations are included in the test rig shaft. A highly dynamic test drive is being reproduced on the prototype to prove the functionality of the Car-in-the-Loop-concept.
Fietzek, RafaelRinderknecht, Stephan
As the number of fixed gear ratios in automatic transmissions continues to increase in the pursuit of powertrain system efficiency, particular consideration must continue to be focused on optimizing the design for shifting performance. This investigation focuses on the effect of shift time on the performance attributes of shift quality, durability, on schedule fuel consumption and enablers to further reduce shift time. A review of fundamental design features that enable reduced shift times in both planetary and dual clutch transmissions is presented along with key operating features of both the transmission and engine/prime mover. A lumped parameter metric is proposed to assess and compare the upshift controllability of new transmission architectures and powerflows using simple analysis. The durability of fast shift times during performance maneuvers are quantified through calculation of shifting clutch energy and power from analysis and form measurements on a powertrain dynamometer. In addition to perceived powertrain performance, powertrain dynamometer measurements running the FTP test schedules fuel consumption trends with respect to inertia phase shift time and can provide upwards of 1.25% by optimization of shift times depending on powertrain details. The paper concludes with vehicle measurements comparing part and wide-open throttle shift times for 6 and 8 speed planetary automatics transmissions.
Robinette, DarrellGibson, GabrielSzpara, DavidTehansky, Eugene
A direct trajectory optimization approach is developed to assess the capability of a GTDI-DCT Powertrain, with a Gasoline Turbocharged Direct Injection (GTDI) engine and Dual Clutch Transmission (DCT), to satisfy stringent drivability requirements during launch. The optimization is performed directly on a high fidelity black box powertrain model for which a single simulation of a launch event takes about 8 minutes. To address this challenging problem, an efficient parameterization of the control trajectory using Gaussian kernel functions and a Mesh Adaptive Direct Search optimizer are exploited. The results and observations are reported for the case of clutch torque optimization for launch at normal conditions, at high altitude conditions and at non-zero grade conditions. The results and observations are also presented for the case of simultaneous optimization of multiple actuator trajectories at normal conditions.
Cho, DavidGupta, RohitDai, EdwardMcCallum, JamesPietron, GregoryShelton, MatthewKolmanovsky, Ilya V.
The 2016 production NSX made its much-awaited global debut at NAIAS in January. More technical details of Acura's mid-engine AWD hybrid supercar will be shared by Honda R&D experts at the SAE 2015 World Congress. Three years removed from its concept-design debut, the Acura NSX supercar took to the 2015 North American International Auto Show (NAIAS) stage once more, this time in its production form. While recognizable as that concept's progeny, the next-generation 2016 NSX revealed this January in Detroit has evolved over its 36-month development program. The Ohio-based, American-led R&D team for the new NSX, with Ted Klaus, Chief Engineer and Global Development Leader, at the helm, has made design and engineering decisions both big and small-but none insignificant-every step of the way.
Gehm, Ryan
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