SAE R-413-2013 Dynamic Analysis and Control System Design of Automatic Transmissions (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、Dynamic Analysis and Control System Design of Automatic Transmissions 6293_Book.indb 1 1/11/13 3:51 PMOther SAE books of interest: Design Practices: Passenger Car Automatic Transmissions, Fourth Edition (Product Code: AE-29) Innovations in Automotive Transmission Engineering By Martin G. Gabriel (Pr

2、oduct Code: T-109) Continuously Variable Transmission (CVT) By Bruce D. Anderson and John R. Maten (Product Code: PT-125) For more information or to order a book, contact SAE International at 400 Commonwealth Drive, Warrendale, PA 15096-0001, USA; phone 877-606-7323 (U.S. and Canada only) or 724-776

3、-4970 (outside U.S. and Canada); fax 724-776-0790; email CustomerServicesae.org; website http:/books.sae.org. 6293_Book.indb 2 1/11/13 3:51 PMDynamic Analysis and Control System Design of Automatic Transmissions By Shushan Bai, Joel Maguire, and Huei Peng Warrendale, Pennsylvania USA 6293_Book.indb

4、3 1/11/13 3:51 PM Copyright 2013 SAE International eISBN: 978-0-7680-7932-6400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-0790 Copyright 2013 SAE International. All rights reserve

5、d. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the prior written permission of SAE International. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 1

6、5096-0001 USA; email: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765. ISBN 978-0-7680-7604-2 SAE Order Number R-413 DOI 10.4271/R-413 Library of Congress Cataloging-in-Publication Data Bai, Shushan.Dynamic analysis and control system design of automatic transmissions / by Shushan Bai, Joel

7、 Maguire, and Huei Peng.pages cm“SAE Order Number R-413.”Includes bibliographical references.ISBN 978-0-7680-7604-21. AutomobilesTransmission devices, Automatic. 2. AutomobilesPower trains. I. Maguire, Joel. II. Peng, Huei. III. Title. TL263.B35 2013629.2446dc23 2012037412 Information contained in t

8、his work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omiss

9、ions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an ap

10、propriate professional should be sought. To purchase bulk quantities, please contact: SAE Customer Service Email: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-0790 Visit the SAE International Bookstore at http:/books.sae.org 6293_Book.indb

11、 4 1/11/13 3:51 PMv Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Chapter 1 Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Powertrain system

12、 2 1.2 Why is a transmission necessary? . 2 1.2.1 First perspective: wheel power 4 1.2.2 Second perspective: engine operation . 5 1.3 Different types of automatic transmissions 6 Chapter 2 Mechanics of Planetary Gear Automatic Transmissions . . . . . . . . . . 9 2.1 Torque converter . 11 2.1.1 Descr

13、iption of torque converter 11 2.1.2 Dynamic model of engine and torque converter system . 14 2.1.3 Backward calculation of torque converter variables . 18 2.2 Planetary gear trains 21 2.2.1 Planetary gear set 21 2.2.2 Planetary gear train 23 2.2.3 Static analysis of planetary gear trains: algebraic

14、method 26 2.2.4 Static analysis of planetary gear trains: lever analogy method 29 2.2.5 Static analysis of planetary gear trains: matrix method 33 2.2.6 Gear-shifting mechanics 37 2.2.7 Frictional clutches and their mathematical models . 45 2.2.8 Dynamic equations of simple planetary gear sets . 47

15、2.2.9 Dynamic equations and simulation model of planetary gear trains 49 2.2.10 Generic dual-clutch model 57 2.2.11 Matrix dual-clutch model . 60 2.2.12 Inertia balancing 62 2.2.13 Six- and eight-speed planetary automatic transmissions . 65 6293_Book.indb 5 1/11/13 3:51 PMvi Contents Chapter 3 Contr

16、ol of Planetary Gear Automatic Transmissions . . . . . . . . . . . 71 3.1 Electrohydraulic pressure control system . 72 3.1.1 Hydraulic pressure control system and its simulation models . 73 3.1.2 Detailed model of PPC solenoids . 80 3.1.3 High-flow, direct-acting pressure control valves . 81 3.1.4

17、Pulse width modulated (PWM) solenoid . 82 3.1.5 Analytical study of hydraulic clutch control systems . 84 3.2 Clutch-to-clutch gear-shift control . 105 3.2.1 Gear-shifting mechanics from a control perspective 105 3.2.2 Hydraulic control system for clutch-to-clutch shift controls 110 3.2.3 Dynamic si

18、mulation model for studying clutch-to-clutch shift controls. 110 3.2.4 Control of power-on up-shifts . 110 3.2.5 Control of power-on down-shifts 112 3.2.6 Hydraulic clutch control system design . 112 3.2.7 Clutch fill detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19、. . . . . . . . . . 114 3.2.8 Acceleration estimator 114 3.2.9 Canceled shifts, transitional shifts, and double-transition shifts. 118 3.3 Electronic torque converter clutch control . 121 3.3.1 Hydraulic system for torque converter clutch control . 121 3.3.2 Electronic control algorithm for torque c

20、onverter clutch control 122 3.4 Dynamic analysis of torque converter clutch damper 126 3.5 Friction launch control . 129 3.6 Shift scheduling system . 135 3.6.1 Shift map . 135 3.6.2 Dynamic-programming-based shift map generation 137 3.6.3 Artificial intelligence-based shift scheduling system 142 3.

21、7 Integrated powertrain controls for driveability and fuel economy . 150 3.7.1 Overall architecture of integrated powertrain control system. 150 3.7.2 Power-based gear selection 152 3.7.3 Constant-output-torque power-on up-shift control . . . . . . . . . . . . . . . . . . . 154 3.8 Centrifugal pendu

22、lum vibration absorber . 156 3.8.1 Basic concept and various designs for CPV A. 157 3.8.2 Equations of motion of CPV A . 159 3.8.3 Simulink model of CPV A . 161 3.8.4 Tuning of CPV A . 162 3.8.5 Path of pendulum motion. 162 Chapter 4 Metal Pushing V-Belt Continuously Variable Transmissions . . . . 1

23、67 4.1 Mechanics of metal pushing V-belt continuously variable transmissions . 168 4.2 Controls of metal pushing V-belt continuously variable transmissions . 170 4.3 Comparison with other ratio control systems 173 4.4 Feed-forward/feedback control and its application to V-CVT ratio control . 177 629

24、3_Book.indb 6 1/11/13 3:51 PMvii Contents 4.4.1 Introduction 177 4.4.2 Limitations of feedback controls . 177 4.4.3 Feedback and feed-forward control systems . 179 4.4.4 Design of feed-forward controls . 180 4.4.5 Application: direct pulley pressure control of V-CVT . 181 Chapter 5 Dynamics and Cont

25、rols of Dual-Clutch Transmissions . . . . . . . . . 185 5.1 Construction of dual-clutch transmissions. 186 5.2 Synchronizer and its control . 187 5.3 Dual-clutch module 189 5.4 Control algorithms for DCTs 192 5.5 Conclusion . 193 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26、 . . . . . . . . . . . . . . . . . . . . . . . . . 195 Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27、. . 201 About the Authors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 6293_Book.indb 7 1/11/13 3:51 PM6293_Book.indb 8 1/11/13 3:51 PMix Introduction Automatic transmissions for automobiles are not simply gearboxes, but have evolved into comp

28、lex integrated mechanical/electrical/hydraulic/electronic systems for achieving optimal operation of vehicle powertrains. To achieve optimal design and control of modern automatic transmissions, adequate dynamic analyses and control system designs are indispensable. This book exclusively covers the

29、topic of dynamic analysis and control system design of automatic transmissions. Why is dynamic analysis indispensable for achieving optimal design of automatic transmis- sions? First, the gear shifting of automatic transmissions is a dynamic process, which involves synchronized torque transfer from

30、one clutch to another, smooth engine speed change, engine torque management, and minimization of output torque disturbance. Dynamic analysis is required to gain the necessary understanding of gear shifting mechanics, and therefore to support the creation of an optimal design for gear shift control s

31、ystems. Hydraulic clutch control systems in automatic transmissions are highly dynamic systems. Good dynamic and steady-state behaviors such as response time, stability, repeatability, steady-state error, and robustness are the foundation for achieving premium gearshift quality. The ratio of the con

32、tinuously variable transmission (CVT) is controlled by hydromechanical ratio feedback systems or electrohydraulic ratio feedback control systems. It is well known that dynamic analysis is absolutely necessary for achieving adequate designs of hydraulic control systems and feedback control systems. I

33、n addition, an automatic transmission also provides isolation of engine torque pulsation to reduce torsional vibrations of the powertrain and driveline. This is achieved through torque converter clutch slip speed control and adequate design of the torque converter clutch damper. In recent years, as

34、a result of pursuing higher engine fuel efficiency, the magnitude of the engine torque pulsation is increasing. To provide the required isolation for this higher level of engine torque pulsations, adequate design of torque converter clutch dampers and torque converter clutch control systems is neces

35、sary. This requires the use of dynamic- analysis-based system design as well. The electronic control algorithms for automatic transmissions include gearshift control algorithms, gear schedule algorithms, torque converter clutch control algorithms, friction launch control algorithms, and integrated p

36、owertrain control algorithms. Good designs of such control algorithms must be based on a thorough understanding of the dynamic characteristics of the systems as well as the use of the relevant dynamic analysis and design methodologies. 6293_Book.indb 9 1/11/13 3:51 PMx Introduction While the basic w

37、orking principle and the mechanical construction of automatic trans- missions has not changed significantly, in recent years the tightening requirements for performance, fuel economy, and drivability, as well as the increasing number of gears, have made the design of transmission controls more chall

38、enging. The recent emergence of new types of transmissions such as the Continuously Variable Transmission (CVT), Dual-Clutch Transmission (DCT), and hybrid powertrain has presented added challenges. To respond to such developments in automatic transmission technologies, this book will cover the broa

39、d topics of dynamic analysis and control system design of automatic transmissions. The book starts with the basic mechanics of automatic transmissions, and then covers in detail topics of dynamics and controls of automatic transmissions. The topics covered include gear-shifting mechanics and control

40、s, dynamic modeling of planetary automatic transmis- sions, design of hydraulic control systems, learning algorithms for achieving consistent shift quality, torque converter clutch controls, the centrifugal pendulum vibration absorber, friction launch controls, shift scheduling and integrated powert

41、rain controls, CVT ratio controls, and DCT controls, to name a few. The book strives to provide a good balance between theory and practice. For the beginner, the book will provide enough details to understand the basics of dynamics and controls of automatic transmissions. For experienced engineers,

42、this book will provide sufficient theoretical discussions to help elevate the readers knowledge to a higher level. The book can be used as a reference handbook for engineers as well as a teaching tool for classrooms. In the sections that cover basic analytical skills, homework is provided for classr

43、oom usage. 6293_Book.indb 10 1/11/13 3:51 PM1 Chapter 1 Automatic Transmissions 6293_Book.indb 1 1/11/13 3:51 PMChapter 1 2 An automatic transmission is a small component in automobiles, yet it plays an impor- tant role in optimizing vehicle operations. This short, first chapter will provide a brief

44、 description of the role of automatic transmissions and will serve as an introduction to the book. 1.1 Powertrain system The powertrain system in an automobile consists of an internal combustion engine and a transmission, as shown in Fig. 1.1. The crankshaft of the engine is coupled to the input sha

45、ft of the transmission through a launch unit. The launch unit could be a frictional clutch or a torque converter. The output shaft of the transmission is connected to the vehicle wheels through a final drive gear and a differential unit. A transmission has multiple speed ratios (torque ratios and ge

46、ar ratios). Speed ratio is defined as the ratio of transmission output speed to input speed. Torque ratio is defined as the ratio of transmission output torque to input torque. Therefore, speed ratio and torque ratio have reciprocal values. The torque ratio also equals the ratio of input speed to ou

47、tput speed, and is referred to as the gear ratio. The gear ratio of a transmission is selectable by a driver (in the case of a manual transmission) or by a pow- ertrain controller (in the case of an automatic transmission) to achieve optimal operation of a powertrain system. Typical transmission gea

48、r ratios are (for a six-speed transmission): 2.6 (1st gear), 1.7 (2nd gear), 1.2 (3rd gear), 0.94 (4th gear), 0.77 (5th gear), and 0.62 (6th gear). The first question one may ask is, “Why is a transmission necessary?” Lets consider the answer to this fundamental question before we start our discussi

49、ons of dynamics and controls of auto- matic transmissions. 1.2 Why is a transmission necessary? To answer this question, lets start by taking a look at the characteristics of internal combus- tion engines. An internal combustion engine could be characterized by three graphs. The first graph, Fig. 1.2, shows engine torque as a function of engine speed for each throttle opening. The second graph, the engine power graph shown in Fig. 1.3, presents engine power as a function of engine speed and throttle opening. The maximum engine power curve is the 100%-throttle-opening power cur