Browse Topic: Friction clutches

Items (152)
Development of a Low Loss Clutch for CVT Reverse Function2019-01-07744/2/2019
Continuously variable transmissions (CVT) provide superior fuel economy by enabling internal combustion engines to operate at their “sweet spots”. However, there is still potential to improve CVT system’s mechanical efficiency, and further enhance vehicle-level fuel economy. In the past, extensive research work has focused on the core continuously variator unit (CVU) that includes pulleys and a belt or chain. Another thread of research has centered on optimization of CVT clamping force control to reduce hydraulic system loss. Nonetheless, to the best of our knowledge, very little research has looked into the planetary gear sets and clutches that enable the CVT system to switch between forward, neutral and reverse gears. The state-of-the-art reverse clutch usually consists of multiple friction and steel plates, and is normally open during all forward driving maneuvers. The relative speed between friction and steel plates is identical to turbine speed, which generate spin loss. We believe there is an opportunity to improve the CVT system mechanical efficiency by replacing the reverse plate clutch with a low loss clutch, for example a binary clutch. At first, we studied the theoretical spin loss associated with plate clutches. Secondly, we identified the most challenging shifting maneuver using the lever diagram analogy. Thirdly, we proposed a control strategy to address the most critical rolling garage drive-to-reverse shift, and conducted one-dimensional simulation using an AMESim model to validate our strategy by comparing our simulation result with available vehicle data. At last, we obtained spin loss data from dynamometer testing to evaluate the potential fuel economy benefit.
Duan, ChengwuLee, ChunhaoYao, JianSamie, FarzadHuang, Ying
Modeling, Control, and Adaptation for Shift Quality Control of Automatic Transmissions2019-01-11294/2/2019
The parameters determining shift quality control in automatic transmissions are determined as part of the calibration of the transmission control. The resulting control system typically has three components: feedforward control, where the control output is determined before a gearshift; feedback control, where the control output is determined during the gearshift based on sensed feedback; and learning control (adaptation), where the feedforward or feedback controller parameters are modified after the current gearshift has ended and before the next similar gearshift begins. Gearshifts involving the same ratio change are referred to here as similar gearshifts, though such gearshifts may involve differences in other variables such as vehicle speed or engine torque. In most automatic transmissions, gearshifts are controlled by hydraulic clutches, and operating conditions for these clutches may vary widely, requiring a dedicated transmission controller involving significant calibration effort. In the current work, novel model-based methods are used to accomplish feedforward control of gearshifts, involving offline calibration of fill and torque phase control parameters and learning control of the fill phase. Towards this end, a physics-based model of the oncoming clutch involved in an upshift of a production automatic transmission was developed and experimentally validated against test bench experiments for a wide variety of inputs and operating conditions. The resulting model is used to generate a feedforward controller, offline model-based calibration algorithm, and a learning controller that corrects for clutch under-fill and over-fill. The effectiveness of the resulting controller is validated by simulation studies using the experimentally validated transmission hydraulic system model, in conjunction with a powertrain model. In particular, it is demonstrated that the learning controller corrects for initial under- or over-fill error in two to three gearshifts. Convergence and robustness properties, and transient performance of the learning controller are also discussed.
Mishra, Kirti DeoCardwell, GilbertSrinivasan, Krishnaswamy
Commercial Truck and Bus SAE Recommended Procedure for Vehicle Performance Prediction and ChartingJ2188_201807 (Current)7/25/2018
This SAE Recommended Practice takes into account modern standardized methods for collecting and summarizing data that has an effect on vehicle steady-state performance, such as engine output (gross and net), transmission losses, drivetrain efficiency, vehicle aerodynamic devices for various vehicle and body configurations, as well as road surface variations and air density variations resulting from altitude and barometric effects. The procedure does not address vehicle transient performance (acceleration, braking, and cornering), because of the considerable amount of additional data required such as moment of inertia of all the rotating parts. Nor does it address vehicles with torque converters and automatic transmissions. This document is, therefore, intended for vehicles having fixed-ratio type transmissions and positive engagement clutches. Metric and ISO unit conversions are provided in the metric conversion tables at the end of this procedure (see Appendix B). Some modern vehicles with electronic engine controls have the ability to vary the maximum engine revolutions for each gear, as well as permitting the power or rpm to increase if more time is spent in the lower gears, as when climbing a grade. These special cases can be handled by this procedure, just by customizing the data for each transmission ratio and superimposing the long-term data on top of the instantaneous data. All of the equations are written in a form suitable for programming into a mainframe or desk-top computer, using a spreadsheet/database or a higher level language, such as Basic, Fortran, Pascal, C or Unix, etc. However, they are simple enough, to be performed on a hand-held calculator.
Truck and Bus Powertrain Committee
Structural Analysis Based Sensor Placement for Diagnosis of Clutch Faults in Automatic Transmissions2018-01-13574/3/2018
This paper describes a systematic approach to identify the best sensor combination by performing sensor placement analysis to detect and isolate clutch stuck-off faults in Automatic Transmissions (AT) based on structural analysis. When an engaged clutch in the AT loses pressure during operation, it is classified as a clutch stuck-off fault. AT can enter in neutral state because of these faults; causing loss of power at wheels. Identifying the sensors to detect and isolate these faults is important in the early stage of the AT development. A universal approach to develop a structural model of an AT is presented based on the kinematic relationships of the planetary gear set elements. Sensor placement analysis is then performed to determine the sensor locations to detect and isolate the clutch stuck-off faults using speed sensors and clutch pressure sensors. The proposed approach is then applied to a 10-Speed AT to demonstrate its effectiveness. A simulator is developed to qualitatively study the effects of clutch stuck-off faults on speeds of different elements in an AT. Simulator results are presented to support the sensor placement analysis. Later, a comparative analysis of different sensor sets based on the cost and performance is conducted to choose the optimal sensor combination. This paper concludes by discussing in detail the different sensor sets that give different fault isolation performance and suggests that only increasing number of sensors does not guarantee better fault isolation.
Deosthale, Eeshan VijayAhmed, QadeerArasu, MukilanRizzoni, GiorgioMohammed, MajedHathaway, Richard
Performance Optimization of Compressor Rotor Clutch Sub-assembly Using Electro- Magnetic Analysis2018-01-04844/3/2018
Rotor Clutch sub-assembly is one of the very important sub-assemblies (S/A) of an automotive compressor as it delivers the required torque/power to run the compressor. It mainly consists of rotor and bearing, stator, hub and armature. Rotor is rotated by engine pulley through belt drive system, while stator housing has got number of coils winded around stator slot. The hub sub-assembly is attached to the compressor shaft via spline arrangement and bolted across. When direct current (DC) is supplied to the terminal of the rotor, an electromagnetic field is generated which causes to attract the hub part towards rotor. Once the hub and rotor gets engaged each other, torque is transmitted to the compressor shaft which then helps to complete the suction and compression of refrigerant gas and thus making the vapor cycle run to produce adequate cooling in the air-conditioning (AC) system. Hence it is most important to ensure adequate and even distribution of electromagnetic field which is solely responsible for providing torque to the compressor. The present paper describes the numerical simulation of electromagnetic field of a clutch sub-assembly of an automotive compressor. ANSYS software was used to simulate the same. 2dimensional geometry of clutch rotor sub-assembly was created from computer aided design (CAD) tool and imported in suitable format. Meshing was performed using shell elements and the necessary material properties like permeability and B-H curve were defined along with the load conditions. The obtained flux density was then optimized by changing the shape and size of clutch sub-assembly. Further to this shaft torque was calculated analytically using the numerically obtained flux density and validated with the required torque for compression/suction process. The validation results exhibit a good trend and correlation, thus helping to develop a procedure to design clutch sub-assembly ‘first time right’ at the design stage. It is also ensured by this to have adequate torque delivered to the compressor.
Meena, AvadheshSen, Somnath
Inertial Continuously Variable Transmissions and Ways to Improve Their Performance2018-01-10594/3/2018
The inertial continuously variable transmissions are transmissions of mechanical type. They have a number of advantages in comparison with other types of transmissions. For example, they have a big value of the coefficient of efficiency, since the principle of their action does not imply the need to convert energy from one type to another one. These transmissions have a compact design, a wide range of torque transformation. They can operate in direct mode, smoothing the torsional vibrations in the system. At the moment when the output shaft is stopped, the input transmission shaft continues to rotate, that prevents the engine from overloading. There are other advantages. But despite these advantages, the inertial transmissions are not widely used in the automotive industry. The main reason for this is the inadequate durability of the freewheel mechanisms involved in the designs of the inertial transmissions. The paper considers some ways to improve the efficiency and durability of the inertial transmissions. Dynamics of the inertial transmissions is considered. For this purpose, physical and mathematical models of the inertial transmissions have been developed. The transmissions have a variable structure, nevertheless, new mathematical methods have been developed in the paper, which made it possible to describe the dynamics of the transmissions in the form of only one system of differential equations. On the basis of the developed mathematical model, periodic solutions of the system are constructed, and the external characteristic of the inertial transmissions is obtained. It is shown that the obtained external characteristic is close to ideal one. To increase the reliability and durability of the inertial transmissions, a new design of the overrunning clutches is proposed, which is distinguished by increased capacity of operating. The proposed design has a new principle of activity. It is shown that the load on the details of the developed overrunning clutches can be reduced in several times in comparison with the existing designs of overrunning clutches. A mathematical model of the proposed design of the overrunning clutches is investigated in this paper. Periodic solutions of the systems of differential equations that describe the dynamics of the overrunning clutches with the new principle of action are constructed. It is shown that the application of the proposed design allows increasing significantly the durability of the inertial transmissions. In this paper computer simulation was carried out, which confirmed the correctness of the results of the theoretical studies.
Aliukov, SergeiKeller, AndreiAlyukov, Alexander
Derivation of Test Schedule for Clutch Using Road Load Data Analysis and Energy Dissipation as Basis2018-01-04044/3/2018
During every clutch engagement energy is dissipated in clutch assembly because of relative slippage of clutch disc w.r.t. flywheel and pressure plate. Energy dissipated in clutch is governed by many design parameters like driveline configuration of the vehicle vis-a-vis vehicle mass, and operational parameters like road conditions, traffic conditions. Clutch burning failure, which is the major failure mode of clutch assembly, is governed by energy dissipation phenomenon during clutch engagement. Clutch undergoes different duty cycles during usage in city traffic, highways or hilly regions during its lifetime. A test schedule was derived using energy dissipated during every clutch engagement event as a base and using road load data collected on the vehicle. Road load data was collected in different road mix conditions comprised of city traffic, highway, hilly region, rough road for few hundred kilometers. Using this data clutch energy was calculated in all the clutch engagement events observed in road load data. Cumulative energy calculated from all these events was extrapolated for stated life of the clutch, for vehicle application under consideration. A test cycle was derived considering maximum energy dissipated in engagement events, clutch engagement pattern and maximum temperature observed inside clutch housing, for rig testing. The life predictions and failure modes observed with this test schedule were evaluated against the field vehicles and it showed a good correlation. This paper proposes a methodology to derive test schedule for clutch life prediction based on energy dissipated in clutch and using road load data. The test on the rig with such schedules provides better avenues to shorten the development time line of clutch system as well as vehicle driveline.
Mohire, SujitUttamani, RahulTendulkar, VishveshvarKatarki, ShrirangPatil, Shahaji
Electronic Bi-Directional Shift Control Design and Calibration for Farm Vehicle2017-01-220510/8/2017
Agricultural tractors are often subjected to various applications like front end loading work, cultivation work, where frequent forward and reverse gears are needed. Most of Indian agricultural tractors are equipped with mechanical transmission system which demands repeated clutching and de-clutching operation for such applications resulting in increased operator fatigue and lesser productivity. Also need of electronics in Indian agricultural industry for better farm mechanization is growing high. This research work depicts development of electronic bi-directional shifting (power shuttle) control design and calibration for farm vehicle fitted with wet clutch transmission. This research also reduces operator fatigue via frequent directional shift through electronic transmission. The control system is designed without any electronic interfacing with engine and also provides clutch-less gear shifting and auto-launch which offers ease to drive even for novice driver. The power shuttle transmission control system offers more functionality and features in adjunct to in-built safety features without any additional sensors or components. Use of minimal sensor for system control and calibration delivers cost effect solutions. Adaptive control strategy is adopted for achieving efficient and optimal clutch fill modulation which is calibrateable for various climatic zone, vehicle loads, gears etc. Control software is designed by considering the vehicle variants pertinent to clutch load and engine characteristics. Modular control system design is employed in this research which can be extended across all tractor variants.
M A, VelmuruganRajagopal, MahendraMohan
Modeling of Dynamic Processes for Inertial Continuously Variable Transmissions2017-01-10603/28/2017
The inertial continuously variable transmissions are mechanical transmissions that are based on the principle of inertia. These transmissions have a lot of advantages. Usually, the design of the inertial continuously variable transmissions consists of inertia pulsed mechanism with unbalanced inertial elements and two overrunning clutches. Dynamics of the transmissions is described by systems of substantial nonlinear differential equations. In general, precise methods of solution for such equations do not exist. Therefore, in practice, approximate analytical and numerical methods must be employed. The main analytical methods employ successive approximation, a small parameter, or power series expansion. Each approach has its advantages and disadvantages. Therefore, we need to compare them in order to select the best method for dynamic study of such kind of transmissions. In this paper a comparative analysis of approximate methods of solving of differential equations for the inertial continuously variable transmissions is done. The object of the investigation is structural dynamics of the continuously variable automatic inertial mechanical transmissions. Approximate methods of solving the nonlinear differential equations of motion of inertial transmissions based on a pulsed mechanism are compared. These methods take account of the no uniform driveshaft rotation and the dynamic characteristics of the motor. Analysis of the solutions reveals the best method for dynamic study of the given transmissions. The comparative analysis showed that the best method of approximate solution is the method of a small parameter.
Aliukov, SergeiKeller, AndreiAlyukov, Alexander
Analysis of Methods for Solution of Differential Equations of Motion of Inertial Continuously Variable Transmissions2017-01-11053/28/2017
The inertial continuously variable transmissions are mechanical transmissions that are based on the principle of inertia. These transmissions have a lot of advantages. Usually, the design of the inertial continuously variable transmissions consists of inertia pulsed mechanism with unbalanced inertial elements and two overrunning clutches. Dynamics of the transmissions is described by systems of substantial nonlinear differential equations. In general, precise methods of solution for such equations do not exist. Therefore, in practice, approximate analytical and numerical methods must be employed. The main analytical methods employ successive approximation, a small parameter, or power series expansion. Each approach has its advantages and disadvantages. Therefore, we need to compare them in order to select the best method for dynamic study of such kind of transmissions. In this paper a comparative analysis of approximate methods of solving of differential equations for the inertial continuously variable transmissions is done. The object of the investigation is structural dynamics of the continuously variable automatic inertial mechanical transmissions. Approximate methods of solving the nonlinear differential equations of motion of inertial transmissions based on a pulsed mechanism are compared. These methods take account of the no uniform driveshaft rotation and the dynamic characteristics of the motor. Analysis of the solutions reveals the best method for dynamic study of the given transmissions. The comparative analysis showed that the best method of approximate solution is the method of a small parameter.
Aliukov, SergeiAlyukov, Alexander
Estimation of the Clutch Characteristic Map for an Automated Wet Friction Clutch Transmission2016-01-11134/5/2016
Higher demands on comfort and efficiency require a continuous improvement of the shift process. During the launch and shift process the clutch control is used to get a smooth and efficient behavior. In this short time of acting the shifting behavior can be rated. Many control concepts use a clutch characteristic to calculate the actuator signal based on the clutch torque. Therefore, a high quality of this characteristic is necessary. Because of the dynamic process during clutch engagement the clutch characteristic needs further information to reach a high accuracy for the control algorithm. In this paper an existing clutch torque characteristic is extended to a characteristic map where the clutch torque becomes a function of the current actuator signal of the clutch and the clutch slip. The extension of the torque characteristic describes the slip based dependencies, e.g. the friction coefficient. The model of the characteristic map consists of the multiplication of two separate functions in these two dimensions. The parameters of this model are estimated using different identification algorithms, in this case a non-linear recursive and a non-recursive identification algorithm. Both estimation algorithms result in a characteristic map of the clutch behavior. A further advantage of the presented approach is the normalization during the estimation process of the slip-based function with the cost function. Thus, the original torque characteristic can be used as fallback if the identification of the slip-based part still need reference data to converge or shows an implausible behavior.
Arndt, ThorstenTarasow, AlexBohn, ChristianWachsmuth, GuidoSerway, Roland
Commercial Truck and Bus SAE Recommended Procedure for Vehicle Performance Prediction and ChartingJ2188_201510 (Historical)10/21/2015
This SAE Recommended Practice takes into account modern standardized methods for collecting and summarizing data that has an effect on vehicle steady-state performance, such as engine output (gross and net), transmission losses, drivetrain efficiency, vehicle aerodynamic devices for various vehicle and body configurations, as well as road surface variations and air density variations resulting from altitude and barometric effects. The procedure does not address vehicle transient performance (acceleration, braking, and cornering), because of the considerable amount of additional data required such as moment of inertia of all the rotating parts. Nor does it address vehicles with torque converters and automatic transmissions. This document is, therefore, intended for vehicles having fixed-ratio type transmissions and positive engagement clutches. Metric and ISO unit conversions are provided in the metric conversion tables at the end of this procedure (see Appendix B). Some modern vehicles with electronic engine controls have the ability to vary the maximum engine revolutions for each gear, as well as permitting the power or rpm to increase if more time is spent in the lower gears, as when climbing a grade. These special cases can be handled by this procedure, just by customizing the data for each transmission ratio and superimposing the long-term data on top of the instantaneous data. All of the equations are written in a form suitable for programming into a mainframe or desk-top computer, using a spreadsheet/database or a higher level language, such as Basic, Fortran, Pascal, C or Unix, etc. However, they are simple enough, to be performed on a hand-held calculator.
Truck and Bus Powertrain Committee
Design of an Eddy Current Torque Bypass Clutch for Seamless Automated Manual Transmissions of Electric and Hybrid Vehicles2015-01-91437/1/2015
This paper presents the design and experimental validation of an eddy current torque transfer clutch for use inside Automated Manual Transmissions (AMTs) to perform seamless gear upshifts. Electric vehicles (EVs) with a single-ratio gearbox may provide high levels of smoothness, but using a multi-speed gearbox provides significant benefits in terms of vehicle acceleration, top speed, powertrain cost, mass, and energy consumption. AMTs can provide smooth shifts without torque interruption when coupled to a normally-open torque bypass clutch. However, conventional dry friction clutches are not best suited for such torque bypass due to wear and controllability concerns, while wet clutches would decrease powertrain efficiency due to viscous losses. An eddy current clutch would be highly controllable, simple to manufacture, low-cost, robust, and do not wear compared to friction clutches. The potential of eddy current clutches is assessed from a representative case study consisting of a ∼190 Nm clutch for a seamless two-speed AMT. The clutch design is based upon Wouterse's model, which is further refined using a Finite Element Analysis (FEA) on the clutch magnetic circuit. A prototype clutch is built and installed inside an existing AMT. The measured clutch coupling torque agrees well with Wouterse's model results, with a maximum error of 6%. The AMT performed seamless gear upshifts on a test bench thanks to the eddy current clutch, which confirms their viability for torque bypass.
Pouliot, GabrielLacerte, Marc-OlivierPlante, Jean-SebastienMicheau, Philippe
A Low Cost System for Active Gear Shift and Clutch Control2015-01-02284/14/2015
The objective of this study is to demonstrate the design and construction of an innovative active gear-shift and clutch for racecars, applied to a Formula Student car, based on the use of DC gear-motors. Racecars require extremely quick gear-shifts and every system to be as light as possible. The proposed solution is designed to reduce energy consumption, weight and improve gear-shift precision compared to traditionally employed electro-hydraulic solutions, although maintaining state of the art performances. The proposed gear motor actuation satisfies all the above objectives: energy can be saved by removing the need for power when clutch is not pulled, thus improving efficiency; by substituting the entire electro-hydraulic-systems, that accounts for approx. 5% of the overall car weight (10kg); a significant weight reduction is achieved (weight is reduced to 2kg); a fine actuation force modulation, in order to properly shift to neutral, can easily obtained with an DC electric motor; and, above all, shifting time is less than 20ms. System modeling, regulator design, based on PI-control, and simulation were carried out. Electronics, both signal and power, micro-controller based design and program coding, written in C language, were the next steps. Finally, accurate tests to validate the solution and assess performances were carried out.
Braghin, FrancescoSalis, Francesco
Dry Dual Clutch Transmission (DCT) Thermal Model2015-01-11444/14/2015
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
Normally-Engaged Dual-Piston Clutch for Engine Stop-Start Application2015-01-11414/14/2015
For the conventional 6 speed automatic transmission with engine stop-start powertrain, an electrically-driven auxiliary pump is implemented to maintain the transmission line pressure as required to lock-up the CB1234 clutch during engine auto-stop conditions. Upon releasing the brake pedal, the transmission engages into first gear with the objective to accelerate the vehicle in a responsive manner. In this study, a novel normally-engaged dual-piston clutch concept is designed to keep the CB1234 clutch locked-up during engine auto-stop conditions with the intention to eliminate the auxiliary pump without compromising vehicle performance. This dual piston clutch concept requires a relatively low line pressure to release the normally-engaged clutch when needed, thus, minimizing the hydraulic pumping work. To explore the functionality of this concept under a wide-open-throttle (WOT) auto-start transition, modeling and simulation of the normally-engaged dual-piston clutch is completed. A component-level model of the dual-piston clutch and preloaded Belleville spring is developed in the AMESim environment. The model is refined and validated by comparing the simulated results with spin rig performance data. Important dynamic features, including the CB1234 clutch pressure and release pressure profiles are predicted and explained. The developed component model is integrated into a vehicle model and validated by comparing simulation and vehicle test data under auto-start conditions. Using the validated model, a parametric study is conducted to examine the effect of the hydraulic orifice size in the release piston fluid passage. The study identified the appropriate orifice size requirements, illustrating that the normally engaged dual-piston clutch has potential to lock-up the CB1234 clutch under wide-open-throttle auto-start condition.
Duan, ChengwuSamie, FarzadHebbale, KumaraswamyLi, DongxuLee, Chunhao
The Performance Study of Air-Friction Reduction System for Hydraulic Retarder2014-01-22839/30/2014
The hydraulic retarder, which is an auxiliary brake device for enhancing traffic safety, has been widely used in kinds of heavy commercial vehicles. When the vehicle equipped with the retarder is traveling in non-braking state, the transmission loss would be caused because of the stirring air between working wheels of the rotor and the stator no matter if the retarder connects in parallel or in series with the transmission [1]. This paper introduces an elaborate hydraulic retarder air-friction reduction system (AFRS) which consists of a vacuum generating module and pneumatic control module. AFRS works to reduce the air friction by decreasing the gas density between working wheels when the retarder is in non-braking state. The pneumatic control model of hydraulic retarder is built first. Then various driving conditions are considered to verify the performance of the AFRS. The stability of the AFRS is analyzed based on the complete driveline model. And the vacuum power of AFRS and the air-friction of retarder are analyzed comprehensively. On the basic of the whole vehicle driving cycle, the fuel economy of the vehicle equipped with AFRS is studied. The result indicates that the performance and stability of the AFRS could meet the system requirement in different driving condition. Comparing with traditional hydraulic retarder, the transmission loss could be reduced by 60% and the fuel consumption decreases by 5%.
Wang, CanTan, GangfengYang, BoChen, MingWei, FudongNi, Yabei
New Gear Locking Design in Synchromesh Gearbox Which Reduces Gear Shift Effort2014-01-23289/30/2014
This paper introduces a new design for the synchromesh gear boxes, which serves dual purpose of economizing the production cost and time of the gears manufacturing and enhancing the shift experience by reducing the shift effort. This is achieved by making changes in the “Entry chamfers” which are the angles placed on the shift sleeve and gear dog teeth, and the “Back Taper Angle” also placed on the shift sleeve and gear dog teeth. In the new design the “Entry chamfer angles” is reduced from 120° (in the existing design) to 90° and is made “Un-symmetric” from “Symmetric”. This help in reducing the shift effort, hence enhancing the shift experience by making it smooth. Another change is the “Back Taper Angle”, which is eliminated from the sleeve and the gear dog teeth and is repositioned on the hub, keeping all other important design parameters like strut / insert design, gear cone angle, gear cone finish, number of cones, cone friction material the same. The new design ensures that the change in back taper angle position does not compromise its function of avoiding the “Gear jump out”. As per existing design for making the back taper angle on the sleeve and gear dog teeth special machining operations are required which increase the production cost and time. But according in new design for making the same angle (back taper angle) on the hub, only simple machining operations are enough. There is no need of any special machining operation, so this helps in reducing the production cost and time in making gears.
Singh, JagjeetSingh, Gagandeep
On the Question of External Characteristic of the Inertial Continuously Variable Transmission2014-01-17334/1/2014
The inertial continuously variable transmission is a mechanical transmission which is based on the principle of inertia. This transmission has a lot of advantages, namely: compactness, minimum friction losses and high efficiency as a result of the relatively small number of rotating components, a wide range of transformation of the torque. It does not need any conventional friction clutches. This transmission protects the engine from overload when the output shaft is braked. This drive guarantees optimum conditions of work for the engine regardless of the changing of load, and smoothly changes output speed according to the load. Mostly, design of this transmission consists of a pulsed mechanism with unbalanced inertial units and two one-way clutches. The pulsed mechanism is well developed and possesses high reliability. However, the one-way clutches are the most unreliable parts of the transmission and restrain wide use of the transmission. In this paper a new design of the inertial transmission with the only one-way clutch is considered. This transmission provides a higher level of the load ability. The object of the investigation is the external characteristic of the inertial transmission with the only one-way clutch. The physical and mathematical models of this transmission are used. Besides, periodic solutions of the equations were received by means of the numerical methods. It was shown that the resulting external characteristic is close to an ideal one.
Aliukov, SergeiGorshenin, Vladimir
Development and Implementation of Hardware in the Loop Simulation for Dual Clutch Transmission Control Units2013-01-08164/8/2013
A control oriented model of a Dual Clutch Transmission was developed for real time Hardware In the Loop (HIL) applications. The model is an innovative attempt to reproduce the fast dynamics of the actuation system maintaining a step size large enough for real time applications. The model comprehends a detailed physical description of hydraulic circuit, clutches, synchronizers and gears, and simplified vehicle and internal combustion engine sub-models; a stable real time simulation is achieved with a simplification of the model without losing physical validity. After an offline validation, the model was implemented in a HIL system and connected to the TCU (Transmission Control Unit) via two input-output boards, and to a load plate which comprehends all the actuators. The paper presents a selection of the several tests that have been performed for the development of the DCT controller: electrical failure tests on sensors and actuators, mechanical failure tests on hydraulic valves, clutches and synchronizers, and application tests comprehending all the main features of the control performed by the TCU, i.e. drive away and gear shift strategies, and interactions with the driver. Furthermore, the paper shows that the model is capable of reproducing the behavior of the real system during adaption procedures performed by the TCU under particular conditions, i.e. synchronizer position detection and clutch pressure characteristic detection. Being based on physical laws, in every condition the model simulates a plausible reaction of the system to the imposed failure or maneuver, as demonstrated by the possibility of performing a complete new software release test in fully automatic mode.
Cavina, NicoloOlivi, DavideCorti, EnricoMancini, GiorgioPoggio, LucaMarcigliano, Francesco
Commercial Truck and Bus SAE Recommended Procedure for Vehicle Performance Prediction and ChartingJ2188_201207 (Historical)7/31/2012
This SAE Recommended Practice takes into account modern standardized methods for collecting and summarizing data that has an effect on vehicle steady-state performance, such as engine output (gross and net), transmission losses, drivetrain efficiency, vehicle aerodynamic devices for various vehicle and body configurations, as well as road surface variations and air density variations resulting from altitude and barometric effects. The procedure does not address vehicle transient performance (acceleration, braking, and cornering), because of the considerable amount of additional data required such as moment of inertia of all the rotating parts. Nor does it address vehicles with torque converters and automatic transmissions. This document is, therefore, intended for vehicles having fixed-ratio type transmissions and positive engagement clutches. Metric and ISO unit conversions are provided in the metric conversion tables at the end of this procedure (see Appendix B). Some modern vehicles with electronic engine controls have the ability to vary the maximum engine revolutions for each gear, as well as permitting the power or rpm to increase if more time is spent in the lower gears, as when climbing a grade. These special cases can be handled by this procedure, just by customizing the data for each transmission ratio and superimposing the long-term data on top of the instantaneous data. All of the equations are written in a form suitable for programming into a mainframe or desk-top computer, using a spreadsheet/database or a higher level language, such as Basic, Fortran, Pascal, C or Unix, etc. However, they are simple enough, to be performed on a hand-held calculator.
Truck and Bus Powertrain Committee
High Efficiency, Hydro-Mechanical Passenger Vehicle Transmission using Fixed Displacement Pump/Motors and Digital Hydraulics2012-01-06244/16/2012
It is widely accepted that the plug-in hybrid vehicle is the most economically viable near-term solution to the petroleum and CO₂ problems associated with passenger vehicles. The battery and electrics costs of gas/electric plug-in hybrid vehicles can be significantly reduced with the use of a hydraulic transmission and the implementation of hydraulic regenerative braking. This has not been done to date due to the unavailability of a low cost, reliable, compact, and efficient hydraulic transmission. This paper describes a conceptual design of such a transmission and evaluates its performance using the attributes of existing components. The main causes of the lack of past success with hydraulic transmissions are the many drawbacks of variable-displacement hydraulic pumps and motors. This transmission is based on fixed displacement pumps and motors to avoid these drawbacks. The efficiency of the transmission is evaluated under various driving conditions and is equal to or better than present day automatic transmissions due in part to the use of an all-mechanical bypass when cruising. The transmission is configured to allow a continuously variable level of braking torque. The design, construction and performance of this digital hydraulic transmission are detailed. The use of internal gear type pump/motors results in a small size that will allow the transmission to fit within the outline of a typical SUV transmission, offering a low cost way to convert existing vehicles to hybrids. The required accumulator size is discussed. The design eliminates the need for either a friction clutch or torque converter and is scalable such that it is applicable from compact cars to large trucks and buses. A variation is described that is suitable for adding hydraulic regenerative braking to an all-electric vehicle. The technical trend in hydraulic pumps and motors is to higher operating pressures and speeds. Both these trends result in proportional reductions in the size and cost of this style of transmission and increased power handling capability.
Lloyd, Robert H.F.
Parametric Importance Analysis and Design Optimization of a Torque Converter Model Using Sensitivity Information2012-01-08084/16/2012
Torque converters are used as coupling devices in automobile powertrains involving automatic transmissions. Efficient modeling of torque converters capturing various modes of operation is important for powertrain design and simulation, (Hroval and Tobler 1, Ishihara and Emori 2) optimization and control applications. Models of torque converters are available in various commercial simulation packages, Hadi et. al. 3. The information about the effect of model parameters on torque converter performance is valuable for any design operation. In this paper, a symbolic sensitivity analysis of a torque converter model will be presented. Direct differentiation (Serban and Freeman 4) is used to generate the sensitivity equations which results in equations in symbolic form. By solving the sensitivity equations, the effect of a perturbation of the model parameters on the behavior of the system is determined. A parametric importance analysis is performed on the model: the model parameters are arranged according to their effect on the amount loss of energy during the operation of the torque converter. The radii of the pump, turbine and stator, the density of the hydraulic fluid and the exit angle of the vanes of the stator were found to have the most significant effects on the model. Using the sensitivity information, a design optimization problem is defined and solved to obtain a set of parameter values that minimizes the energy lost during the torque converter operation.
Banerjee, JoydeepAdibi asl, HadiLashgarian Azad, NasserMcPhee, John
Method for Identification of the Kiss Point as well as Takeoff Point of a Hydraulically Actuated Friction Clutch2012-01-01124/16/2012
For control of most automatic transmissions with wet clutches (e.g. dual clutch transmission), it is important to know the kiss point with high accuracy. The kiss point describes the value of the control variable for which the friction clutch begins to transmit torque. Another significant value during the filling process of a wet clutch is the takeoff point. This is the hydraulic pressure which causes the clutch piston to begin to move. This paper presents an innovative approach that enables the joint determination of the kiss point as well as the takeoff point in only one identification procedure. In contrast to existing methods, this method is able to identify both points without the necessity for undesired auxiliary system excitation. Therefore it is possible to reduce wear on system components such as synchronization rings. The method presented in this paper analyzes the measured filling pressure characteristic over time as the system response to a defined excitation. The innovation of this method consists of dividing this pressure characteristic into three phases, where the separation is motivated by physical considerations. Each of these phases is approximated by appropriate linear and nonlinear functions. With the help of offline methods for system identification, the parameters of the approximation function are adjusted to reach the optimal approximation of the pressure characteristic. The takeoff point and the kiss point are distinct points between the approximating functions of the neighboring phases of the filling pressure characteristic. These points can be analytically determined for all phases of the characteristic. The choice of a suitable identification method has to take into account the electronic control units used for transmission control in modern vehicles and the capabilities they have. These methods are designed to work with noisy signals and allow for the accurate determination of the system parameters.
Tarasow, AlexBohn, ChristianWachsmuth, GuidoSerway, RolandEisbach, MarcelZhao, QiBauer, Georg
Independent Power Take Off (IPTO) with Mechanically Operated Multiplate Wet Clutch for Agricultural Tractors2010-01-198210/5/2010
Tractors along with implements are used to prepare the soil. There are two broad classification in implements attached, one is passive or trailed implements and other one is active tilling implements which will take drive from engine through Power Take Off (PTO). The drivelines for transmission and PTO should have clutches to engage / disengage them from the engine while changing gears and switching PTO On/Off respectively. In present scenario, there are independent clutches for both drivelines to operate PTO driven implements without disrupting vehicle speed. In general, IPTO is being achieved by dry clutch which is integral with engine mounted clutch operated by separate linkages or by hydraulically operated wet clutch located in PTO driveline after auxiliary pump. An attempt is made with mechanically operated wet clutch in the PTO driveline to have an IPTO. Design proposals for mechanically operated multiplate wet clutch and linkage mechanism for engagement/disengagement were generated by considering the design targets to be met and having equivalent performance as that of hydraulically operated wet clutch. A mathematical model for drag torque based on Newton's law of viscosity is developed. The drag torque increases linearly with increasing speed at low speed region. However; in actual case, drag torque decreases with increasing rotational speed at high speed range due to the lower coefficient of viscosity of interface oil. This is attributed to the air trapped between friction disc and separator disc. Hence, the law of viscosity cannot be used to explain this (high speed range i.e. greater than 1500) phenomenon. The torque response is calculated by determining the hydrodynamic torque and asperity torque as a function of oil film thickness and time by another mathematical model. Actual torque transmitted is increased to a maximum value of 390 Nm within 0.8 to 1.2 second where as the simulated torque response value is approximately 1.3 seconds. Parameters like force required to disengage the clutch, oil temperature rise were also compared with test results.
Range Gounder, RamarajSriraman, SethuramanVerma, Rakesh
Shudder Durability of a Wet Launch Clutch Part II - Durability Study2009-01-03304/20/2009
Under the initiative of the United States Council for Automotive Research LLC (USCAR§) Transmission Working Group, a collaborative effort was made with LuK USA LLC to study the influence of the friction interface parameters on the shudder durability of a wet launch clutch. Clutch configurations with different combinations of four friction materials (A, B, C and D), three groove patterns (waffle, radial and waffle-parallel) and two separator plate conditions (nitrided and non-nitrided) were considered. Durability testing consisted of a test profile, with 110 kJ energy per test cycle, developed earlier in this project. Materials A, B and C with nitrided separator plates reached the end of test criteria for the torque gradient and showed shudder. Materials B and C were more wear resistant as compared to materials A and D. The loss of friction coefficient (μ) was lower for materials B, C and D as compared to material A. Material D showed good friction properties but failed via material break-out. The radial groove pattern showed lower wear and μ loss but higher pore plugging than the waffle and the waffle-parallel pattern. Materials C and D showed lowest pore plugging. The durability life of the waffle-parallel pattern was lower than the waffle and the radial groove pattern. The non-nitrided separator plates showed high μ loss and high wear although they did not show shudder. Reducing the friction contact area by 50% showed significant μ loss, wear, pore plugging and black spotting due to heat on the separator plates.
Jafri, Firoz AliFuß, MartinBailey, GeorgeKao, Chi-KuanRazzacki, Syed T.Avny, Eli
Shudder Durability of a Wet Launch Clutch Part I – Thermal Study and Development of Durability Test Profile2009-01-03294/20/2009
Under the initiative of the United States Council for Automotive Research LLC (USCAR§) Transmission Working Group, a collaborative effort was made with LuK USA LLC to study the influence of the friction interface parameters on the shudder durability of a wet launch clutch. A test bench was designed. Clutch configurations with different combinations of four friction materials (A, B, C and D), three groove patterns (waffle, radial and waffle–parallel) and two separator plate conditions (nitrided and non–nitrided) were considered. Considerable improvement in performance was seen by changing from CVT fluid* to DCT fluid*. A thermal analysis based on thermal model predictions and measurement correlations was conducted. Comparisons of clutch configurations with four and five friction plates were done. The waffle and radial groove pattern showed better heat transfer than the waffle–parallel groove pattern. The friction material type and separator plate conditions do not show any significant influence. The separator plate temperatures were the highest for the waffle–parallel pattern. Using this analysis, a test profile with 110 kJ energy per test cycle and four friction plate configuration was developed for durability testing.
Jafri, Firoz AliFuß, MartinBailey, GeorgeKao, Chi–KuanRazzacki, Syed T.Avny, Eli
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