Browse Topic: Front wheel drive

Items (180)
This SAE Recommended Practice covers power transfer units (PTUs) used in passenger car and sport utility vehicles to support all wheel drive (AWD) operation. PTUs are typically full-time use geared devices (see 3.1). Some PTUs have additional features such as part-time on-demand capability via electronically actuated disconnect features, and other configurations are possible.
Drivetrain Standards Committee
Research on Technique for Correction of Running Resistance with Focus on Tire Temperature and Tire Thermal Balance Model2019-01-06234/2/2019
At present, measurements of running resistance are conducted outdoors as a matter of course. Because of this, the ambient temperature at the time of the measurements has a considerable impact on the measurement data. The research discussed in this paper focused on the temperature characteristic of the tires and developed a new correction technique using a special rolling test apparatus. Specifically, using a tire rolling test apparatus that made it possible to vary the ambient temperature, measurements were conducted while varying the levels of factors other than temperature that affect rolling resistance (load, inflation pressure, and speed). Next, a regression analysis was applied to the data for each factor, and coefficients for a relational expression were derived, making it possible to derive a quadratic equation for the tire rolling resistance correction formula. It was verified that the application of the new correction formula reduced variation in running resistance from 2.7% (in the case of regulation correction) to 1.0%. In addition, in order to offer a simpler method of realizing the same correction, a technique for correction using a conventional tire rolling test apparatus and based on the material characteristics of the tire tread rubber was also developed. It was verified that this method allowed the same degree of correction. Giving consideration to the application of the method to future tire modeling, the development of heat generation and dissipation models for tire rolling tests was also examined. The addition of terms for the temperature characteristic of the tread rubber and heat generation and dissipation between the tire and the drum reduced error between measured and predicted values to ±0.6%.
Hotaka, TakeshiSakai, TomonoriMiura, Hideki
Explanation for Variability in Lower Frequency Structure-Borne Noise and Vibration: Roles of Rear Subframe Dynamics and Right-Left Spindle Phasing10-02-01-00025/17/2018
This investigation focuses on a class of rear suspension systems that contain both direct and intersecting structural paths from the tire contact patches to the vehicle body. The structural paths intersect through a dynamically active rear subframe structure. New experiments and computational models are developed and analyzed in this article to investigate the variability of structure-borne noise and vibration due to tire/road interactions in the lower- to mid-frequency regimes. Controlled operational experiments are conducted with a mass-production minivan on a chassis dynamometer equipped with rough road shells. Unlike prior literature, the controlled experiments are analyzed for run-run variations in the structure-borne noise up to 300 Hz in a single vehicle to evaluate the nature of excitations at the spindle as the key source of variation in the absence of significant manufacturing, assembly and instrumentation errors. Further, a deterministic modal expansion approach is used to examine these variations. Accordingly, an illustrative eleven-degree-of-freedom lumped parameter half vehicle model is developed and analytically utilized to demonstrate that left-right spindle excitation phasing dictates the participation of the subsystem vibrational modes in the system forced response. The findings are confirmed through the analysis of a reduced finite element model of the vehicle system with a high-fidelity, modally dense suspension model, where the left-right rolling excitation phasing at the spindle alone is found to affect the component dynamic vibration amplitudes up to ±30 dB depending upon the component location and frequency range. These results are in qualitative agreement with the type of variations observed in the experiments.
Noll, ScottSingh, Rajendra
In this SAE Recommended Practice, attention will be given to passenger cars and light trucks (through Class III).
Drivetrain Standards Committee
Simulation Based Control Strategy Design of All Wheel Drive Electric Vehicle Regenerative Braking System2018-01-04114/3/2018
Maximising the recovered regenerative braking energy during the deceleration can significantly reduce the Electric Vehicle (EV) energy consumption and increase the range. Compared with the Front Wheel Drive (FWD) or Rear Wheel Drive (RWD) EV, an All Wheel Drive (AWD) EV with 2 electric machines (e-machines) has more control degree freedom when developing the regenerative braking control strategy. By implementing the regenerative braking at the front axle, rear axle, or at the front and rear axles simultaneously, the amount of recovered kinetic energy will be affected. Furthermore, the e-machines at the front and rear axle in the AWD EV can have different sizes or be the same. Therefore, the ratio between front and rear e-machine power rating should also be investigated to understand its effect on the amount of recovered energy during deceleration. This paper starts with the analysis of the vehicle braking behaviour compared over different driving cycles, and the comparison of two configurations of regenerative braking system, Category A and B. Then, the AWD EV is modelled, and its regenerative braking controller is developed using Ricardo in-house, proprietary simulation tools. The power rating of front and rear axle e-machines in this model is varied. The regenerative braking controller simulates Category A or B regenerative braking system with various control strategies (such as front axle or rear axle only regenerative braking, and all wheel regenerative braking). Simulation is done to investigate: 1) the difference in recovered energy by implementing the regenerative braking at different axles with Category A or B systems, and 2) how the ratio between the front and rear axle e-machine power rating affects the amount of recovered regenerative braking energy. This in turn affects the overall brake balance distribution and impacts upon vehicle stability. Finally, the simulation result is analysed and discussed.
Bao, RanGriggs, PhilipBaxter, James
A Study on Reducing Gear Rattle Noise Based on Sensitivity Analysis of Drivetrain Torsional Model2017-01-17796/5/2017
With drastically reduction of engine noise, the gear rattle noise generated by the impact between neutral gears inside transmission can be much easily perceived. It is well known that the torsional mode has a direct relationship with the transmission gear rattle noise. This paper establishes a torsional model of a front wheel drive automotive drivetrain, including clutch system, transmission box and equivalent load of a full vehicle, in AMESim software. The experimental engine speed fluctuations at different gears are used to excite the torsional model. The influences of several parameters, including flywheel inertia, clutch stiffness, clutch hysteresis and drive shaft stiffness, on the 2nd order (major engine firing order for a 4-cylinder-4-stroke engine) torsional resonant frequency and the 2nd order torsional resonant peak of the transmission input shaft are analyzed by changing them alternatively. The model is validated by a comparison between the simulated and measured 2nd torsional resonant peaks. It is concluded that the optimized drivetrain parameters reduce the 2nd order torsional resonant peak of the transmission input shaft effectively. Some control strategies are successfully applied to a prototype vehicle to reduce the gear rattle noise which meets the subjective evaluation criterion.
Yang, XianwuPang, JianWang, LanjunTian, XiongTang, Yu
Value of Optimal Wavelet Function in Gear Fault Diagnosis2017-01-17716/5/2017
Gear fault diagnosis is important in the vibration monitoring of any rotating machine. When a localized fault occurs in gears, the vibration signals always display non-stationary behavior. In early stage of gear failure, the gear mesh frequency (GMF) contains very little energy and is often overwhelmed by noise and higher-level macro-structural vibrations. An effective signal processing method would be necessary to remove such corrupting noise and interference. This paper presents the value of optimal wavelet function for early detection of faulty gear. The Envelope Detection (ED) and the Energy Operator are used for gear fault diagnosis as common techniques with and without the proposed optimal wavelet to verify the effectiveness of the optimal wavelet function. Kurtosis values are determined for the previous techniques as an indicator parameter for the ability of early gear fault detection. The comparative study is applied to real vibration signals. First, to eliminate the frequency associated with interferential vibrations, the vibration signal is filtered with a band-pass filter determined by a Morlet wavelet whose parameters are optimized based on maximum Kurtosis. Then, to further reduce the residual in-band noise and highlight the periodic impulsive feature, an envelope analysis enhancement algorithm is applied to the filtered signal. The test stand is equipped with three dynamometers; the input dynamometer serves as the internal combustion engine, the output dynamometers introduce the load on the output joint shaft flanges. The gearbox used for experimental measurements is the type most commonly used in modern small to mid-sized passenger cars with transversely mounted powertrain and front wheel drive.
El morsy, MohamedAchtenova, Gabriela
Optimization of Front Wheel Drive Engine Mounting System for Third Order Shudder Improvement2017-01-91754/11/2017
Nowadays, the vehicle design is highly ruled by the increasing customer demands and expectations. In addition to ride comfort and vehicle handling, the Noise, Vibration and Harshness (NVH) behavior of the powertrain is also a critical factor that has a big impact on the customer experience. To evaluate the powertrain NVH characteristics, the NVH error states should be studied. A typical NVH event could be decoupled into 3 parts: source, path, and receiver. Take-off shudder, which evaluates the NVH severity level during vehicle take-off, is one of the most important NVH error states. The main sources of Front Wheel Drive (FWD) take-off shudder are the plunging Constant Velocity Joints (CVJ) on the left and right half shafts. This is because a plunging CVJ generates a third order plunging force with half shaft Revolution Per Minute (RPM), which is along the slip of the plunging CVJ. The primary path of take-off shudder is the Engine Mounting System (EMS), which isolates the vibration inputs from the vehicle body. A typical receiver of shudder is the passenger seat, so seat track acceleration and velocity are usually chosen to be the design objective for vehicle NVH optimization. This paper presents the optimization of FWD engine mounts for third order shudder improvement. Pointer automatic optimizer is used to perform the optimization with respect to a large number of design variables.
Zhu, YitaoAddepalli, KalyanRemisoski, NatalieDatar, Makarand
Optimal Tire Force Control & Allocation for Longitudinal and Yaw Moment Control of HEV with eAWD Capabilities2017-01-15583/28/2017
Hybrid Electric Vehicles (HEV) offer improved fuel efficiency compared to their conventional counterparts at the expense of adding complexity and at times, reduced total power. As a result, HEV generally lack the dynamic performance that customers enjoy. To address this issue, the paper presents a HEV with eAWD capabilities via the use of a torque vectoring electric rear axle drive (TVeRAD) unit to power the rear axle. The addition of TVeRAD to a front wheel drive HEV improves the total power output. To further improve the handling characteristics of the vehicle, the TVeRAD unit allows for wheel torque vectoring at the rear axle. A bond graph model of the proposed drivetrain model is developed and used in co-simulation with CarSim. The paper proposes a control system which utilizes tire force optimization to allocate control to each tire. The optimization algorithm is used to obtain optimal tire force targets to at each tire such that the targets avoid tire saturation. The Youla parameterization technique is used to develop robust tracking controllers for each axle. The proposed control system is ultimately tested on the drivetrain model with a high fidelity CarSim vehicle model for validation. Simulation results show that the control system is able to maximize vehicle longitudinal performance while avoiding tire saturation on a low mu surface. More importantly, the control system is able to track the desired yaw moment request on a high speed double lane change maneuver through the use of the TVeRAD to improve the handling characteristic of the vehicle.
Velazquez Alcantar, JoseAssadian, FrancisKuang, Ming
Study of Power Hop on Front Wheel Drive Vehicles Influence of Mounts, Driveline, Tires and Wheels2016-36-017210/25/2016
This paper has the objective to present the study made on a front wheel drive passenger car with “3 Points Pendular Mounts System” to minimize the “Power Hop effect” (powertrain forced oscillation) and reduce the loads on Powertrain Mounts System. In this study, we used the Taguchi Method (Design of Experiments) to optimize the number of tests performed to evaluate the influence of powertrain mounts system design characteristics, as well as axle shafts stiffness, and tire/wheels assemblies size. The data acquisition work was all done in a physical hardware (vehicle) on test track used instrumented parts and load cells. Accelerometers were used in previous tests to get qualitative understanding of the behavior of all interface components (mounts and wheels hubs) during the power hop event. The study results showed the best components combination in order to reduce peak loads over Powertrain System and, as a consequence, reducing the potential of components breakage under extreme conditions. As learning, we got a better understanding of the dynamic behavior of the Powertrain System and its interfaces during power hop event by controlling the main interface components design characteristics of this system.
Amparo, João Fernando MendesBarbetti, Marcos Rogério SantosZavala, Paulo Alexandre GalarceBallardie, GeorgeMoriya, Roberto
NVH Analysis of Powertrain Start/Stop Transient Phenomenon by using Wavelet Analysis and Time Domain Transfer Path Analysis2015-01-22936/15/2015
Tactile vibration during vehicle key on/off is one of the critical factors contributing to the customer perceived quality of the vehicle. Minimization of the powertrain transient vibration in operating conditions such as key on/off, tip in/out and engagement/disengagement of engine in hybrid vehicles must be addressed carefully in the vehicle refinement stage. Source of start/stop vibration depends on many factors like engine cranking, engine rpm at which the combustion process starts and rate of engine rpm rise etc. The transfer path consists of elastomeric mounts of powertrain and the part of vehicle structure from mounts to tactile response location. In this paper, the contribution of rigid body motion of powertrain of a front wheel drive vehicle during key on/off is analyzed in both frequency and time domain. The signal is analyzed in frequency domain by using fast fourier transform, short time fourier transform and wavelet analysis. The merits and demerits of each method are illustrated. Wavelet analysis is used to analyze the transient event in frequency domain with small time steps. Also, the operational deflection shape analysis is used to visualize the modal behavior of powertrain at each time step. From the results of wavelet analysis, the contribution of each rigid body mode of the powertrain to the tactile vibration is ascertained by conducting frequency domain transfer path analysis for each time step. Design modifications at the powertrain mount level are suggested to reduce the intensity of tactile vibration presuming that the best is achieved in the parameters related to engine cranking and combustion initiation. Also, time domain transfer path analysis is conducted to estimate the mount forces and path contributions in time domain. The mount forces are estimated using relative displacements and mount stiffness data in time domain. The path contribution in time domain are ascertained by calculating the spectral inverse of product of force spectrums with corresponding vibration transfer function to target locations. The results of path contribution analysis of frequency and time domain methods are compared. The time domain TPA analysis is very useful in understanding the nonlinear behavior of the powertrain mounts. The elastomeric mount design is optimized by considering the vibration comfort and the manufacturability.
Rao, Manchi VenkateswaraMoorthy, S NatarajaRaghavendran, Prasath
Beyond Driveline Disconnect - The Ultimate On-Demand Dry Sump RDM System with PTU Disconnect2015-01-10994/14/2015
Recent developments in front wheel drive based all-wheel drive (AWD) systems have focused on the disconnection of the secondary driveline to provide a high efficient 2-Wheel Drive (2WD) mode in order to minimize parasitic losses and increase fuel economy when all-wheel drive is not required. This present study compares a base on-demand all-wheel drive system without disconnect features to one with disconnect features in the rear drive module (RDM) and power transfer unit (PTU) to fully disconnect the secondary drive line. In order to further reduce parasitic losses the RDM also utilized an on-demand lubrication system. In conjunction with the active lubrication system, the oil sump level was reduced to assure all clutch housings and their associated plates were above the oil level at all times in order to minimize shear losses. Positive plate separation was also employed to assure ample clearance for free-running clutch plates. Essentially, the tested disconnect system represents the best possible configuration for the reduction in unwanted parasitic losses and their deleterious effects on fuel economy while enhancing the traction and vehicle dynamics performance benefits of independent side to side torque transfer control. Vehicle data shows that the disconnect system increased fuel economy in 2WD mode as compared to the base all-wheel drive system by 3.3% in the FTP75 drive schedule and 2.4% in the Highway Fuel Economy drive cycle. It should also be understood that these fuel economy savings potential represent a 100% 2WD mode duty cycle which is the maximum possible savings. Any AWD mode duty cycle either manual or automatically selected will deteriorate this potential savings under real world driving conditions. The vehicle manufacturer will need to manage this expectation at the consumer level. Fuel economy benefit of a disconnect system is the focus of this paper. Disconnect system response and AWD performance will not be covered.
Kopp, ThadPritchard, Larry A.
MMLV: Automatic Transmission Lightweighting2015-01-12404/14/2015
This paper details the lightweighting efforts of the Ford Research & Advanced Transmission team as part of the Multi Material Lightweight Vehicle Project. The Multi Material Lightweight Vehicle (MMLV) developed by Magna International and Ford Motor Company is a result of a US Department of Energy project DE-EE0005574. The project demonstrates the lightweighting potential of a five passenger sedan, while maintaining vehicle performance and occupant safety. Prototype vehicles were manufactured and limited full vehicle testing was conducted. The Mach-I vehicle design, comprised of commercially available materials and production processes, achieved a 364kg (23.5%) full vehicle mass reduction, enabling the application of a 1.0-liter three cylinder engine resulting in a significant environmental benefits and fuel consumption reduction. Several Ford 6-speed Front Wheel Drive (FWD) automatic transmission components were considered for lightweighting action with three ultimately being chosen as the best candidates to prototype for the MMLV. The first part is the rear carrier clutch shell & sun gear assembly where the shell was converted from steel to aluminum. The second part is the pump support where the support material was changed from cast iron to cast aluminum and its associated fasteners converted from steel to aluminum. The third part is the cast control body where the body material was changed from cast aluminum to cast magnesium and the associated fasteners converter from steel to aluminum. The associated weight saves were 0.39 kg, 1.84 kg, and 1.3 kg respectively. The specifics of the lightweighting efforts will be presented for each part including the Finite Element Analysis (FEA) results, prototype part fabrication, and all component level test results.
Kearns, JamesPark, SoonSabo, JohnMilacic, Dusan
CAE-Based Driving Comfort Optimization of Passenger Cars2015-01-15834/14/2015
One of the key challenges in developing a vehicle for excellent vehicle dynamics is being able to achieve a high level of driving comfort without degrading the steering and handling performance. The part of driving comfort discussed in this paper are tactile vibrations up to f = 100 Hz. This paper describes how Multi-Body Dynamics (MBD) Computer Aided Engineering (CAE) tools are applied to optimize such vibrations in the early phase of the development process. The approach hereby presented combines system level testing with MBD for the study of ride comfort, similar to the way that system level kinematics and compliance testing is combined with MBD to support steering and handling investigations. Laboratory investigations have been executed to fully characterize a reference suspension with respect to frequency and amplitude behavior. The respective MBD models have been subsequently refined and validated versus physical laboratory measurements. Several examples for a front wheel drive passenger car will be given, which show how these models can be used to effectively support chassis development in early design phases. The first example demonstrates the effect of subframe isolation on ride comfort via analyses of the forces transmitted to the vehicle body. The second example demonstrates the sensitivity of bushing stiffness to impact harshness using a full vehicle model. The final example demonstrates how impact harshness can be optimized using different levels of compliance split between the subframe and suspension bushings.
Drotar, TimothyPalandri, JacopoWolf-Monheim, FriedrichZandbergen, PaulReff, Bjoern
Vibration Reduction in Motors for the SPORT HYBRID SH-AWD2015-01-12064/14/2015
A new motor has been developed that combines the goals of greater compactness, increased power and a quiet drive. This motor is an interior permanent magnet synchronous motor (IPM motor) that combines an interior permanent magnet rotor and a stator with concentrated windings. In addition, development of the motor focused on the slot combination, the shape of the magnetic circuits and the control method all designed to reduce motor noise and vibration. An 8-pole rotor, 12-slot stator combination was employed, and a gradually enlarged air gap configuration was used in the magnetic circuits. The gradually enlarged air gap brings the centers of the rotor and the stator out of alignment, changing the curvature, and continually changing the amount of air gap as the rotor rotates. The use of the gradually enlarged air gap brings torque degradation to a minimum, and significantly reduces torque fluctuation and iron loss of rotor and stator. A superposed harmonic current is used as the control method for the motor. This control method reduces torque fluctuation by adding a harmonic current component on the motor drive control in order to cancel the peaks of the torque waveform. The application of the newly developed three motors in the SPORT HYBRID SH-AWD reduced cogging torque by 50% and torque fluctuation by 50% at an average torque of 5 Nm. The noise and vibration were reduced by at least 12 dB. This technology made it possible to realize quiet motor operation.
Yazaki, Manabu
Analysis of Drive Line Vibration and Boom Noise in an All Wheel Drive Utility Vehicle2014-01-19754/1/2014
The customer demand for all wheel drive (AWD) vehicles is increasing over the period of time which also requires NVH performance on par with front wheel drive vehicles. AWD vehicles are equipped with power transfer unit, propeller shaft and independent rear differential assembly to achieve their functional requirement. The additional drive train components in AWD vehicles may amplify torsional fluctuations in the drive line. Hence achieving the NVH performance of AWD vehicles on par with FWD vehicles without any major change in the existing design is a major challenge. In this work, an AWD vehicle with severe body vibration and booming noise is studied. The operational measurements are taken throughout the drive train on all sub-systems from engine to the rear part of the body in the problematic operating condition. An operational deflection shape analysis is conducted to visualize the vibration behavior of the drive train. The result of analysis shows that the dynamic torsional fluctuations of the drive shaft and rear drive module (RDM) vibration are the major contributors for the high levels of vibration and noise. Powertrain torsional vibration measurements are also carried out with and without the part of the drive train that belongs to AWD. The reduction in vibration to certain extent is achieved by optimizing the stiffness of RDM mounts. The complete vibration and boom is eliminated by installing a tuned mass damper on RDM. The reduction of 4 dB (A) in interior noise and 5 dB in seat vibration are achieved with the effect of modifications.
Rao, Manchi VenkateswaraFrank, JosRaghavendran, Prasath
In this SAE Recommended Practice, attention will be given to passenger cars and light trucks (through Class III).
Drivetrain Standards Committee
Forward-Looking Simulation of the GM Front-Wheel Drive Two-Mode Power-Split HEV Using a Dynamic Programming-Informed Equivalent Cost Minimization Strategy2013-01-08154/8/2013
This paper presents a forward-looking simulation (FLS) approach for the front wheel drive (FWD) General Motors Allison Hybrid System II (GM AHS-II). The supervisory control approach is based on a dynamic programming-informed Equivalent Cost Minimization Strategy (ECMS). The controller development uses backward-looking simulations (BLS), which execute quickly by neglecting component transients while assuming exact adherence to a specified drive cycle. Since ECMS sometimes prescribes control strategies with rapid component transients, its efficacy remains unknown until these transients are modeled. This is addressed by porting the ECMS controller to a forward-looking simulation where component transients are modeled in high fidelity. Techniques of implementing the ECMS controller and commanding the various power plants in the GM AHS-II for FLS are discussed. It is shown that FLS-derived component states agree well with states commanded using the BLS-derived robust control strategy, with any difference being accounted for by transient effects. Fuel economy results from FLS decrease, as to be expected, by approximately 3-7% from that of BLS due to the increase in propulsion energy required by component transients. Overall, these two points of good agreement demonstrate the viability of the DP-informed ECMS as an online-implementable supervisory control strategy.
Pei, DekunLeamy, Michael
Using Vehicle Simulation to Investigate Controllability2013-01-01804/8/2013
All functional safety standards have some definition of “risk” and the automotive standard ISO 26262 is no exception. Risk is related to the exposure, the severity of the outcome, and in the case of ISO 26262, the controllability in relation to a specific vehicle hazard or hazards associated with the behavior of the vehicle or part of the vehicle. Thus hazards are central to understanding the risk associated with systems. When considering traditional power train systems, based on internal combustion engines or centralized electric motors, hazards are most usually limited to unintended acceleration and deceleration. The situation is complicated somewhat with the introduction of electronically controlled differentials, which can induce limited amounts of induced yaw, as can ABS and ESC. In a similar manner, replacing the centralized driveline system with in-wheel electric motors brings with it a similar set of issues. In this paper we describe the work undertaken to qualitatively identify the hazards associated with in-wheel motors and to quantify the vehicle level effects that could be expected. With this being done to ensure that, when realized as an engineering object, the level of controllability and hence the residual risk to a vehicle fitted with in-wheel motors remains within tolerable bounds.
Ellims, MichaelMonkhouse, Helen ElizabethHarty, DamianGade, Teena
7-XDCT: Compact and Cost-Efficient Dual Clutch Transmission for Small and Mid-Size Vehicles2013-01-12714/8/2013
The automotive industry continues to develop new powertrain technologies aimed at reducing overall vehicle level fuel consumption. The ongoing trends of “downsizing” and “down speeding” have led to the development of turbocharged engines with low displacement and high torque density. In order to meet the launch response requirements with these engines as well as fuel economy needs, transmissions with large ratio spreads will need to be developed. Due to the lack of torque amplification from the torque converter, the next generation of dual clutch transmissions (DCT) will need to have larger launch ratios and ratio spreads than currently available in production today. This paper discusses the development of a new family of DCT (called “xDCT”) for use in front wheel drive vehicles, aimed at meeting some of these challenges. The xDCT family features two innovative concepts, the idea of “gear generation” and “supported shifts”. A combination of these features results in the development of a highly compact and efficient family of DCTs. The paper will begin with a definition of the xDCT concept followed by a layout of the gear sets for 7 and 10 speed versions of this transmission. Simulation results are used to show the powershift capability as well as efficiency of the developed transmission concept. Finally, a 3D design study is utilized to demonstrate key features of the transmission concept that will result in a highly efficient and compact transmission with low mechanical complexity and full powershift capabilities.
Govindswamy, KiranHellenbroich, GereonRuschhaupt, Johannes
Development of a Standard Spin Loss Test Procedure for FWD-Based Power Transfer Units2013-01-03614/8/2013
As vehicle fuel economy continues to grow in importance, the ability to accurately measure the level of efficiency on all driveline components is required. A standardized test procedure enables manufacturers and suppliers to measure component losses consistently and provides data to make comparisons. In addition, the procedure offers a reliable process to assess enablers for efficiency improvements. Previous published studies have outlined the development of a comprehensive test procedure to measure transfer case speed-dependent parasitic losses at key speed, load, and environmental conditions. This paper will take the same basic approach for the Power Transfer Units (PTUs) used on Front Wheel Drive (FWD) based All Wheel Drive (AWD) vehicles. Factors included in the assessment include single and multi-stage PTUs, fluid levels, break-in process, and temperature effects. The resultant procedure is proposed as a new SAE J-standard (Surface Vehicle Recommended Practice) for release by the AWD Standards Committee. The overview presented in this paper includes definitions for the PTUs used in the study along with an overview of the test setup and instrumentation. This paper will outline some of the key investigations undertaken including the step size and duration, assessment of repeatability, as well as the influences of break-in and oil level. This project was undertaken and financially supported by the Transmission Working Group of the United States Council of Automotive Research (USCAR) for the SAE AWD Standards Committee.
Kirk, Michael P.D'Anna, ThomasSeldon, WilliamPerakes, AndreasRoss, Craig
A Dual Clutch Torque Converter for Dual Input Shaft Transmissions2013-01-02324/8/2013
This paper presents an alternative launch device for layshaft dual clutch transmissions (DCT's). The launch device incorporates a hydrodynamic torque converter, a lockup clutch with controlled slip capability and two wet multi-plate clutches to engage the input shafts of the transmission. The device is intended to overcome the deficiencies associated with using conventional dry or wet launch clutches in DCT's, such as limited torque capacity at vehicle launch, clutch thermal capacity and cooling, launch shudder, lubricant quality and requirement for interval oil changes. The alternative device enhances drive quality and performance at vehicle launch and adds the capability of controlled capacity slip to attenuate gear rattle without early downshifting. Parasitic torque loss will increase but is shown not to drastically influence fuel consumption compared to a dry clutch system, however synchronizer engagement can become a concern at cold operating temperatures. The performance of the dual clutch torque converter is assessed in a 7 speed front wheel drive DCT application and compared against the dry clutch system in the areas of launch, start/stop, driveline torsional isolation, gear rattle mitigation and fuel consumption. The dual clutch torque converter is shown to overcome the shortcomings of a dry friction launch system and deliver equivalent fuel economy performance.
Robinette, DarrellSkrzycke, Ted
Parallel-Through-The-Road Plug-In Hybrid Vehicle Modeling and Simulation by Wayne State University for EcoCAR22013-01-05414/8/2013
The Wayne State University (WSU) EcoCAR2 student team designed, modeled, Model-In-the-Loop (MIL) tested, Software-In-the-Loop (SIL) simulation tested, and Hardware-In-the-Loop (HIL) simulation tested the team's conversion design for taking a 2013 Chevrolet Malibu and converting it into a Parallel-Through-The-Road (PTTR) plug-in hybrid. The 2013 Malibu is a conventional Front Wheel Drive (FWD) vehicle and the team's conversion design keeps the conventional FWD and adds a Rear Wheel Drive (RWD) powertrain consisting of an electric motor, a single speed reduction gearbox and a differential to drive the rear wheels -where none of these previously existed on the rear wheels. The RWD addition creates the PTTR hybrid powertrain architecture of two driven axles where the mechanical torque path connection between the two powertrains is through the road, rather than a mechanical torque path through gears, chains, or shafts. Finally, a battery pack and an on-board charger are added to complete the plug-in hybrid vehicle powertrain. This paper covers WSU's PTTR plant modeling and simulation, hybrid supervisory controller code development by the team during the first year of the three year competition. The PTTR hybrid powertrain vehicle architecture modeling is discussed in the plant model development section and the results section show the mixed results for SIL testing the physics of plant modeling for following a drive cycle trace and the resulting fuel consumption. The team wrote and MIL tested their hybrid supervisory control software, skipped SIL testing by going straight to HIL testing. The testing is discussed in the powertrain controls integration methods and results sections, with unsatisfactory results achieved during the HIL test demonstration at the final competition of the first year. Safety critical CAN loss detection is discussed as an example of code the team wrote for the hybrid supervisory controller for vehicle operational safety.
Snyder, Kevin L.Lor, LoveKu, Jerry
New Launch Devices for Automatic Transmissions2013-01-02334/8/2013
Hydrodynamic launch elements, from the Foettinger principle of the torque converter to the first series production HCC wet clutch, are becoming more relied on in the transmission world for their high power density, launch comfort, and vibrational isolation capability. In order to attain the ambitious fuel economy objectives of the future, engine vibrations have to be successfully isolated from the driveline at low engine speed ranges without the use of the hydrodynamic circuit. This is now all the more challenging as new combustion engines are producing higher torsional vibrations as a result of fewer cylinders, higher combustion pressures, cylinder deactivation, and lower critical speeds. This paper will describe the next generation of powertrain vibrational isolation, dampening via powersplit. Additionally, a next generation wet launch element, the Hydrodynamically Cooled Clutch will be discussed. A brief description of the current state of the art dampening technologies will be reviewed, highlighting the limitations of these solutions which pave the way for the new generations. The challenge with front wheel drive or hybrid layouts is to reduce the dimensions of the hydrodynamic and clutch systems, while sustaining high thermal capacity in order to improve vibrational isolation, and ensure protection against judder in a challenging packaging environment.
Binder, Scott WilliamFischer, MatthiasSasse, ChristophTrampler, Joerg
Vehicle Integration Factors Affecting Brake Caliper Drag2012-01-18309/17/2012
Disc brakes operate with very close proximity of the brake pads and the brake rotor, with as little as a tenth of a millimeter of movement of the pads required to bring them into full contact with the rotor to generate braking torque. It is usual for a disc brake to operate with some amount of residual drag in the fully released state, signifying constant contact between the pads and the rotor. With this contact, every miniscule movement of the rotor pushes against the brake pads and changes the forces between them. Sustained loads on the brake corner, and maneuvers such as cornering, can both produce rotor movement relative to the caliper, which can push it steadily against one or both of the brake pads. This can greatly increase the residual force in the caliper, and increase drag. This dependence of drag behavior on the movement of the brake rotor creates some vehicle-dependent behavior. Major factors affecting rotor movement include wheel bearing stiffness, wheel radius, vehicle mass and mass distribution, and brake corner geometry. The present work studies two vehicle-integration dependent mechanisms which can affect brake drag. The first involves rotor movement due to sustained tire/wheel loading conditions and brake corner geometry, and is examined through a case study involving two vehicles. The second involves rotor movement due to cornering loads. In both cases, rotor movement is related to brake drag by component dynamometer measurements of brake drag versus small axial movements of the rotor.
Antanaitis, David B.
The i-REAL Personal Mobility Vehicle2011-39-72425/17/2011
The need for small personal mobility vehicles is growing as urbanization, the aging of society, traffic congestion, and parking become major issues, particularly in inner-city areas. The aging of society also means that more short trips within communities will be made. The i-REAL personal mobility vehicle is a next-generation single-passenger electric vehicle that enables the driver to move around town using a smaller amount of energy. This compact EV has three wheels: two front wheels driven by in-wheel motors and one rear wheel. According to the driver's needs, the i-REAL switches driving modes by changing its wheelbase. It can go slowly, allowing the driver to meet the eyes of passers-by when driving in parks, on sidewalks, or inside shopping malls. When on the road, it can lower its height and drive quickly like a bicycle or motorcycle. The body of the i-REAL leans automatically based on the speed and the turn angle to maintain the balance of the vehicle for any driver. For safety, the i-REAL detects obstructions and people ahead by radar and slows down automatically. In addition, areas likely to be impacted in collisions are made of softer materials. The i-REAL also has built-in contact sensors that stop the vehicle automatically if a collision occurs. Demonstration tests have been held at the Chubu International Airport from June 2009 toward practical use of the i-REAL in the future.
Akihiro, YanakaMakoto, MoritaTakeo, Moriai
Prospects for Future 4WD and AWD Developments for Pick Ups, SUVs and Passenger Cars in Brazil2010-36-047910/6/2010
The purpose of this paper is to present the origins and the technology of the different types of AWD (All Wheel Drive) and 4WD (Four Wheel Drive) systems currently available and the wide potential to incorporate such technologies to the vehicles made in Brazil. In the Brazilian market the 4WD and AWD vehicle options are available only on expensive pickups and imported SUVs, which include only a small part of the total market. Conversely, there are a large number of 4WD & AWD technologies available in developed markets that are not currently available in the South American markets. Most South American consumers regard vehicles with 4WD/AWD systems as off-road vehicles to be driven in the countryside, in an off-road environment. These markets still don`t have a clear understanding of the differences between 4WD and AWD, and the benefits of each. This paper will describe the concepts, the architecture and the operations of such systems and point out the correct application of each ones. Some of these systems are more adequate for off-road usages while others are more focused on safety on slippery roads. Others are designed to enhance the driveability and vehicle control. On the other hand there are 4WD systems that are more efficient for commercial vehicles while others are more adequate for city traffic passenger cars. This paper will also encompass the main components that constitute the 4WD and AWD system and the interface of such systems with Engine Management Strategy, Transmission Management, ABS, Traction Control and Stability Control in order to provide more safety, performance and low fuel consumption. The paper will also present and explain low cost AWD system such as the PTU (Power Transfer Unit) usually applied at crossover vehicles and passenger cars. The cutting edge in AWD Technology, the Torque Vectoring, will also be presented. The message of this paper is to point out the large array of new 4WD and AWD technologies currently available on developed markets and the great potential we have to bring these technologies to the car makers in Brazil for the benefit of the customer and the Brazilian economy.
Neto, Demetrio VettorazzoFornari, RafaelRupcic, JorgeSuzuki, Alexandre
General Motors Small Front Wheel Drive Six speed Automatic Transmission Family2010-01-08574/12/2010
General Motors introduced a family of small front wheel drive six speed automatic transmissions for the 2008 model year. The family currently has two variants: 6T40 and 6T45, which cover a range of vehicles from small & compact cars to small SUVs and handle engines torque capacities up to 240 Nm Gas(280 Nm Diesel) & 315 Nm Gas (380 Nm Diesel) respectively. The 6T40/45 transmissions replace GM traditional four speed automatic wrap around transmissions 4T40/45. The wrap around transmissions have Torque Converter, Pump & Controls on the engine axis and the rest of the transmission content on the output axis. The 6T40/45 have an on-axis architecture with majority of the transmission content on the engine axis and final drive & differential on the output axis. The 4T40/45 have input chain transfer whereas the 6T40/45 have an output chain transfer. The objectives behind the creation of the 6T40/45 transmissions were improved fuel economy, performance, mass and NVH as compared to the transmissions they replaced. Packaging in the existing vehicle architectures and high mileage dependability were givens. This architecture was required to offer low cost for a front wheel six speed transmission while meeting the givens and objectives. A six speed powerflow, common with GM's 6T70/75 transmission, was selected by General Motors Propulsion Systems Research Laboratories, for the 6T40/45. The powerflow includes three simple planetary gear sets, three brake clutches and two rotating clutches. The resultant on-axis transmission architecture utilizes a hyper-elliptical (squashed) torque converter, an on-axis pump and three close coupled gear sets. Two rotating clutches have been radially stacked for minimized axial length of the transmission. The architecture also includes a chain axis transfer and a planetary final drive. This architecture yields a 6.1 overall ratio spread, enabling up to 7% improvement in 0-60 mph performance because of a deeper first gear ratio and up to 4% better fuel economy due to lower N/V for the top gear when compared to the 4T40/45 transmissions that it replaces. A wide range of axle ratios are available by utilizing the flexibility of sprocket sets and final drive ratios. The architecture is cost effective by virtue of the chain axis transfer, on axis pump, one piece case and significant part commonality among the variants of the family. The transmission controller and control system are similar to the General Motors 6T70/75 transmission family. There was also special attention focused on flexible manufacturing design features that enables a global manufacturing footprint. The architecture utilizes a center clutch housing that enables the required shape of the transmission case, making it optimal for packaging in a variety of applications. The 6T40/45 transmissions package in the existing vehicle architectures with 197 mm center distance between engine & output axes and an output axis vertical drop of 75 mm from engine axis. On axis design makes the architecture package similar to manual transmissions, and hence, opens it up to more global vehicle architectures. The 6T40/45 transmissions, depending on applications, offer 1-3 kg mass savings when compared to the 4T40/45 while offering two extra forward speeds and an internal transmission controller. The 6T40 and 6T45 have components with identical radii but component lengths have been flexed for torque capacity differences. Additional family variants based on input & output torque, packaging, and other geometry/hardware parameters are also possible. The overall result is a robust, compact and cost effective transmission family which offers significant fuel economy and performance benefit over its four speed counterpart transmissions and should provide an attractive balance of overall metrics in the automatic transmission market.
Singh, TejinderOlenzek, Richard
Items per page:
1 – 50 of 180