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Dynamic Modeling, Friction Parameter Estimation, and Control of a Dual Clutch Transmission

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Dynamic Modeling, Friction Parameter Estimation, and Control of a Dual Clutch Transmission DYNAMIC MODELING, FRICTION PARAMETER ESTIMATION, AND CONTROL OF A DUAL CLUTCH TRANSMISSION THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Matthew Phillip Barr, B.S.M.E Graduate Program in Mechanical Engineering The Ohio State University 2014 Master's Examination Committee: Approved by Professor Krishnaswamy Srinivasan, Advisor Professor Shawn Midlam-Mohler Advisor Department of Mechanical and Aerospace Engineering Copyright by Matthew Phillip Barr 2014 ABSTRACT In this thesis, a mathematical model of an automotive powertrain featuring a wet dual clutch transmission is developed. The overall model is comprised of models that describe the dynamic behavior of the engine, the transmission mechanical components, the hydraulic actuation components, and the vehicle and driveline. A lumped-parameter model, that incorporates fluid film dynamics and a simplified thermal model, is used to describe wet clutch friction. The model of the hydraulic actuation system includes detailed models of the clutch and synchronizer actuation subsystems. A simulation of the dynamic powertrain model is built using AMEsim and MATLAB/Simulink. The powertrain simulator is used to demonstrate how changes in transmission parameters affect the quality of clutch-to-clutch shifts and the overall dynamic response of the powertrain. Based on this model, measurements of clutch pressure and the rotational speeds and estimated accelerations at the input and output sides of the clutch are used in the design of a friction parameter estimation scheme that can be implemented offline using past simulation data or online using current simulation signals. For both offline and online cases, simulation results demonstrate that friction parameters are estimated with reasonable accuracy. ii An integrated powertrain controller is developed with a model-based feedforward controller and multiple feedback loops. The feedforward controller, which generates a pressure command to either clutch, is developed by inverting a simplified model of the powertrain, and using a static friction model to relate clutch pressure to friction torque. The inputs to the feedforward controller are speeds and estimated accelerations of the engine and clutches. The feedforward controller adapts to changes in friction characteristics by updating the friction parameters used in the static friction model using the values generated by the estimation scheme. The feedback controller contains loops that control clutch slip and engine speed by manipulating clutch pressure, throttle angle, and spark advance. Simulation results for the proposed controller demonstrate that for upshifts, the adaptation of the feedforward controller to varying friction parameters results in improved shift quality relative to the non-adaptive case where the friction parameters input to the feedforward controller are not varied along with the simulated friction characteristics. iii DEDICATION This one’s for you, Pop-pop. iv ACKNOWLEDGMENTS I wish to thank my advisor, Professor Krishnaswamy Srinivasan, for his encouragement, patience and support, and technical expertise. I have learned a great deal from him over the last two and a half years, and it is due to his guidance that I will leave The Ohio State University a much more confident engineer. I also wish to thank my committee member, Professor Shawn Midlam-Mohler for his time, as well as his helpful suggestions and comments. I want to express my thanks to Professor Ahmet Selamet for giving me the opportunity to be a teaching assistant, and the Department of Mechanical and Aerospace Engineering for providing financial support throughout my graduate studies. Through this experience, I found that I truly enjoy teaching and I hope to return to the classroom someday. Last, but not least, I wish to thank my parents, Gilbert and Gale Barr, my brother, Jason Barr, and my friends for their constant encouragement, love, and support. Without all of you, I could not have made it to this point. v VITA June 2007 .......................................................Solon High School December 2011 ..............................................B.S. Mechanical Engineering, The Ohio State University January 2012 to present ................................Graduate Teaching Associate, Department of Mechanical and Aerospace Engineering, The Ohio State University FIELDS OF STUDY Major Field: Mechanical Engineering System Dynamics, Hydraulic Systems, Modeling and Control of Dual Clutch Transmissions vi TABLE OF CONTENTS ABSTRACT ........................................................................................................................ ii DEDICATION ................................................................................................................... iv ACKNOWLEDGMENTS .................................................................................................. v VITA .................................................................................................................................. vi FIELDS OF STUDY.......................................................................................................... vi LIST OF TABLES .............................................................................................................. x LIST OF FIGURES .......................................................................................................... xii NOMENCLATURE ...................................................................................................... xviii CHAPTER 1: INTRODUCTION ....................................................................................... 1 1.1 Background and motivation .............................................................................. 1 1.2 Objectives of the research ................................................................................. 4 1.3 Organization of the thesis ................................................................................. 5 CHAPTER 2: LITERATURE REVIEW ............................................................................ 7 2.1 Modeling of a dual clutch transmission ............................................................ 7 2.1.1 Overview of dual clutch transmissions .............................................. 7 2.1.2 Gear synchronization and the clutch pressure control valve ............. 9 2.1.3 Compensation for lost torque converter benefits ............................. 11 2.2 Control of clutch and gear engagement in a dual clutch transmission ........... 13 2.2.1 Phases of a clutch-to-clutch shift during upshifting and downshifting ....................................................................................................... 13 2.2.2 Clutch slip control and friction parameter estimation using pressure and speed measurements ............................................................... 15 2.2.3 Gear preselection and gear skipping ................................................ 23 2.3 Conclusion ...................................................................................................... 26 CHAPTER 3: POWERTRAIN MODEL .......................................................................... 28 3.1 Top level structure of powertrain model ......................................................... 28 vii 3.2 Mean-value engine model ............................................................................... 30 3.2.1 Intake manifold air dynamics ........................................................... 32 3.2.2 Intake manifold fueling dynamics ................................................... 33 3.3 Dual clutch transmission mechanical system ................................................. 35 3.3.1 Rotational dynamics of the dual clutch transmission ...................... 38 3.3.2 Effect of gear selection on the torque acting on the input shafts ..... 41 3.3.3 Implementation of Karnopp friction model .................................... 44 3.3.4 Dynamic clutch friction model ........................................................ 48 3.4 Longitudinal vehicle dynamics ....................................................................... 54 3.4.1 Vehicle dynamics with tire-road interaction .................................... 55 3.4.2 Simplified vehicle dynamics for feedforward control ..................... 57 3.5 Hydraulic component actuation ...................................................................... 58 3.5.1 Pressure regulation system ............................................................... 63 3.5.1.1 Pressure regulation valve .................................................. 65 3.5.1.2 Pressure regulation control solenoid ................................. 70 3.5.2 Clutch actuation system ................................................................... 75 3.5.2.1 Clutch pressure control valve, N215 ................................. 77 3.5.2.2 Clutch piston, K1 .............................................................. 84 3.5.3 Synchronizer actuation system ........................................................ 85 3.5.3.1 Multiplexer valve .............................................................. 87 3.5.3.2 Multiplexer control solenoid ............................................. 89 3.5.3.3 Shift fork, SF13 ................................................................. 93 3.5.3.4 Synchronizer solenoid, N88 .............................................. 95 3.6 Model limitations
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