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Optimized Shift Control in Automatic Transmissions with Respect to Spontaneity, Comfort, and Shift Loads

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Optimized Shift Control in Automatic Transmissions with Respect to Spontaneity, Comfort, and Shift Loads RUHR-UNIVERSITÄT BOCHUM FAKULTÄT FÜR MASCHINENBAU Institut: Product and Service Engineering Schriftenreihe Heft 15.2 Peng Dong Optimized Shift Control in Automatic Transmissions with respect to Spontaneity, Comfort, and Shift Loads Lehrstuhl für Industrie- und Fahrzeugantriebstechnik Prof. Dr.-Ing. Peter Tenberge RUHR-UNIVERSITÄT BOCHUM FAKULTÄT FÜR MASCHINENBAU Institut: Product and Service Engineering Schriftenreihe Heft 15.2 Peng Dong Optimized Shift Control in Automatic Transmissions with respect to Spontaneity, Comfort, and Shift Loads Lehrstuhl für Industrie- und Fahrzeugantriebstechnik Prof. Dr.-Ing. Peter Tenberge Optimized Shift Control in Automatic Transmissions with respect to Spontaneity, Comfort, and Shift Loads Dissertation zur Erlangung des Grades Doktor-Ingenieur der Fakultät für Maschinenbau der Ruhr-Universität Bochum von Peng Dong, M.Sc. aus Yantai, China Bochum 201η Herausgeber: Lehrstuhl für Industrie- und Fahrzeugantriebstechnik Institut: Product and Service Engineering Fakultät für Maschinenbau Ruhr-Universität Bochum, 44780 Bochum Dissertation: Referent: Prof. Dr.-Ing. Peter Tenberge Korreferent: Prof. Dr.-Ing. Xiangyang Xu Tag der Einreichung: 06. Januar 2015 Tag der mündlichen Prüfung: 06. März 2015 © 201η Institut: Product and Service Engineering Ruhr-Universität Bochum Alle Rechte vorbehalten ISBN 3-89194-216-8 Acknowledgements Acknowledgements This dissertation was written during my work as a Ph.D. student at the Chair of Industrial and Automotive Drivetrains of Ruhr-University Bochum. I truly enjoy the time I spent here with all the colleagues and friends. It is a big honor for me to work in such a great team in the past three years. I am deeply thankful to my Ph.D. father, Prof. Dr.-Ing. Peter Tenberge, who provides me with this interesting research topic. His excellent supervision, consistent support and encouragement, and many invaluable suggestions greatly help me throughout the research work. I am also grateful to Prof. Dr.-Ing. Xiangyang Xu, who carefully took review of my dissertation and contributed to it with a lot of good suggestions. I would like to thank Prof. Dr.-Ing. Alexander Hartmaier for his interest in my research and for taking time to serve as the chairman of my oral examination. I would also like to thank all my colleagues from the Chair of Industrial and Automotive Drivetrains and the colleagues from Chemnitz University of Technology. It’s my pleasure to work with them in such a pleasant working atmosphere. The good communication and discussion benefit me a lot in the creation of this dissertation. I would like to express my gratitude to the industry partner Shengrui Transmission Co., Ltd. President Xiangwu Liu and his team launched the 8AT successfully into the Chinese market in 2014. It is a remarkable achievement. I would like to thank all the engineers for good communication and discussion. Especially, I will give my special thanks to Dr. Wei Guo for his support of the test data. I also thank the China Scholarship Council for providing me with the financial support during my study in Germany. Finally, I am deeply indebted to my parents and my girlfriend. Without their selfless support, deep love, and great patience, I cannot finish this dissertation. Bochum, March 2015 Peng Dong Acknowledgements Kurzfassung Kurzfassung Automatikgetriebe sind komplexe und hochintegrierte Elemente des Fahrzeugantriebsstrangs. Mit dem Ziel die Kraftstoffeffizienz heutiger Fahrzeuge zu steigern, nimmt die Zahl der Gänge und die Gesamtspreizung der Automatikgetriebe in den letzten Jahren stark zu. Das hat eine Häufung der Schaltvorgänge im Betrieb zur Folge. Gleichzeitig steigt die Anforderung der Kunden sowohl an den Komfort als auch die Spontanität der Schaltungen. Darüber hinaus muss die Schaltqualität auch im Serienprodukt und über dessen gesamte Lebensdauer sichergestellt werden. Die Verbesserung der Schaltqualität trotz der vorhandenen Fertigungstoleranzen, Verschleiß und Alterung ist also eine der Hauptaufgaben der Steuerungssoftwareentwicklung für automatisch schaltende Getriebe. Um das dynamische Verhalten eines Automatikgetriebes während des Schaltvorgangs untersuchen zu können wird ein Simulationsmodell eines Fahrzeugantriebsstrangs entwickelt. Um die damit durchgeführten Schaltungen bewerten zu können, werden fünf objektive Kriterien eingeführt. Diese sind quantitative Größen, die einen Vergleich verschiedener Simulationen ermöglichen. Zwei verschiedene Regelstrategien werden untersucht: Eine Steuerung mit offener Wirkungskette und eine Regelung mit Rückkopplung. Mit diesen Regelstrategien werden Schaltvorgänge eines 8-Gang Automatikgetriebes simuliert, und die Kernursachen identifiziert, die zu einer schlechten Schaltung führen. Gegenüber der Steuerung weißt die Regelung weniger einzustellende Parameter auf und ist robuster gegenüber Störungen. Eine gute Regelstrategie ist nicht ausreichend um eine hohe Schaltqualität sicherzustellen, da die eingesetzten Schaltelemente empfindlich auf Fertigungstoleranzen, Alterung und Verschleiß reagieren. Daher wird deren Einfluss genauer untersucht und eine adaptive Regelung, die einige dieser Einflüsse kompensiert, entwickelt. Auf Basis der Drehzahlverläufe über der Zeit während eines Schaltvorgangs wird ein Adaptionsalgorithmus für den Befüllvorgang des Hydraulikzylinders des zu schließenden Schaltelementes entworfen. In Fahrversuchen wird gezeigt, dass mithilfe des entwickelten Adaptionsalgorithmus ein starker Drehzahlabfall, ein Hochdrehen des Motors oder ein Verspannen des Getriebes, welches durch eine schlechte Parametrierung hervorgerufen wird, beseitigt werden kann. Solche Maßnahmen können also dazu beitragen die Schaltqualität über der Lebensdauer auf einem hohen Niveau zu bewahren. Abstract Abstract Automatic transmissions are complicated and highly integrated gearboxes in the vehicle powertrain. In order to improve fuel economy of the vehicle, automatic transmissions tend to have more speeds and a big total ratio range in recent years. The number of shift operations increases in the normal daily driving. People want to have a smoother and faster shift feeling than before. In addition, shift quality is required to be consistent in mass production and with mileage accumulation. Therefore, how to improve shift quality and how to cover the influence of build-to-build variations and life-cycle variations are the key issues in the development of transmission control software. In this dissertation, a simulation model of the vehicle powertrain is developed. The dynamic behaviour of the automatic transmission in the shifting process can be simulated through this model. In order to evaluate the shift quality through simulation, five objective criteria are proposed. They are quantitative indicators that can be calculated and compared between different simulations. Two different kinds of control strategies, namely the open-loop control strategy and the closed-loop control strategy are developed in the simulation model. The shifting process of an 8-speed automatic transmission is simulated under the control of the developed strategies. According to the simulation results, the key points which result in a bad shift quality in both control strategies are identified and described. Compared with the open- loop control strategy, the closed-loop control strategy has fewer calibration parameters and improves the control robustness. Only a good control strategy is not enough for the control of the shifting process. Shift quality is easily affected by build-to-build variations in mass production and life-cycle variations with mileage accumulation. The main influencing factors in build-to-build variations and life-cycle variations are investigated in this dissertation. It is necessary to have the adaptive control in the software to compensate for the tolerances of different transmission builds, the system variations throughout the transmission service life, and the disturbances from the transmission inside and outside. Some adaptive control methods which make use of the speed information and the time information thus are proposed in this thesis. Based on these adaptive control methods, an adaptive control strategy for the filling of the on-coming clutch is developed for the 8-speed automatic transmission. Vehicle tests verify that this adaptive control strategy can effectively eliminate the sharp speed drop, the engine flare, and the clutch tie-up in the shifting process of power on upshift. Shift quality thus can be improved by the adaptive control. Table of Contents I Table of Contents 1 Introduction ........................................................................................................ 1 1.1 Background and Motivation ..................................................................................... 2 1.2 Objectives of the Research ....................................................................................... 4 1.3 Overview of the Dissertation.................................................................................... 5 2 Basics ................................................................................................................... 9 2.1 Vehicle Transmissions .............................................................................................. 9 2.1.1 Manual Transmissions (MT) .......................................................................... 9 2.1.2 Automated Manual Transmissions (AMT) .................................................. 10 2.1.3 Automatic Transmissions (AT) ...................................................................
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