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Submitted in Accordance with the Requirements for the Degree Of Integrated Powertrain Control for Twin Clutch Transmissions Manuel Goetz Submittedin accordancewith the requirementsfor the degreeof Doctor of Philosophy University of Leeds School of Mechanical Engineering February 2005 The candidateconfirms that the work submitted is his own and that appropriatecredit has been given where referencehas been made to the work of others. This copy has been supplied on the understandingthat it is copyright material and that no quotation from the thesis may be published without proper acknowledgement. Abstract Abstract In this thesis an integrated powertrain control for gearshifts on twin clutch transmissionsis developed. First, a detailed model of an automotive powertrain featuring a twin clutch transmission is developed in Matlab/Simulink®. This model includes detailed friction models for the twin clutch that enable an investigation into the effects of different friction materials on the performance of the gearshift controller. The transmission model also includes detailed models of the synchronisers and thus allows a simulation of synchroniser-to-synchronisershifts. A simplified phenomenological model, derived from a more complex non-linear model, is employed to model the hydraulic actuation of clutches and synchroniser.The thesis finds that the dependencyof the friction coefficient on the sliding speedhas an important influence on the gearshift quality and the performance of gearshift controller, while the absolute level of the friction coefficient is less important. Based on this powertrain model the key problems of gearshifts on twin clutch transmissions were identified and a control that overcomesthese problems was developed.The first stagewas to devise a gearshift control algorithm that handlessingle clutch-to-clutch shifts without a one- way (freewheeler-, overrunning-) clutch. This basic gearshift control algorithm featured a control of clutch slip for the engine torque transfer and a control of engine speedthrough engine torque manipulation (plus clutch pressuremanipulation for downshifts). In a second stage, an optional transmission output torque control was developedthat could be integrated in the basic control. The thesis shows that these control strategiesare superior, in terms of shift quality, to conventional gearshift controls as used on planetary-type transmissions and are also robust against variations in the powertrain parameters(including friction coefficient) and sensornoise. The control strategies developed for single clutch-to-clutch shifts were extended to handle double and other multiple gearshiftsthat take place in the sametransmission half. The thesis also investigates the other main part of gearshifts on twin clutch transmissions,the gear pre-selection. The thesis shows that, on power-on gearshifts, the torque reactions at the transmission output due to the gear pre-selection with conventional hydraulically actuated synchroniserscan be effectively compensatedfor by a simple manipulation of engine torque. Acknowledgements 11 Acknowledgements I am very grateful to Prof. Dave Crolla and Dr. Martin Levesley for their excellent supervision, their continuous support and encouragementover the past years. The many inspiring comments that they have provided have been an enormoushelp in the creation of this thesis. I would also like to thank all the people in the school of mechanical engineering and in particular, my colleagues at the control and dynamics laboratory for their valuable support and help over the last years. Finally, I would like to thank the School of Mechanical Engineering and the EPSRC for providing the funding for this PhD studentship. I would like to dedicatethis thesis to my father. Table of Contents U1 Table of Contents Abstract I NNNN. NN.N.. N. N.. NN....... NN.... N ................................................... .......... N... N... N. Acknowledgements... il N..N. N.. N. N........... N .............................................................................. List Illustrations of ..N.. N. N... N ..................... N....................................................................... vil List of Tabies.NNNNN... NNN. N... N...... N... NN. N. NN... NNNN. NI. N. N.... N. N... NN. N.. NN... NNN. NN..... N.. zv Notation N..NN. »N. N. N. N........... N.. N. N... N.. N.. N.. N ................................................................ N... xvi List Abbreviations of .....NN......... N................... N............................................................... N.xxiil Chapter 1 Introduction 1 ....» ........ ............ ........................................................................». 1.1 Transmission Concepts An Overview Discussion Characteristics 2 - and of .................... 1.2 The Twin Clutch Transmission 5 ....................................................................................... 1.3 Powertrain Controls IntegratedPowertrain Control Approach 7 and the .......................... 1.4 Map Thesis 9 of the ............................................................................................................ 2 Review Literature Chapter of .................».................................................................... »11 2.1 Control Gearshifts Powershift-Transmissions 11 of on ....................................................... 2.1.1 Brief Clutch-to-Clutch Powershifts 12 Introduction to ........................................ 2.1.2 Gearshift Control Local TransmissionControl Strategies 14 - .......................... 2.1.3 Gearshift Control IntegratedPowertrain Control Approach 26 - ........................ 2.2 Control Issues Gearshifts Twin Clutch Transmissions 31 specific to on ............................. 2.2.1 Multiple Gearshifts 31 .......................................................................................... 2.2.2 Gear Pre-Selection 34 ........................................................................................... 2.3 Control Gearshifts AutomatedManual Transmissions 36 of on .......................................... 2.4 Gearshift Quality Metrics 39 ................................................................................................ TransmissionTorque 42 2.5 SensorMeasurements and Observationof ................................... 45 2.6 Powertrain Dynamics and Modelling ................................................. 2.6.1 Automotive Powertrain: Dynamics, Modelling Techniquesand Simulation..45 2.6.2 Engine Dynamics Modelling 47 and .................................................................... 2.6.3 Transmission Modelling 48 Dynamics and .......................................................... 2.7 Conclusions Literature Review 59 of the ............................................................................. 2.8 Aim Objectives Research 61 and of the ............................................................................... Table of Contents iv Chapter 3 Dynamic Model Powertrain 63 of the ......................»........................................... 3.1 General Structure the Powertrain Model 63 of ..................................................................... 3.2 Dynamic Engine Model 66 ................................................................................................... 3.2.1 Engine Model Torque Production 66 - ................................................................. 3.2.2 Engine Model Rotational Dynamics 67 - ............................................................ 3.2.3 Engine Model Characteristics Mai) 68 - and ....................................................... 3.3 Dynamic Model Twin Clutch Transmission 70 of the ......................................................... 3.3.1 Dynamics the Transmission 72 of ........................................................................ 3.3.2 Dynamics Hydraulic System 88 of ....................................................................... 3.4 Model Differential, Driveshafts,Tyres Vehicle Dynamics 98 of and .................................. 3.4.1 Differential, Driveshafts Tyres 99 and ................................................................. 3.4.2 Vehicle Dynamics 101 ........................................................................................... 3.5 The Powertrain Model first Simulation Result Discussion 104 -A and ................................ 3.5.1 Simulation Clutch-to-Clutch Upshift Model Validation 104 of a and ................... 3.5.2 Discussion Clutch Friction 107 of .......................................................................... 3.6 Conclusions 108 ..................................................................................................................... Chapter 4 Gearshift Controller for Twin Clutch Transmissions 110 ................................... 4.1 Introduction to Powershifts Conventional Clutch-to-Clutch Control Strategy 111 and ........ 4.2 Control Power-On Shifts Twin Clutch Transmissions 115 of on ........................................... 4.2.1 Control Power-On Upshifts 115 of ........................................................................ 4.2.2 Control Power-On Downshifts 129 of .................................................................... 4.3 Control Power-Off Shifts Twin Clutch Transmissions 141 of on .......................................... 4.3.1Control Power-offUpshifts 142 of ......................................................................... 4.3.2 Control Power-off Downshifts 145 of ...................................................................
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