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Bell & Howell Information and Learning 300 North Zeeb Road, Ann Arbor, Ml 48106-1346 USA UMI800-521-0600 NOTE TO USERS This reproduction is the best copy available UMI MODELING AND CONTROL OF POWERTRAINS WITH STEPPED AUTOMATIC TRANSMISSIONS DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Quan Zheng, B.S., M.S. ***** The Ohio State University 1999 Dissertation Committee: Approved by Professor Krishnaswamy Srinivasan, Co-Adviser Professor Giorgio Rizzoni, Co-Adviser Professor Stephen Yurkovich ' Co-Advisers Department of Mechanical Engineering UMI Number 9951755 UMI UMI Microform9951755 Copyright 2000 by Bell & Howell Information and Learning Company. All rights reserved. This microform edition is protected against unauthorized copying under Title 17, United States Code. Bell & Howell Information and Learning Company 300 North Zeeb Road P.O. 80x1346 Ann Arbor, Ml 48106-1346 Copyright by Quan Zheng 1999 ABSTRACT This dissertation addresses the modeling and control of automotive powertrains with emphasis on stepped automatic transmissions. An extensive survey of the state-of- the-art of modeling and control issues with emphasis on automatic transmission is provided, the survey indicating the need for improved modeling and control of powertrain systems, especially the need for integrated powertrain control. Development of model-based approaches to integrated engine - transmission control design offers the potential for addressing more demanding control applications and significantly greater gains. Simulation models of the automatic transmission shift process with varying levels of complexity, suitable for dynamic response simulation, controller design and validation, are implemented using Matlab/Simulink. Linearized models of transmission dynamic response during the inertia phase of a gear shift are obtained directly from the S imulink block diagram. Closed-loop shift control algorithms for the inertia phase of a gear shift are developed based on these linearized models and implemented in the powertrain simulation. An open-loop control strategy for the torque phase of a gear shift is developed and shown to be effective in reducing the torque drop in the torque phase. The results indicate the abili^ of integrated engine and transmission control to achieve satisfactory shift quality. Powertrain neutral idle control improves fuel economy in urban driving and minimizes the engine vibrations transmitted to the driveline. Neutral-idle control requires fast and smooth application of the forward clutch in coordination with engine control functions. Understanding of pressure control system dynamics is essential to devise a control strategy for the neutral-idle process, as well as for other shift control applications 11 such as clutch-to-clutch control. Detailed analysis of the dynamic response of a clutch pressure control system resulting in a nonlinear simulation model is presented and validated by experiments. Closed loop control of clutch pressure using feedforward plus feedback control is implemented in a test semp. Experimental results show that clutch pressure can be accurately controlled. The formulation of the powertrain neutral-idle control problem is presented. A multivariable control strategy involving coordinated engine and transmission control is developed based on quantitative models of powertrain dynamic responses. Simulation results show that satisfactory neutral-to-first gear shift quality is achieved. lU To my heavenly Father and My parents IV ACKNOWLEDGMENTS I wish to thank my adviser. Professor Krishnaswamy Srinivasan, for his guidance, commitment to excellence, encouragement, challenge, integrity, support, patience in correcting both my language and scientific errors, and his efforts to meet me over weekends. I wish to thank my co-adviser. Professor Giorgio Rizzoni, for opening the door for me five years ago. Without his understanding and support in a turning point of my life, I would not have been able to study in this field. I also wish to thank him for guidance, encouragement, financial support, and correcting the stylistic errors of this dissertation. I also wish to thank my committee member. Professor Stephen Yurkovich for suggestions and comments. I wish to thank Department of Mechanical Engineering for providing financial support and the valuable teaching experience. I wish to thank Professor Cdl. Menq for his encouragement. I wish to thank General Motors for their financial support. I also wish to thank Advanced Systems & Components of GM Powertrain — Transmission Engineering Center, especially Mr. Bob Moses and Mr. Ronald Lochocki, for their technical, financial and equipment support. I wish to thank Jerry Kingzett, Gary Gardner and Bob Frank for equipment and instrumentation support. I am grateful to the management and colleagues at Delphi Technical Center Brighton, especially John Waller, James Waters and Peter Olin, for understanding, encouragement and support. I wish to thank fellow students at the Powertrain Control and Diagnostics Lab and the Fluid Power Lab for their encouragement and help. I wish to thank my families for their encouragement and love, and especially my parents for instilling in me the desire to learn, and for their sacrifice and understanding. I also wish to thank my friends Jian Lin and Guang Yang for hosting our numerous visits to Columbus. I wish to thank my Bible study group in Columbus for their prayers and encouragement, which kept me going through various frustrating moments. Finally, I wish to thank my husband Qingyuan Li for loving me, sharing my struggle, patiently supporting me, checking and editing the manuscripts, and taking care of me without complaint. VI VITA May 16, 1968 Bom - Harbin, China July 1989 B. S., Mechanical Engineering, Harbin Institute of Technology, China March 1992 . M. S., Mechnical Engineering Harbin Institute of Technology, China January 1993 - February 1994 Visiting research scholar. Department of Electrical Engineering, The Ohio State University March 1994 - March 1999 . Graduate Teaching and Research Associate, The Ohio State University April 1999 - present . Controls Engineer, Delphi Automotive Systems, Technical Center Brighton, Michigan PUBLICATIONS Zheng, Q., Srinivasan, K. and Rizzoni, G., "Transmission shift controller design based on a dynamic model of transmission response, " Control Engineering Practice, Volume (issue): 7 (8 ) 1999, pp. 1007 - 1014. Zheng, Q. Srinivasan, K., and Rizzoni, G., "Dynamic modeling and characterization of transmission response for controller design, " SAE Technical Paper 981094, Book Number: SP-1324, hitemational Congress & Exposition, February 1998, Detroit, MI, USA, also in SAE 1998 Transactions - Joumal of Passenger Cars. FIELDS OF STUDY Major Field: Mechanical Engineering System Dynamics, Measurement and Controls; Automatic Control of Hydraulic Systems; Modeling and Control of Automotive Powertrains; Automatic Transmissions Vll TABLE OF CONTENTS Page Abstract ....................................................................................................................................... ii Dedication ..................................................................................................................................iv Acknowledgments ...................................................................................................................... v V ita .............................................................................................................................................vii Table of Contents ....................................................................................................................viii List of Tables ............................................................................................................................ xii List of Figures .........................................................................................................................xiii Nomenclature ......................................................................................................................... xxii Chapters: 1. Introduction ...........................................................................................................................