无级变速器电液控制系统开发及关键技术研究
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摘要
依托某企业的无级变速器‘产学研’研发平台，围绕其在国家科技部国际合作专项资金资助下的国际联合研发项目‘新一代大功率密度无级变速器’，选题来源于CVT产品工程化应用所需，致力于解决从产品的概念设计到批产化实现过程所遇到的电液控制系统关键技术难题，理论分析中融合作者多年从事CVT产业化研究的实践经验，提出了新颖、实用、量化且行之有效的解决方案，并得到了充分的试验验证。本文主要工作如下：
1、从客户需求入手，确定了电液系统设计目标和功能实现方案，选择双独立回路作为系统的基本结构。通过对CVT使用工况的分析计算，根据夹紧力安全和速比变化率的需求，确定了系统压力、夹紧力及速比控制回路的最高压力及各回路的动态响应特性的需求；
2创造性地将具有双压油口的双作用叶片泵等效为双联泵作为CVT电液控制系统动力源，并利用仿真计算方法，根据CVT运行的特殊工况对流量和压力的需求，确定了油泵的排量；
3、为降低系统能耗，创新地在液压回路中采用了节能型设计方案。其一，自适应流量控制回路。既回避了主动流量控制的结构复杂性，又消除了流量计算的难点，根据系统实际所需，精确调整进入系统的流量，可以大大降低油泵能量损耗；其二，使离合器压力作为其上级辅助压力回路的先导控制，使得辅助压力可以按需实时调节，消除了辅助压力背压对系统压力的遏制作用，使得系统压力有了进一步优化的空间；
4、对文中设计的电液系统，分析了各元器件的物理特性之后，采用模块化方法搭建了其物理模型，包括油缸的压力响应及变速机构的速比响应模型。利用试验数据对模型进行了验证，结果表明两者的时域和频域响应一致性较好，该模型可以用于开环系统分析和闭环非实时仿真分析；
5、参数的多样性、不确定性和时变性导致了DNR湿式离合器开环控制存在一致性难题，在分析其结合过程之后，针对半离合点和滑摩过程的控制提出了一种自学习方法。该方法将涡轮加速度作为目标，构建了李亚普诺夫判据的二次型性能方程，制定了学习规则，从理论上确保了自学习过程的渐进收敛性，工程化应用效果良好；
6、为降低夹紧力、提高传动效率，利用利用速比对夹紧力谐波输入的跟踪相位特征，制定了夹紧力控制方案,试验表明其可以有效降低夹紧力；
7、综合考虑系统对迅速改变速比的需求（较高的速比变化率）、油泵的泵油能力、系统的流量需求等因素，提出了一种对传统PID速比控制器的改进方案，试验表明，该方案在快速、稳定跟踪目标速比的前提下，确保了系统的流量安全和夹紧力安全。
8、开展了电液控制模块测试和整车级别的测试。电液控制模块的测试内容包括静态压力测试，稳态调压测试以及阶跃响应测试等，结果表明压力水平、稳态调压重复精度及阶跃响应的快速性均能满足系统的设计目标。整车级别的测试主要针对紧急制动、急加速以及综合使用工况，目的是为了测试电液控制系统在整车的控制效果能否满足动力总成的使用需求，从试验曲线来看，速比、压力跟踪的准确性和快速性、以及整机的热平衡流量均能满足设计要求和使用要求。
Relying on the platform of combination of ‘production, studying andresearching’, based on International Cooperation Project’New-GenerationEnergy-saving CVT’, the subject is selected out from the need of CVT engineering,which focuses on the difficulties of the electric-hydraulic encountered during the CVTmass production realizing process. In this paper, the theory analysis is combined withthe author’s experience in the CVT mass production; some innovative, applicable andquantitative methods are raised up, which are fully evaluated by test. The maincontent is listed as follows.
1Start from the customer request, design destination and scheme to realize it aredetermined and the independent circuit is chosen. By analysis and calculation of theCVT working conditions, based on the request of belt clamping force and ratiochanging, the max value of the line pressure, secondary pressure and the primarypressure are determined,also the time requirements on their dynamic response.
2The dual-acting blade vane pump is chosen, then its displacement is calculatedby simulation method based pressure and flow needed on the emergent stop.
3To reduce the power consuming, two new energy-saving proposals areimplemented into the system. One is the self-adaptive flow regulating, comparing tothe active flow regulating，it gets rid of the complicated structure and the difficulty tocalculated the flow needed. Also, it can reduce the pump energy consuming byregulating the flow precisely fitting the system need. Second is to take the clutchpressure as the pilot pressure of the auxiliary value, which is of higher level of clutch,this proposal makes the auxiliary pressure varying according to realistic need, then thelower pressure limitation applied on the line pressure by auxiliary pressure isremoved.
4Regarding the designed hydraulic circuit, the characteristic of the componentsare analyzed, then the simulation model of this circuit is built up, also the cylindermodels and the ratio response model. Comparing between the simulation results andthe test results is carried out, result shows well alignment between model responseand test (both time domain and frequency domain). This model is proved can be usedfor open loop system analyzing and the non-real-time close-loop simulation.
5The diversity，uncertainty and time-varying bring the consistency problem intothe DNR control. Regarding the filling time and the slipping process, oneself-learning method is introduced into, which takes the smooth turbine accelerationas the target. The learning rule is derived from on the Lyapunov argument. Then bytest, this method is proved to be applicable and asymptotic stable.
6Taken the benefit of the Phase transition point of ratio tracing the clampingforce variation, one new clamping control concept is introduced, which can beobviously decrease the pressure level and the increase the efficiency.
7Comprehensively considered the rapidly ratio changing request, the pumpability and the flow needed, one updated proposal is raised up. Comparing with thetraditional PID, this method is testing proved not can only follow the target ratio fastand stable, but also more safe for the flow and clamping force.
6. The test rig specific for the hydraulic valve body is built for testing theperformance of the hydraulic body, including the static characteristic, repeatabilityand the step response. Also on the vehicle level, kick down, emergency stop andcomprehensive working conditions are tested. By these test items, it is obviously thatthe rapidity, stability of ratio, pressure tracing and heat balance ability can fulfill thedesign purpose and customer request.
1、从客户需求入手，确定了电液系统设计目标和功能实现方案，选择双独立回路作为系统的基本结构。通过对CVT使用工况的分析计算，根据夹紧力安全和速比变化率的需求，确定了系统压力、夹紧力及速比控制回路的最高压力及各回路的动态响应特性的需求；
2创造性地将具有双压油口的双作用叶片泵等效为双联泵作为CVT电液控制系统动力源，并利用仿真计算方法，根据CVT运行的特殊工况对流量和压力的需求，确定了油泵的排量；
3、为降低系统能耗，创新地在液压回路中采用了节能型设计方案。其一，自适应流量控制回路。既回避了主动流量控制的结构复杂性，又消除了流量计算的难点，根据系统实际所需，精确调整进入系统的流量，可以大大降低油泵能量损耗；其二，使离合器压力作为其上级辅助压力回路的先导控制，使得辅助压力可以按需实时调节，消除了辅助压力背压对系统压力的遏制作用，使得系统压力有了进一步优化的空间；
4、对文中设计的电液系统，分析了各元器件的物理特性之后，采用模块化方法搭建了其物理模型，包括油缸的压力响应及变速机构的速比响应模型。利用试验数据对模型进行了验证，结果表明两者的时域和频域响应一致性较好，该模型可以用于开环系统分析和闭环非实时仿真分析；
5、参数的多样性、不确定性和时变性导致了DNR湿式离合器开环控制存在一致性难题，在分析其结合过程之后，针对半离合点和滑摩过程的控制提出了一种自学习方法。该方法将涡轮加速度作为目标，构建了李亚普诺夫判据的二次型性能方程，制定了学习规则，从理论上确保了自学习过程的渐进收敛性，工程化应用效果良好；
6、为降低夹紧力、提高传动效率，利用利用速比对夹紧力谐波输入的跟踪相位特征，制定了夹紧力控制方案,试验表明其可以有效降低夹紧力；
7、综合考虑系统对迅速改变速比的需求（较高的速比变化率）、油泵的泵油能力、系统的流量需求等因素，提出了一种对传统PID速比控制器的改进方案，试验表明，该方案在快速、稳定跟踪目标速比的前提下，确保了系统的流量安全和夹紧力安全。
8、开展了电液控制模块测试和整车级别的测试。电液控制模块的测试内容包括静态压力测试，稳态调压测试以及阶跃响应测试等，结果表明压力水平、稳态调压重复精度及阶跃响应的快速性均能满足系统的设计目标。整车级别的测试主要针对紧急制动、急加速以及综合使用工况，目的是为了测试电液控制系统在整车的控制效果能否满足动力总成的使用需求，从试验曲线来看，速比、压力跟踪的准确性和快速性、以及整机的热平衡流量均能满足设计要求和使用要求。
Relying on the platform of combination of ‘production, studying andresearching’, based on International Cooperation Project’New-GenerationEnergy-saving CVT’, the subject is selected out from the need of CVT engineering,which focuses on the difficulties of the electric-hydraulic encountered during the CVTmass production realizing process. In this paper, the theory analysis is combined withthe author’s experience in the CVT mass production; some innovative, applicable andquantitative methods are raised up, which are fully evaluated by test. The maincontent is listed as follows.
1Start from the customer request, design destination and scheme to realize it aredetermined and the independent circuit is chosen. By analysis and calculation of theCVT working conditions, based on the request of belt clamping force and ratiochanging, the max value of the line pressure, secondary pressure and the primarypressure are determined,also the time requirements on their dynamic response.
2The dual-acting blade vane pump is chosen, then its displacement is calculatedby simulation method based pressure and flow needed on the emergent stop.
3To reduce the power consuming, two new energy-saving proposals areimplemented into the system. One is the self-adaptive flow regulating, comparing tothe active flow regulating，it gets rid of the complicated structure and the difficulty tocalculated the flow needed. Also, it can reduce the pump energy consuming byregulating the flow precisely fitting the system need. Second is to take the clutchpressure as the pilot pressure of the auxiliary value, which is of higher level of clutch,this proposal makes the auxiliary pressure varying according to realistic need, then thelower pressure limitation applied on the line pressure by auxiliary pressure isremoved.
4Regarding the designed hydraulic circuit, the characteristic of the componentsare analyzed, then the simulation model of this circuit is built up, also the cylindermodels and the ratio response model. Comparing between the simulation results andthe test results is carried out, result shows well alignment between model responseand test (both time domain and frequency domain). This model is proved can be usedfor open loop system analyzing and the non-real-time close-loop simulation.
5The diversity，uncertainty and time-varying bring the consistency problem intothe DNR control. Regarding the filling time and the slipping process, oneself-learning method is introduced into, which takes the smooth turbine accelerationas the target. The learning rule is derived from on the Lyapunov argument. Then bytest, this method is proved to be applicable and asymptotic stable.
6Taken the benefit of the Phase transition point of ratio tracing the clampingforce variation, one new clamping control concept is introduced, which can beobviously decrease the pressure level and the increase the efficiency.
7Comprehensively considered the rapidly ratio changing request, the pumpability and the flow needed, one updated proposal is raised up. Comparing with thetraditional PID, this method is testing proved not can only follow the target ratio fastand stable, but also more safe for the flow and clamping force.
6. The test rig specific for the hydraulic valve body is built for testing theperformance of the hydraulic body, including the static characteristic, repeatabilityand the step response. Also on the vehicle level, kick down, emergency stop andcomprehensive working conditions are tested. By these test items, it is obviously thatthe rapidity, stability of ratio, pressure tracing and heat balance ability can fulfill thedesign purpose and customer request.
引文
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