基于TC的AMT湿式主离合器操控系统及控制研究
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摘要
结合液力变矩器(Torque Converter, TC)和机械式自动变速器(Automated Manual Transmission, AMT)的研究成果,吉林大学葛安林教授创造性地提出将TC与AMT集成的液力机械式自动换档系统(TC+AMT),该基于TC的AMT系统避开了AT制造工艺的复杂和高成本以及AMT在起步困难和换档品质差的缺点,国内完全具有设计、加工能力。
本文结合“轻型战术车辆的牵引力控制系统”项目,针对TC+AMT系统的结构特点分析了其液压操控系统的特性,开展了主离合器的设计与控制技术研究工作,并通过优化湿式主离合器的控制策略来提高TC+AMT系统的换档品质。
为实现主离合器的分离、结合的精确控制,提出离合器的操控系统对高速开关电磁阀和压力传感器的需求,搭建了主离合器电磁阀特性试验台,实验研究了电磁阀的流量-压力特性,并对压力传感器进行了标定。
建立了以电磁阀PWM控制信号为输出量的离合器操控系统模型,仿真研究了离合器接合PID控制算法。根据目标值与实际值的比较,分析PID控制算法并进行了参数调整,取得了较好的控制效果。
基于总线技术为湿式离合器的操控系统建立了一个信息采集系统。由PC机作为上位机,用CANoe软件来监测系统的运行。控制高速开关电磁阀的动作,采集离合器分离、接合过程中的压力变化,并将数据转换后传到上位机处理。
The Automated Manual Transmission (AMT) retains the merits of the traditional manual gearboxes, such as high efficiency and good economy efficiency; it greatly meets the realistic demand of China’s automobile development. By combining the research achievements on Torque Convertor and automatic gear shifting system development of parallel gearbox, Pro. Anlin Ge in Jilin University proposes a new type gear shifting system, which is hydro-dynamic mechanical gear shifting system, namely“TC+AMT”, and our country is capable of designing and machining of the system. The system avoids the shortcomings of Automatic Transmission (AT) and AMT, that is to say, the high cost, manufacturing technology complexity of AT for using planetary transmission and the difficulty in starting process and poor shift quality of AMT.
The dissertation is based on the research project“Traction Control system of Light Duty Tactical Vehicle”, I have been done a series of research work. Firstly, I have done some work on designing the layout of the system according to the vehicle; Secondly, by combining the structure property of the system, I have designed and analyzed the hydraulic sub-system of the transmission; Finally I carried out a research work on the design and control of the wet shifting clutch, moreover, I do a further study on the hydraulic circuit for the clutch. The main purpose of the dissertation is to improve the shift quality of the automatic transmission by optimizing the engagement schedule of clutch.
Because of the using of Torque Convertor, which has the ability of amplifying torque from the engine, the New-type Automatic Shifting System avoid the complex control of starting process in AMT, and all we need to do is the control of shifting process. According to difference power source of the automatic actuator for clutch, it mainly can be divided into three types: the electro-hydraulic, the fully electronic and the electro-pneumatic. Based on the property of the“TC+AMT”system, we selected the electro-hydraulic actuator, the power is provided by the hydraulic pump integrated to the automatic transmission system, and the cost has been pulled down immensely.
Binding to the property, function and principle of the wet clutch, we developed its structure, analyzed its friction characteristics. There are three stages in the engagement of the wet clutch: squeeze, compact and rough, and the lubrication change from liquid lubricate to boundary lubricate. According to the sliding friction property of wet clutch, I have constructed the MATLAB/Simulink simulation model for the sliding stage and locked stage of the clutch.
By analyzing the engagement of the wet clutch, we obtained the key points of the operation mechanism of the clutch. According to the design specification, it calculates the structure parameters and adjusted by the reference design manual. The fluid state is defined by the calculated Reynolds number, and the corresponding resistance and pressure drop is calculated in different situations. Because the clutch needs accurate control in the disengagement and engagement process, therefore, we selected the high speed on-off solenoid valve and the pressure sensor for the clutch according to our experimental and design experience, besides, I have prepared a hydraulic test bench for the solenoid valve, and obtained the flow-pressure property of the solenoid valve, furthermore, I have done an experiment calibration for the pressure sensor.
Several important properties of clutch are analyzed before the electro-hydraulic system’s simulation and analysis: the load and disengagement characteristic of disc spring which means the load-distortion relation of its big and small end during the process of clutch engagement and disengagement; the torque transmission property of three phases during the process of clutch engagement, analyzes those factors which influence the torque transmission; the wear abrasion property analyzes the relation between abrasion loss and friction work and how the application factors work on the relation between abrasion loss and friction work, and studies how the change of abrasion loss affects torque transmission. The viscosity of hydraulic oil is chosen by previous experimental experience and then sets the initial condition of the hydraulic valves and the properties of fluid. The simplified model of clutch disengagement and engagement process is built respectively; the simulation and analysis work is taken based on those calculated structure parameters. The pressure and flow change at the output port of on-off hydraulic valve, the volume and pressure change and the displacement of piston of hydraulic actuator cylinder.
The control law during clutch engagement is gained through stressing the analysis of three phases of clutch engagement. The respective feature and range of application of PID control, fuzzy control, self-adapting control and intelligent control is introduced and then choose PID as the control algorithm. According to the feature of system structure and control, a clutch engagement model is established which takes the PWM signal of the hydraulic valve as the control output, and then simulate and analyze the engagement process, and it will give some help to the next experimental work.
A information acquisition system is built based on the CAN bus technology aiming at the clutch automatic operating system. It takes PC as position machine and uses the software: CANoe to monitor the run state, and sets CAN database and CAPL and the variables according to the test requirement, such as the hydraulic pressure of the cylinder. Then we designed the panel which can appropriately control those variables. It uses the built MATLAB/Simulink model to produce program code and transfer to Cosmic to run, the control program and bottom API could be compiled in Cosmic. It debugs program by changing the control variables on panel while running CANoe to monitor the system state. It uses the panel to control the action of hydraulic valves, collect the data about the hydraulic pressure in the hydraulic cylinder of the wet clutch during disengagement and engagement process, and then convert these data to pass to position machine. It analyzes and adjusts the PID control algorithm by comparing the difference between the target and realistic pressure and the control purpose is gained properly.
本文结合“轻型战术车辆的牵引力控制系统”项目,针对TC+AMT系统的结构特点分析了其液压操控系统的特性,开展了主离合器的设计与控制技术研究工作,并通过优化湿式主离合器的控制策略来提高TC+AMT系统的换档品质。
为实现主离合器的分离、结合的精确控制,提出离合器的操控系统对高速开关电磁阀和压力传感器的需求,搭建了主离合器电磁阀特性试验台,实验研究了电磁阀的流量-压力特性,并对压力传感器进行了标定。
建立了以电磁阀PWM控制信号为输出量的离合器操控系统模型,仿真研究了离合器接合PID控制算法。根据目标值与实际值的比较,分析PID控制算法并进行了参数调整,取得了较好的控制效果。
基于总线技术为湿式离合器的操控系统建立了一个信息采集系统。由PC机作为上位机,用CANoe软件来监测系统的运行。控制高速开关电磁阀的动作,采集离合器分离、接合过程中的压力变化,并将数据转换后传到上位机处理。
The Automated Manual Transmission (AMT) retains the merits of the traditional manual gearboxes, such as high efficiency and good economy efficiency; it greatly meets the realistic demand of China’s automobile development. By combining the research achievements on Torque Convertor and automatic gear shifting system development of parallel gearbox, Pro. Anlin Ge in Jilin University proposes a new type gear shifting system, which is hydro-dynamic mechanical gear shifting system, namely“TC+AMT”, and our country is capable of designing and machining of the system. The system avoids the shortcomings of Automatic Transmission (AT) and AMT, that is to say, the high cost, manufacturing technology complexity of AT for using planetary transmission and the difficulty in starting process and poor shift quality of AMT.
The dissertation is based on the research project“Traction Control system of Light Duty Tactical Vehicle”, I have been done a series of research work. Firstly, I have done some work on designing the layout of the system according to the vehicle; Secondly, by combining the structure property of the system, I have designed and analyzed the hydraulic sub-system of the transmission; Finally I carried out a research work on the design and control of the wet shifting clutch, moreover, I do a further study on the hydraulic circuit for the clutch. The main purpose of the dissertation is to improve the shift quality of the automatic transmission by optimizing the engagement schedule of clutch.
Because of the using of Torque Convertor, which has the ability of amplifying torque from the engine, the New-type Automatic Shifting System avoid the complex control of starting process in AMT, and all we need to do is the control of shifting process. According to difference power source of the automatic actuator for clutch, it mainly can be divided into three types: the electro-hydraulic, the fully electronic and the electro-pneumatic. Based on the property of the“TC+AMT”system, we selected the electro-hydraulic actuator, the power is provided by the hydraulic pump integrated to the automatic transmission system, and the cost has been pulled down immensely.
Binding to the property, function and principle of the wet clutch, we developed its structure, analyzed its friction characteristics. There are three stages in the engagement of the wet clutch: squeeze, compact and rough, and the lubrication change from liquid lubricate to boundary lubricate. According to the sliding friction property of wet clutch, I have constructed the MATLAB/Simulink simulation model for the sliding stage and locked stage of the clutch.
By analyzing the engagement of the wet clutch, we obtained the key points of the operation mechanism of the clutch. According to the design specification, it calculates the structure parameters and adjusted by the reference design manual. The fluid state is defined by the calculated Reynolds number, and the corresponding resistance and pressure drop is calculated in different situations. Because the clutch needs accurate control in the disengagement and engagement process, therefore, we selected the high speed on-off solenoid valve and the pressure sensor for the clutch according to our experimental and design experience, besides, I have prepared a hydraulic test bench for the solenoid valve, and obtained the flow-pressure property of the solenoid valve, furthermore, I have done an experiment calibration for the pressure sensor.
Several important properties of clutch are analyzed before the electro-hydraulic system’s simulation and analysis: the load and disengagement characteristic of disc spring which means the load-distortion relation of its big and small end during the process of clutch engagement and disengagement; the torque transmission property of three phases during the process of clutch engagement, analyzes those factors which influence the torque transmission; the wear abrasion property analyzes the relation between abrasion loss and friction work and how the application factors work on the relation between abrasion loss and friction work, and studies how the change of abrasion loss affects torque transmission. The viscosity of hydraulic oil is chosen by previous experimental experience and then sets the initial condition of the hydraulic valves and the properties of fluid. The simplified model of clutch disengagement and engagement process is built respectively; the simulation and analysis work is taken based on those calculated structure parameters. The pressure and flow change at the output port of on-off hydraulic valve, the volume and pressure change and the displacement of piston of hydraulic actuator cylinder.
The control law during clutch engagement is gained through stressing the analysis of three phases of clutch engagement. The respective feature and range of application of PID control, fuzzy control, self-adapting control and intelligent control is introduced and then choose PID as the control algorithm. According to the feature of system structure and control, a clutch engagement model is established which takes the PWM signal of the hydraulic valve as the control output, and then simulate and analyze the engagement process, and it will give some help to the next experimental work.
A information acquisition system is built based on the CAN bus technology aiming at the clutch automatic operating system. It takes PC as position machine and uses the software: CANoe to monitor the run state, and sets CAN database and CAPL and the variables according to the test requirement, such as the hydraulic pressure of the cylinder. Then we designed the panel which can appropriately control those variables. It uses the built MATLAB/Simulink model to produce program code and transfer to Cosmic to run, the control program and bottom API could be compiled in Cosmic. It debugs program by changing the control variables on panel while running CANoe to monitor the system state. It uses the panel to control the action of hydraulic valves, collect the data about the hydraulic pressure in the hydraulic cylinder of the wet clutch during disengagement and engagement process, and then convert these data to pass to position machine. It analyzes and adjusts the PID control algorithm by comparing the difference between the target and realistic pressure and the control purpose is gained properly.
引文
[1]葛安林.车辆自动变速理论与设计[M].机械工业出版社,1993
[2]雷雨龙.提高电控机械式自动变速器性能的研究[D].吉林工业大学博士学位论文.1999.1.20
[3]葛安林.自动变速器(一)自动变速器综述[J].汽车技术,2001(5)
[4]葛均师.重型商用车离合器自动操纵系统研究[D].吉林大学硕士学位论文,2008
[5]仝鑫.自动变速器换档规律及仿真[D].吉林大学硕士学位论文,2008
[6]雷雨龙,盛培德,葛安林,胡廷辉.液力机械式自动换档系统[P] :中国,200820071758.4[P].2009-01-21
[7]Professor Dr.-Ing.Gisbirt Lechner. Automotive Transmissions: fundamentals, selection ,design, and application[M].Berlin:Springer-Verlag Berlin Heidelberg,1999
[8]中国汽车高峰论坛组委会.中日汽车高峰论坛[C].湖南:2008
[9]朱经昌,魏宸官,郑慕侨.车辆液力传动(下册)[M].北京:国防工业出版社,1983-6:163-213
[10]北京市粉末冶金研究所.粉末冶金摩擦材料[M].北京:机械工业出版社,1977-1
[11]易先忠.碟形弹簧基本特性参数分析[J].石油机械,1995(3)
[12]温诗铸.摩擦学原理[M].北京:清华大学出版社,1990
[13]金伦.双离合器自动变速器建模与控制策略的研究[D].吉林大学博士学位论文,2006
[14]王健.换档质量综合评价系统的研究[D],吉林大学博士学位论文,2007
[15]李宽.AMT起步及换档过程冲击特性的研究[D],吉林大学硕士学位论文,2008
[16]张建国.基于神经网络的AMT换档品质评价方法研究[D].吉林大学硕士学位论文,2007
[17]Tadashige Hirano, Kenji Maruo, Xiaoming Gu and Tamotsu Fujii, Development of Friction Material and Quantitative Analysis for Hot Spot Phenomenon in Wet Clutch System[R].SAE International.SAE2007-01-0242.
[18]G. Rizzoni X. Wei. Objective metrics of fuel economy, performance and driveability- a review[R]. SAE International. SAE 2004-01-1338.
[19]Sarawoot Watechagit and Krishnaswamy Sriniasan, Modeling and Simulation of aShift Hydraulic system for a Stepped Automatic Transmission[R]. SAE International. SAE2003-01-0314
[20]T. T. Georgiou, Remarks on differential stability on nonlinear system[C]. Proceedings of the 33rd Conference on Decision and Control. Lake Buena Vista, 1994
[21] Hisanao Kitabayashi, Chen Yu Li, Henry Hiraki, Analysis of the Various Factors Affecting Drag Torque in Multi-plate Wet Clutches[R]. SAE International. SAE2003-01-1973
[22]高炳钊.AMT液压系统仿真及其应用[D].吉林大学硕士学位论文,2002
[23]J. Persson. Integrated power train control - a literature survey on longitudinal vibrations, drivability aspects and future challenges [D].Master’s thesis, Department of Signals and Systems, Chalmers University of Technology, March 2004.
[24]Donn Fairbank, Kenji Maruo, Shuqin Du and Timothy Newcomb.ATF Additive Effects on Hot SpotFormation in Wet Clutches[R].SAE International.SAE2001-01-3594
[25] Timothy M. Cameron, Samuel H. Tersigni, Tracy McCombs and Tze-Chi Jao. ATF Effects on Friction Stability in Slip-Controlled Torque Converter Clutches[R].SAE International.SAE2003-01-3255
[26]王积伟,章宏甲,黄宜.液压与气压传动[M].北京:机械工业出版社,2005
[27]刘啸,聂文杰.电磁阀设计计算[J].电器开关,2008(3)
[28]Mazda Motor Corporation. Automatic Transaxle Workshop Manual [M]. PRINTED IN BELGIUM, MAY 1998
[29]Baek-Hyun Cho, Gyu-Hong Jung, Jae-Woong Hur and Kyo-Il Lee. Modeling of Proportional Control Solenoid Valve for Automatic Transmission Using System Identification Theory[R]. SAE International.SAE1999-01-1061
[30]Baek-Hyun Cho, Jong-Sun Oh and Won-Hi Lee. Modeling of Pulse Width Modulation Pressure Control System for Automatic Transmission.SAE International.SAE2002-01-1257
[31]陈宝江,杨树兴,曹泛.PWM高速开关阀特性分析[J]北京理工大学学报,1993(3)
[32]牛铭奎,葛安林,张洪坤.高速开关电磁阀的特性与应用研究[J]汽车工程,1997(7)
[33]李玉贵等. PWM高速开关阀静态特性研究[J].太原重型机械学院学报,2002(3)
[34]张晋凯,周静.高速开关阀在数字调压系统中的研究[J].中国仪器仪表,2007(2)
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[42]张泰.越野汽车液力变矩器和机械自动变速系统的控制理论与试验[D].吉林大学博士学位论文,2004
[43]金伦,程秀生,葛安林,佟静.AMT换档过程的离合器控制[J].汽车技术,2006(1)
[44]牛铭奎,程秀生,葛安林等.AMT离合器接合过程中的压力控制[J].吉林大学学报(工学版),2004(2)
[45]Ching-Huan Tseng and Ming-Feng Hsieh. Analysis and Optimization of Clutch Actuator on Automated Manual Transmission System. SAE International[R].SAE2005-01-1782
[46]J. C. Wheals, C. Crewe, M. Ramsbottom, S. Rook and M. Westby. Automated Manual Transmissions-A European Survey and Proposed Quality Shift Metrics[R]. SAE International.SAE2002-01-0929
[47]Yoshinori Taguchi, Yoshitaka Soga, Akira Mineno , Hideki Kuzuya, Ichiro Horiuchi, Yukio Ueda and Takeshige Miyazaki. Development of an Automated Manual Transmission System Based on Robust Design[R]. SAE International.SAE2003-01-0592
[48]Yong-Sheng Zhao, Li-Ping Chen,Yun-Qing Zhang, Jingzhou Yang. Enhanced Fuzzy Sliding Mode Controller for Automated Clutch of AMT Vehicle[R]. SAE International.SAE 2006-01-1488
[49]刘金琨.先进PID控制及MATLAB仿真[M].北京:电子工业出版社,2003
[50]黄永安,马路,刘慧敏.MATLAB7.0/Simulink6.0建模仿真开发与高级工程应用[M].北京:清华出版社,2005
[51]陶永华,尹怡欣,葛芦生.新型PID控制及其应用[M].北京:机械工业出版社,2001
[2]雷雨龙.提高电控机械式自动变速器性能的研究[D].吉林工业大学博士学位论文.1999.1.20
[3]葛安林.自动变速器(一)自动变速器综述[J].汽车技术,2001(5)
[4]葛均师.重型商用车离合器自动操纵系统研究[D].吉林大学硕士学位论文,2008
[5]仝鑫.自动变速器换档规律及仿真[D].吉林大学硕士学位论文,2008
[6]雷雨龙,盛培德,葛安林,胡廷辉.液力机械式自动换档系统[P] :中国,200820071758.4[P].2009-01-21
[7]Professor Dr.-Ing.Gisbirt Lechner. Automotive Transmissions: fundamentals, selection ,design, and application[M].Berlin:Springer-Verlag Berlin Heidelberg,1999
[8]中国汽车高峰论坛组委会.中日汽车高峰论坛[C].湖南:2008
[9]朱经昌,魏宸官,郑慕侨.车辆液力传动(下册)[M].北京:国防工业出版社,1983-6:163-213
[10]北京市粉末冶金研究所.粉末冶金摩擦材料[M].北京:机械工业出版社,1977-1
[11]易先忠.碟形弹簧基本特性参数分析[J].石油机械,1995(3)
[12]温诗铸.摩擦学原理[M].北京:清华大学出版社,1990
[13]金伦.双离合器自动变速器建模与控制策略的研究[D].吉林大学博士学位论文,2006
[14]王健.换档质量综合评价系统的研究[D],吉林大学博士学位论文,2007
[15]李宽.AMT起步及换档过程冲击特性的研究[D],吉林大学硕士学位论文,2008
[16]张建国.基于神经网络的AMT换档品质评价方法研究[D].吉林大学硕士学位论文,2007
[17]Tadashige Hirano, Kenji Maruo, Xiaoming Gu and Tamotsu Fujii, Development of Friction Material and Quantitative Analysis for Hot Spot Phenomenon in Wet Clutch System[R].SAE International.SAE2007-01-0242.
[18]G. Rizzoni X. Wei. Objective metrics of fuel economy, performance and driveability- a review[R]. SAE International. SAE 2004-01-1338.
[19]Sarawoot Watechagit and Krishnaswamy Sriniasan, Modeling and Simulation of aShift Hydraulic system for a Stepped Automatic Transmission[R]. SAE International. SAE2003-01-0314
[20]T. T. Georgiou, Remarks on differential stability on nonlinear system[C]. Proceedings of the 33rd Conference on Decision and Control. Lake Buena Vista, 1994
[21] Hisanao Kitabayashi, Chen Yu Li, Henry Hiraki, Analysis of the Various Factors Affecting Drag Torque in Multi-plate Wet Clutches[R]. SAE International. SAE2003-01-1973
[22]高炳钊.AMT液压系统仿真及其应用[D].吉林大学硕士学位论文,2002
[23]J. Persson. Integrated power train control - a literature survey on longitudinal vibrations, drivability aspects and future challenges [D].Master’s thesis, Department of Signals and Systems, Chalmers University of Technology, March 2004.
[24]Donn Fairbank, Kenji Maruo, Shuqin Du and Timothy Newcomb.ATF Additive Effects on Hot SpotFormation in Wet Clutches[R].SAE International.SAE2001-01-3594
[25] Timothy M. Cameron, Samuel H. Tersigni, Tracy McCombs and Tze-Chi Jao. ATF Effects on Friction Stability in Slip-Controlled Torque Converter Clutches[R].SAE International.SAE2003-01-3255
[26]王积伟,章宏甲,黄宜.液压与气压传动[M].北京:机械工业出版社,2005
[27]刘啸,聂文杰.电磁阀设计计算[J].电器开关,2008(3)
[28]Mazda Motor Corporation. Automatic Transaxle Workshop Manual [M]. PRINTED IN BELGIUM, MAY 1998
[29]Baek-Hyun Cho, Gyu-Hong Jung, Jae-Woong Hur and Kyo-Il Lee. Modeling of Proportional Control Solenoid Valve for Automatic Transmission Using System Identification Theory[R]. SAE International.SAE1999-01-1061
[30]Baek-Hyun Cho, Jong-Sun Oh and Won-Hi Lee. Modeling of Pulse Width Modulation Pressure Control System for Automatic Transmission.SAE International.SAE2002-01-1257
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