摘要
本文根据皖政文件（〔2009〕108号）关于加快推进“重大科技项目”实施的背景，对重型叉车自动变速器项目进行了研究，同时本文的研究工作也得到国家自然科学基金项目“平衡重式叉车底盘系统横向稳定性集成控制研究”（51205101）和安徽省十二五科技攻关项目“工程机械自动变速控制系统”（12010202032）的支持与资助。项目的实施将提高国内叉车核心零部件的水平，填补国内在该领域的空白;文中针对叉车的特殊工作特点，在改善换挡经济性，尤其是在影响传动系统效率较大的变矩器的性能提升研究方面，进行了大量的基础工作，同时在换挡规律和平顺性、以及特殊工况，如低附着路面、坡道等进行了测试、研究、仿真、试验，主要研究内容和结论如下：
（1）运用DOE方法对液力变矩器叶栅相关参数进行敏感性研究。在建立液流广义的环坐标系的基础上，对叶片数据进行计算、分析，并提炼出叶形设计流线的数学表达式，在此基础上进一步推导出新的变矩器原始特性表达式，完成对变矩器性能的优化，提升工作效率，并进行台架试验验证，此方法拓宽了变矩器研发的新途径。
（2）针对叉车使用场所、工况的特殊性，提出了一种基于操作意愿、叉车工况和路面状态的分层递阶协调控制策略，实现了对不同工况的分析、决策、控制，优化了叉车对恶劣场所操作时换挡的适应性，并获得满意的换挡效果，为叉车自动变速智能化控制策略的深入研究提供一定的理论参考。
（3）坡道换挡是叉车行驶的典型工况，本文通过对重型叉车坡道换挡参数的测试及其对坡道换挡性能的影响分析，采用智能仿人控制的误差理论对坡道状态参数进行识别，同时运用模糊了控制理论建立了换挡数据库，并进行不同载荷下坡道自动换挡试验，有效地解决了传统叉车坡道换挡熄火、溜车以及离合器滑磨时间过长的缺点。
（4）针对叉车起步换挡对其工作性能的影响十分重要的特点，通过分析湿式离合器分离、结合的运动过程，建立离合器换挡动力学模型，得到力学平衡方程，以及离合器传递的扭矩与结合力的关系。并对原变速器的液压控制系统进行重新设计，台架试验表明，新的控制系统比原系统具有更好的平顺性；同时，提出了一套叉车起步、换挡评价方法。
（5）在MATLAB/simulink中建立叉车整车传动系统动力学模型，并对自动变速器及其零部件进行仿真研究，同时，基于ARM7开发平台进行叉车自动变速控制系统TCU软硬件设计，并对其按国家标准进行电磁兼容、抗震、防水等可靠性测试，台架和整车车试验表明，换挡可靠高，平顺性好，满足设计标准。
通过重型叉车自动变速技术研究和产品开发，在叉车自动变速的关键技术方面取得一定突破，打破国外的技术壁垒，降低成本，提高产品综合性能，增加核心竞争力。
According to WAN Zheng (2009) No.108document on the accelerating the implementationof major scientific and technological projects, the heavy truck automatic transmission was studiedin this paper, at the same time, the paper research work also obtained the financial support ofNational Natural Science Foundation Program of China (No.51205101) that was the integratedcontrol study on the lateral stability of balance forklift chassis system and the Twelfth Five-yearscience and technology Program of Anhui Province (No.12010202032) that was the automatictransmission control system of engineering machinery. The implementation of the project wouldimprove the level of the core components of the domestic forklift and fill the domestic blank inthis field. According to the working characteristics of the forklift truck automatic transmission,much fundamental work was carried out in improving shifting economy, in the study of improvingtorque converter efficiency that play large role of transmission performance especially. At thesame time, the shifting tactics and smoothness, and special working conditions such as the lowadhesion road, ramp and etc. were researched, simulated and tested, the main research contentsand conclusions are as follows:
(1) DOE methods was used to study relevant parameters sensitivity of torque converterblades. Based on generalized torus coordinate system of liquid flow, the shape parameters of bladewere calculated and analyzed, the mathematical expression of the blade baseline was put forward,At the same time, the original characteristic expression of new torque converter was furtherdeduced, the converter performance optimization was completed, its efficiency had been improvedand verified by bench test, this method offers a new choice for torque converter research.
(2) According to the particularity of forklift work places and conditions, this paper proposeda method of layered hierarchical coordinated control strategy on the intention of a driver, vehicleand road environment, the method can make the analysis, decision-making, control under differentoperating conditions, and optimize the shifting adaptability of the forklift at bad place, and getsatisfactory shifting effect, this will provide a theoretical reference to in-depth study of intelligentcontrol strategy for the truck automatic transmission.
(3) The ramp shift is typical operating in forklift driving, the shifting parameters were testedand parameters influence was analyzed to ramp performance in this paper. The ramp statusparameters could been recognized by the error theory of simulating human intelligent control, theautomatic shifting database was established by fuzzy control theory, and ramp automatic shifting test was finished under different loading, the method effectively solved the engine flameout, rampsliding and longer clutch friction time.
(4) Forklift starting shift have very important influence on operating performance, byanalyzing the wet clutch movement processes of separation and combination, the clutch shiftingdynamic model was created，its equilibrium equation and the relationship between clutch torqueand binding force were obtained. The hydraulic control system of the transmission was redesignedand the test results indicated that a new control system had better smoothness than the original, aset of forklift starting shift evaluation method was proposed finally.
(5) The forklift vehicle transmission system dynamic model was created and then simulatedon MATLAB/simulink，at the same time, the hardware and software of automatic transmissioncontrol unit（TCU）were designed on the ARM7development platform, TCU reliability tests forelectromagnetic compatibility, earthquake-resistant, waterproof and etc. were finished accordingto national standard, then, bench and vehicle tests showed that higher shifting reliability and bettershifting smoothness had met design requirements.
Through the study and design of heavy-duty truck automatic transmission, our enterpriseobtained the breakthrough in the key technology, it broke the foreign technology barriers, reducedthe cost, but also improved product performance and increased the core competitiveness.
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