<p><p>The Dual Clutch Transmission (DCT) is a relatively new kind of transmission which shows increased efficiency and comfort compared to manual transmissions. Its construction is much like two parallell manual transmissions, where the gearshifts are controlled automatically. The gear-shift of a manual transmission involves a synchronization process, which synchronizes and locks the input shaft to the output shaft via the desired gear ratio. This process, which means transportation of a synchronizer sleeve, is performed by moving the gear shift lever which is connected to the sleeve. In a DCT, there is no mechanical connection between the gear-shift lever and the sleeve. Hence, an actuator system, controlled by a control system, must be used.</p><p>This report includes modelling, control system design and simulation results of a DCT synchronization process. The thesis work is performed at GM Powertrain (GMPT) in Trollhättan. At the time of this thesis, there is no DCT produced by GM, and therefore the results and conclusions rely on simulations. Most of the used system parameters are reasonable values collected from employees at GMPT and manual transmission literature.</p><p>The focus of the control design is to achieve a smooth, rather than fast, movement of the synchronizer sleeve. Simulations show that a synchronization process can be performed in less than 400 ms under normal conditions. The biggest problems controlling the sleeve position occur if there is a large amount of drag torque affecting the input shaft. Delay problems also worsen the performance a lot. An attempt to predict the synchronizer sleeve position is made and simulations shows advantages of that.</p><p>Some further work is needed before the developed control software can be used on a real DCT. Investigations of sensor noise robustness and the impact of dogging forces are the most important issues to be further investigated. Implementation of additional functionality for handling special conditions are also needed.</p></p>

The Dual Clutch Transmission (DCT) is a relatively new kind of transmission which shows increased efficiency and comfort compared to manual transmissions. Its construction is much like two parallell manual transmissions, where the gearshifts are controlled automatically. The gear-shift of a manual transmission involves a synchronization process, which synchronizes and locks the input shaft to the output shaft via the desired gear ratio. This process, which means transportation of a synchronizer sleeve, is performed by moving the gear shift lever which is connected to the sleeve. In a DCT, there is no mechanical connection between the gear-shift lever and the sleeve. Hence, an actuator system, controlled by a control system, must be used. This report includes modelling, control system design and simulation results of a DCT synchronization process. The thesis work is performed at GM Powertrain (GMPT) in Trollhättan. At the time of this thesis, there is no DCT produced by GM, and therefore the results and conclusions rely on simulations. Most of the used system parameters are reasonable values collected from employees at GMPT and manual transmission literature. The focus of the control design is to achieve a smooth, rather than fast, movement of the synchronizer sleeve. Simulations show that a synchronization process can be performed in less than 400 ms under normal conditions. The biggest problems controlling the sleeve position occur if there is a large amount of drag torque affecting the input shaft. Delay problems also worsen the performance a lot. An attempt to predict the synchronizer sleeve position is made and simulations shows advantages of that. Some further work is needed before the developed control software can be used on a real DCT. Investigations of sensor noise robustness and the impact of dogging forces are the most important issues to be further investigated. Implementation of additional functionality for handling special conditions are also needed.

This master’s thesis deals with design of manipulator which manipulate the types of shift forks 1/5, 2/4, 3/7 and 6/R. The machine takes parts from the belt, which transports them from mark station. Parts are moved to the straightening machine by manipulator. Straightened parts are transported on the storage place, from which are sorted into the boxes and palletized by robot. As a part of work is the proposal of alternativ solutions, selecting the best solution, the design of the chosen variant and technical calculations of the main parts of the manipulator. The work includes the accompanying drawings, assembly drawings and 3D model.

Gear shifts are becoming more and more important as engines are adapted to low speed high torque working conditions. Synchronizers are key components for successful gear shifts. To adapt the synchronizers to new working conditions due to adaptations to new engines, improved development tools are needed. The presented thesis describes the development of two types of numerical models for the synchronization process, namely fluid-structure interaction to simulate the pre-synchronization phase and thermomechanical FE models to simulate the main synchronization phase. A methodology for developing friction models based on a combination of physical testing and numerical simulations is presented. Additionally, a comprehensive gear shift and synchronizer frame of reference section is presented. In paper A, two numerical fluid-structure interaction simulation models for assessing the pre-synchronization phase are presented. Simulations show that the synchronizer functionality is highly dependent on the gear shift maneuvering system, and that grooves in the synchronizer surface have a positive effect on the oil evacuation during the pre-synchronization phase. Paper B describes the development of a numerical thermomechanical model for simulating the main synchronization phase. Two parameter studies were performed, one based on external loads and one based on synchronizer geometry. The effect on the temperature increase from differences in thermal properties between molybdenum and carbon friction linings are presented. In paper C, a verification and validation methodology for highly transient thermomechanical processes was presented. Numerical verification, bulk temperature measurement, surface temperature measurement and qualitative visual inspection were combined to verify and validate the simulation model presented in paper B. In paper D, a methodology combining physical testing with an thermomechanical simulation model to develop a friction model was exemplified by a molybdenum coated synchronizer. A simplified thermal model was developed to remove the dependence of full finite element thermal models. The friction models shows good agreement with measured data. / Betydelsen av växlingar i en växellåda har ökat, och synkroniseringsenheter är viktiga komponenter för snabba och robusta växlingar. För att anpassa synkroniseringsenheterna till nya arbetsförhållanden och laster krävs nya utvecklingsverktyg. Denna avhandling innehåller två typer av numeriska modeller för att simulera synkroniseringsförloppet. Multifysikmodeller som kopplar samman oljeflöde och solida kroppar används för att simulera försynkroniseringsfasen. En termomekanisk modell används för att simulera synkroniseringsfasen. En metod för att utveckla friktionsmodeller under synkroniseringsfasen genom att kombinera fysisk provning med numerisk simulering presenteras. Dessutom finns ett utförligt kapitel om synkroniserings- och växlingsteori. I artikel A presenteras två olika "Fluid-Structure interaction" ("Interaktion mellan vätskeflöde och solida kroppar") för att simulera försynkroniseringsfasen. Simuleringarna visar att synkroniseringsenheter är väldigt beroende av de aktuatorer de är kopplade till, samt att oljedräneringsspår i kontaktytan har en positiv effekt för försynkroniseringsförloppet. Artikel B beskriver utvecklingen av en termomekanisk modell för att simulera synkroniseringsförloppet. Två parameterstudier utfördes, en där de externa lasterna utvärderas, och en där geometrin på synkroniseringsenheten utvärderas. Effekten av skillnaden i termiska egenskaper hos molybden och kolfiber utvärderas också. Artikel C beskriver metodik för verifiering och validering av termomekaniska simuleringar av starkt transienta förlopp. En kombination av numerisk verifiering, temperaturmätning i materialet, yttemperaturmätning samt kvalitativ visuell bedömning används för att verifiera och validera simuleringsmodellen som utvecklades i artikel B. I artikel D beskrivs en metodik för att kombinera fysiska prover med en uppdaterad termomekanisk simuleringsmodell för att beskriva friktionsbeteendet under synkronisering. Metoden exemplifieras med en molybdenbelagd synkroniseringsenhet. En förenklad termisk modell utvecklas för att kunna beskriva friktionsbeteendet utan att använda tidskrävande finita elementmodeller. Den nya friktionsmodellen överensstämmer väl med uppmätt data. / <p>QC 20160218</p>

Automated gear-shifts are critical procedures for the driveline as they are demanded to work as fast and accurate as possible. The torque control of a driveline is especially important for the driver’s feeling of driveability. In the case of gear-shifts and torque control in general, the boost pressure is key to achieve good response and thereby a fast gear-shift. An experimental study is carried out to investigate the phenomena of boost pressure drop during gear-shift and gather data for the modelling work. Results confirm the stated fact on the influence of boost pressure drop on gear-shift completion time and also indicate a clear linear dependence between initial boost pressure and the following pressure drop. A dynamic predictive model of the engine is developed with focus on implementation in a heavy duty truck, considering limitations computational complexity and calibration need between truck configurations. The resulting approach is based on a mean value modelling scheme that uses engine control system parameters and functions when possible. To be able to be predictive, a model for demanded torque and engine speed during the gear-shift is developed as reference inputs to the simulation. The simulation is based on a filling and emptying process throughout the engine dynamics, and yields final values of several engine variables such as boost pressure. The model is validated and later evaluated in comparison to measurements gathered in test vehicle experiments and in terms of robustness to input and model deviations. Computer simulations yield estimations of the boost pressure drop within acceptable limits. Consid- ering estimations used prior to this thesis the performance is good. Input deviations and modelling inaccuracies are found to inflict significant but not devastating deviations to the model output, possibly more over time with ageing of hardware taken into account. Final implementation in a heavy duty truck ecu is carried out with results indicating that the current implementation of the module is relatively computationally heavy. At the time of ending the thesis it is not possible to analyse its performance further, and it is suggested that the module is optimized in terms of computational efficiency.

As the greenhouse effect is an imminent concern, motivation for the development of energy efficient systems has grown fast. Today heavy-duty vehicles (HDVs) account for a growing part of the emissions from the vehicular transport sector. One way to reduce those emissions is by driving at short intervehicular distances in so called platoons, mainly on highways. In such formations, the aerodynamic drag is decreased which allows for more fuel efficient driving, meanwhile the roads are used more efficiently. This thesis deals with the question of how those platoons can be controlled without using communications between the involved HDVs. In this thesis, artificial neural networks are designed and trained to predict the velocity profile for an HDV driving over a section of road where data on the topography are available. This information is used in a model predictive controller to control the HDV driving behind the truck for which the aforementioned prediction is made. By having accurate information about the upcoming behaviour of the preceding HDV, the controller can plan the velocity profile for the controlled HDV in a way which minimizes fuel consumption. To ensure fuel optimal performance, a state describing the mass of consumed fuel is derived and minimized in the controller. A system modelling gear shift dynamics is proposed to capture essential dynamics such as torque loss during shifting. The designed controller is able to predict and change between the three highest gears making it able to handle almost all highway platooning scenarios. The prediction system shows great potential and is able to predict the velocity profile for different HDVs with an average error as low as 0.04 km/h. The controller is implemented in a simulation environment and results show that compared to a platoon without these predictions of the preceding HDV, the fuel consumption for the controlled HDV can be reduced by up to 6 %.