dynamics and control of an electromechanically actuated CVT

168 Pages·2017·12.19 MB·English

The empact CVT : dynamics and control of an
electromechanically actuated CVT
Citation for published version (APA):
Klaassen, T. W. G. L. (2007). The empact CVT : dynamics and control of an electromechanically actuated CVT.
[Phd Thesis 1 (Research TU/e / Graduation TU/e), Mechanical Engineering]. Technische Universiteit Eindhoven.
https://doi.org/10.6100/IR625040
DOI:
10.6100/IR625040
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Published: 01/01/2007
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The Empact CVT
Dynamics and Control of an
Electromechanically Actuated CVT
AcataloguerecordisavailablefromtheLibraryEindhovenUniversityofTechnology
ISBN: 978-90-386-0939-3
This thesis was prepared using the LATEX documentation system.
Cover design by B. Bonsen.
Printed by Universiteitsdrukkerij, Technische Universiteit Eindhoven.
Copyright (cid:13)c 2007 by T.W.G.L. Klaassen
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The Empact CVT
Dynamics and Control of an
Electromechanically Actuated CVT
PROEFSCHRIFT
ter verkrijging van de graad van doctor
aan de Technische Universiteit Eindhoven,
op gezag van de Rector Magnificus, prof.dr.ir. C.J. van Duijn,
voor een commissie aangewezen door het College voor Promoties
in het openbaar te verdedigen op
donderdag 12 april 2007 om 16.00 uur
door
Tim Willem Gerard Leo Klaassen
geboren te Nieuw-Bergen
Dit proefschrift is goedgekeurd door de promotor:
prof.dr.ir. M. Steinbuch
Copromotor:
dr.ir. B.G. Vroemen
Preface
The development of the Empact CVT is set in the framework of the SenterNovem
BTS (Bedrijfs Technologische Samenwerking) agreement. The aim of the project is
to stimulate economic developments in the future by cooperation of companies and
universities. This project is a cooperation of the Technische Universiteit (TU/e),
Van Doorne’s Transmissie (VDT) and the University of Twente (UT). The main
goals are the optimization of efficiency, durability and torque transmission capacity
of metal V-belt type CVTs. To achieve these goals, the project initially focussed
on the optimization of the pushbelt and the variator. Preliminary studies, however,
showed that the actuation system of the variator has significant impact on the total
efficiencyoftheCVT.Therefore,thissubjectwassubsequentlyaddedtotheproject.
The focus points and research topics of the project are
1. to maximize efficiency and durability of the variator by applying variator slip
measurement and control techniques (TU/e)
2. to optimize maximal transmittable torque and durability of the pushbelt by
developing and using new materials that combine high yield strength with
good fatigue resistance (VDT)
3. to optimize durability of the variator and pushbelt by developing a failure
mode model and wear prediction model for the boundary lubrication contact
(UT)
4. to maximize efficiency of the variator by developing an alternative actuation
system (TU/e)
The work in this thesis is mainly part of the fourth topic, but combines this with
and contributes to the development of slip control techniques (topic 1).
The project is carried out by three ph.d. students, ir. K.G.O. van de Meerakker,
dr.ir. B. Bonsen, who received his ph.d. dissertation ”Efficiency optimization of
the push-belt CVT by variator slip control” in December 2006 and ir. T.W.G.L.
v
vi Preface
Klaassen, under supervision of prof.dr.ir. M. Steinbuch, dr. P.A. Veenhuizen and
dr.ir. B.G. Vroemen.
Contents
Preface v
1 Introduction 1
1.1 CVT drivelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 CVT efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 CVT driveline control . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Problem description and main contributions . . . . . . . . . . . . . . 13
1.5 Outline of the thesis . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 The Empact CVT 15
2.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Potential of the Empact CVT . . . . . . . . . . . . . . . . . . . . . . 18
2.2.1 Actuation power . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.2 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Modeling 27
3.1 Test rig components . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2 DNR set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.3 Final drive reduction . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.4 Shafts and couplings . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.1 Geometry and definitions . . . . . . . . . . . . . . . . . . . . 30
3.2.2 Clamping force model . . . . . . . . . . . . . . . . . . . . . . 31
3.2.3 Torque transmission . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.4 Transient variator model . . . . . . . . . . . . . . . . . . . . . 37
3.3 Empact actuation system . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.1 Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Friction models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
vii
viii Contents
3.5 Validation results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Control problem formulation 47
4.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2 Performance specification and system requirements . . . . . . . . . . 49
4.3 Control architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 Design limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5 Control oriented identification 55
5.1 Identification experiment design . . . . . . . . . . . . . . . . . . . . . 56
5.2 Approximate realization using pulse responses . . . . . . . . . . . . . 58
5.3 Closed loop identification procedure . . . . . . . . . . . . . . . . . . 62
5.4 Closed loop identification results . . . . . . . . . . . . . . . . . . . . 63
5.4.1 1st identification step results . . . . . . . . . . . . . . . . . . 64
5.4.2 2nd identification step results . . . . . . . . . . . . . . . . . . 70
5.4.3 3rd identification step results . . . . . . . . . . . . . . . . . . 73
5.5 Interaction analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Control design and evaluation 81
6.1 Control designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.1.1 Manually loop-shaped decentralized controller . . . . . . . . . 82
6.1.2 H loop-shaped decentralized controller . . . . . . . . . . . . 82
∞
6.1.3 H MIMO controller . . . . . . . . . . . . . . . . . . . . . . 84
∞
6.2 Gain scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.3 Controller switching strategy . . . . . . . . . . . . . . . . . . . . . . 87
6.4 Closed loop performance evaluation. . . . . . . . . . . . . . . . . . . 90
6.4.1 Simulation evaluation . . . . . . . . . . . . . . . . . . . . . . 90
6.4.2 Experimental evaluation . . . . . . . . . . . . . . . . . . . . . 93
7 Experimental performance evaluation 101
7.1 Ratio reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.2 Slip reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.3 Empact FTP72 cycle performance . . . . . . . . . . . . . . . . . . . 105
7.4 Audi A3 implementation and performance . . . . . . . . . . . . . . . 107
8 Conclusions and recommendations 113
8.1 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.2 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A Measurement setup 119
A.1 Empact prototypes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
A.2 Test rig measurement setup . . . . . . . . . . . . . . . . . . . . . . . 123
A.3 Audi A3 and chassis dyno measurement setup . . . . . . . . . . . . . 124
Contents ix
B Capita selecta 127
B.1 Pulley thrust ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
B.2 Slip dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
B.3 Inverse response of slip during ratio changes . . . . . . . . . . . . . . 128
B.4 Linear system analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Nomenclature 143
Summary 147
Samenvatting 151
Dankwoord 155
Curriculum Vitae 157