汽车自动离合器接合过程控制策略研究
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摘要
自动变速器是汽车变速器的发展方向,机械自动变速器AMT具有成本低、结构简单、传动效率高、经济性好的特点,对现有手动变速器改动小,易于产业化开发,是一种特别适合我国国情的自动变速器。自动离合器是AMT系统最重要的一个功能模块,也是AMT控制的难点和核心。同时它也可以单独作为一个产品开发,同手动变速器相比,自动离合器可大大减轻驾驶强度,提高驾驶舒适性及安全性。自动离合器控制难点在于离合器最佳接合规律的制定和对于离合器接合规律的准确跟踪,目前这两方面的研究均不太成熟,本文主要围绕这两个大的方面进行了自适应控制策略仿真以及试验研究,最后针对试验样车开发了自动离合器控制系统,并进行了相关的道路试验。
1)分析了现有离合器驱动机构的优缺点,在此基础上设计了一种新的电动式驱动机构,采用蜗卷弹簧进行力矩补偿,可以减轻驱动电机的负荷并改善系统的动态性能;采用成熟传感器作为位置传感器,并设计有机械限位机构。分析了蜗卷弹簧机构的设计方法。建立了离合器、驱动机构和电机一体化的动力学模型,为离合器位置跟踪控制器的设计打下了理论基础。
2)利用电涡流测功机系统测取了DA465Q发动机的速度特性,利用数据拟合方法建立了发动机转矩数学模型。建立了车辆传动系统动力学仿真模型。分析了影响离合器接合规律的因素,根据离合器起步控制目标,提出了一种改进的发动机局部恒转速控制策略,作为离合器起步总体控制原则。针对发动机恒转速控制实现问题,提出了一种模糊控制和规则协调控制相结合的控制策略。以节气门开度、发动机转速相对偏差及发动机转速变化率为控制量,设计了模糊控制算法;以最低接合转速、离合器输入输出转速差和离合器输出轴转速为辅助控制量,设计了调整规则。多种起步工况的仿真试验表明所提出的控制策略具有较好的控制效果和较强的适应性,为自动离合器控制软件的开发提供了理论依据。
3)针对离合器磨损补偿问题,提出了一种空行程自学习补偿控制策略,利用离合器磨损后扭矩传递特性相对不变的特点来在线检测空行程结束点的位置,该策略简单易行,具有较强的实用性。
4)针对转速信号的滤波问题,提出了一种自适应中值决策滤波和巴特沃思滤波相结合的滤波算法,利用自适应中值决策滤波滤除较大的脉冲干扰,利用巴特沃思滤波器进行平滑滤波。试验结果表明,同普通中值滤波和单纯的FIR滤波相比,该滤波算法能够利用最小的滤波窗口滤除大脉冲干扰,同时具有较好的平滑性,能够实现快速、准确滤波。
5)离合器位置跟踪控制是一个较复杂的非线性控制问题,本文利用神经元控制理论,设计了具有前馈控制作用的增益可调整离合器位置神经元自适应PID控制器。利用神经元的自学习功能实现权系数的自动调整,利用前馈控制增强控制器的动态性能,利用PSD算法实现增益的自动调整。试验表明,它能够实现离合器位置的准确跟踪,位置跟踪动、静态误差小,另外,它能够适应离合器负荷和目标接合速度的非线性变化,同时能够适应系统参数的变化,表现出了良好的鲁棒性,可以满足离合器位置跟踪控制要求。
6)以infineon XC164CS高性能16位单片机为核心,针对样车设计了自动离合器控制器,根据车辆运行工况和控制策略编写了控制软件。为方便系统的调试,开发了自动离合器辅助调试软件。在样车上进行了多种工况的起步试验和换档试验,试验表明车辆在各工况下均能顺利起步,平地起步时车辆起步平稳,发动机转速波动小,且能充分体现驾驶员意图;坡道起步时,能够防止车辆后溜与发动机熄火,表明控制系统对不同工况均具有较好的适应性。目前样车行驶已经超过了1.5万公里,系统运行良好,车辆舒适性和安全性均达到要求,取得了较好的成效。
Automatic transmission is the development tendency of transmission for vehicle. Automatic mechanical transmission (AMT) has many merits such as low cost, simple structure, high transmission efficiency and good fuel mileage; moreover it needs few changes with the structure of present manual transmission, so AMT is a promising transmission which is suitable for the situation of our country. Automatic clutch is the most important module of AMT and the core and difficulty of ATM control. At the same time, automatic clutch can be developed as an independent production, which can decrease driving intension and improve comfort and safety of driving compared with manual transmission. The control difficulty of automatic clutch focuses on two aspects: how to figure out the optimum engagement rule and how to track the target engagement position precisely. The present researches on them are not mature enough. Aiming the two problems mentioned before, adaptive control strategies were deeply studied. Finally, aiming at a sample car automatic clutch control system was developed and long terms experiments were carried out.
1) The merits and shortcomings of clutch driving mechanism existing were analyzed and a new driving mechanism based on DC motor was designed. In the scheme a whirl spring was adopted to compensate load toque, by which the load of motor can be reduced and system’s dynamic performance will be improved. Additionally, a mechanical limited mechanism was devised. The design method of whirl spring mechanism was represented in detail. Furthermore, the integrated dynamic model of mechanism including clutch, worm reduction box, compensating spring and motor was established, which is the theoretical foundation of position tracking control.
2) Utilizing eddy current dynamometer system, the steady load characteristic of DA465Q engine was measured, and the mathematical model of engine torque was established by way of data fitting method. Moreover the dynamic simulation model of transmission system of vehicle was established. The factors influencing clutch engagement were analyzed. According to the control aim of starting, an improved strategy of constant engine speed in part process is proposed as a total control principle. For the realization of the strategy, a compound control strategy combining fuzzy control and rule coordinating control is proposed. Throttle opening, engine speed relative deviation and engine speed rate were chosen as control parameters to construct fuzzy algorithm, while the minimum engine speed for engaging, the difference of input and output axis speed of clutch and out axis speed of clutch were chosen auxiliary control parameters to design rule controller. The starting simulation results of diverse conditions indicate that the strategy had good control effect and good adaptability, and it provided the theoretical gist for the control software design.
3) A self-learning compensating strategy was put forward to solve the problem of clutch abrasion. The position of unloaded displacement termination point was measured dynamically on line by using the character that the torsion transmission characteristic of clutch kept relatively constant. The method is feasible and practical.
4) A compound filtering method based on self-adaptive median decision filter and IIR filter was proposed to solve the problem of rotation speed signal filtering. Self-adaptive median decision filter was used to filter the big impulse disturbing signal and low order butterworth filter was used to smooth the signal. The experiment results show that the compound filtering method can accurately filter the singular value with the smallest filtering window under big density disturbance and has good smoothing ability compared with common medium filter and pure FIR filter. Real-time and accurate filtering can be implemented.
5) Accurate and quick position tracking of automatic clutch is difficult on account of its nonlinear characteristic. In this subject a neuron adaptive PID controller with feedforward and adjustable gain was designed. The feedforward control was able to accelerate the response of controller, the weight of neuron was adaptively adjusted by self-study function, and PSD algorithm was proposed to adjust its gain. The clutch position tracking experiments showed that the controller could adapt the nonlinear change of clutch load and target engaging speed with small position error. This indicated that the controller had good robustness and can meet position tracking control command.
6) The electronic control unit (ECU) of automatic clutch was developed for the sample car based on infineon XC164CS microcontroller. According to vehicle’s running conditions and control strategy, the control software was developed. Moreover, an auxiliary debugging software was developed based on VB for convenience to debug. The control system starting and shift experiments under diverse condition were carried out on the sample car. The experiments showed that the vehicle can start successfully on no matter flat road or slope road. While starting on flat road, the vehicle started smoothly according to driver’s intention with low engine speed fluctuating; while starting on slope it can prevent vehicle from countermarching and engine halting. This indicates that the automatic clutch control system has good performance. Until now the sample car has traveled over 15,000 km, and the comfort and safety is satisfying, which indicates that the control strategy is effective.
1)分析了现有离合器驱动机构的优缺点,在此基础上设计了一种新的电动式驱动机构,采用蜗卷弹簧进行力矩补偿,可以减轻驱动电机的负荷并改善系统的动态性能;采用成熟传感器作为位置传感器,并设计有机械限位机构。分析了蜗卷弹簧机构的设计方法。建立了离合器、驱动机构和电机一体化的动力学模型,为离合器位置跟踪控制器的设计打下了理论基础。
2)利用电涡流测功机系统测取了DA465Q发动机的速度特性,利用数据拟合方法建立了发动机转矩数学模型。建立了车辆传动系统动力学仿真模型。分析了影响离合器接合规律的因素,根据离合器起步控制目标,提出了一种改进的发动机局部恒转速控制策略,作为离合器起步总体控制原则。针对发动机恒转速控制实现问题,提出了一种模糊控制和规则协调控制相结合的控制策略。以节气门开度、发动机转速相对偏差及发动机转速变化率为控制量,设计了模糊控制算法;以最低接合转速、离合器输入输出转速差和离合器输出轴转速为辅助控制量,设计了调整规则。多种起步工况的仿真试验表明所提出的控制策略具有较好的控制效果和较强的适应性,为自动离合器控制软件的开发提供了理论依据。
3)针对离合器磨损补偿问题,提出了一种空行程自学习补偿控制策略,利用离合器磨损后扭矩传递特性相对不变的特点来在线检测空行程结束点的位置,该策略简单易行,具有较强的实用性。
4)针对转速信号的滤波问题,提出了一种自适应中值决策滤波和巴特沃思滤波相结合的滤波算法,利用自适应中值决策滤波滤除较大的脉冲干扰,利用巴特沃思滤波器进行平滑滤波。试验结果表明,同普通中值滤波和单纯的FIR滤波相比,该滤波算法能够利用最小的滤波窗口滤除大脉冲干扰,同时具有较好的平滑性,能够实现快速、准确滤波。
5)离合器位置跟踪控制是一个较复杂的非线性控制问题,本文利用神经元控制理论,设计了具有前馈控制作用的增益可调整离合器位置神经元自适应PID控制器。利用神经元的自学习功能实现权系数的自动调整,利用前馈控制增强控制器的动态性能,利用PSD算法实现增益的自动调整。试验表明,它能够实现离合器位置的准确跟踪,位置跟踪动、静态误差小,另外,它能够适应离合器负荷和目标接合速度的非线性变化,同时能够适应系统参数的变化,表现出了良好的鲁棒性,可以满足离合器位置跟踪控制要求。
6)以infineon XC164CS高性能16位单片机为核心,针对样车设计了自动离合器控制器,根据车辆运行工况和控制策略编写了控制软件。为方便系统的调试,开发了自动离合器辅助调试软件。在样车上进行了多种工况的起步试验和换档试验,试验表明车辆在各工况下均能顺利起步,平地起步时车辆起步平稳,发动机转速波动小,且能充分体现驾驶员意图;坡道起步时,能够防止车辆后溜与发动机熄火,表明控制系统对不同工况均具有较好的适应性。目前样车行驶已经超过了1.5万公里,系统运行良好,车辆舒适性和安全性均达到要求,取得了较好的成效。
Automatic transmission is the development tendency of transmission for vehicle. Automatic mechanical transmission (AMT) has many merits such as low cost, simple structure, high transmission efficiency and good fuel mileage; moreover it needs few changes with the structure of present manual transmission, so AMT is a promising transmission which is suitable for the situation of our country. Automatic clutch is the most important module of AMT and the core and difficulty of ATM control. At the same time, automatic clutch can be developed as an independent production, which can decrease driving intension and improve comfort and safety of driving compared with manual transmission. The control difficulty of automatic clutch focuses on two aspects: how to figure out the optimum engagement rule and how to track the target engagement position precisely. The present researches on them are not mature enough. Aiming the two problems mentioned before, adaptive control strategies were deeply studied. Finally, aiming at a sample car automatic clutch control system was developed and long terms experiments were carried out.
1) The merits and shortcomings of clutch driving mechanism existing were analyzed and a new driving mechanism based on DC motor was designed. In the scheme a whirl spring was adopted to compensate load toque, by which the load of motor can be reduced and system’s dynamic performance will be improved. Additionally, a mechanical limited mechanism was devised. The design method of whirl spring mechanism was represented in detail. Furthermore, the integrated dynamic model of mechanism including clutch, worm reduction box, compensating spring and motor was established, which is the theoretical foundation of position tracking control.
2) Utilizing eddy current dynamometer system, the steady load characteristic of DA465Q engine was measured, and the mathematical model of engine torque was established by way of data fitting method. Moreover the dynamic simulation model of transmission system of vehicle was established. The factors influencing clutch engagement were analyzed. According to the control aim of starting, an improved strategy of constant engine speed in part process is proposed as a total control principle. For the realization of the strategy, a compound control strategy combining fuzzy control and rule coordinating control is proposed. Throttle opening, engine speed relative deviation and engine speed rate were chosen as control parameters to construct fuzzy algorithm, while the minimum engine speed for engaging, the difference of input and output axis speed of clutch and out axis speed of clutch were chosen auxiliary control parameters to design rule controller. The starting simulation results of diverse conditions indicate that the strategy had good control effect and good adaptability, and it provided the theoretical gist for the control software design.
3) A self-learning compensating strategy was put forward to solve the problem of clutch abrasion. The position of unloaded displacement termination point was measured dynamically on line by using the character that the torsion transmission characteristic of clutch kept relatively constant. The method is feasible and practical.
4) A compound filtering method based on self-adaptive median decision filter and IIR filter was proposed to solve the problem of rotation speed signal filtering. Self-adaptive median decision filter was used to filter the big impulse disturbing signal and low order butterworth filter was used to smooth the signal. The experiment results show that the compound filtering method can accurately filter the singular value with the smallest filtering window under big density disturbance and has good smoothing ability compared with common medium filter and pure FIR filter. Real-time and accurate filtering can be implemented.
5) Accurate and quick position tracking of automatic clutch is difficult on account of its nonlinear characteristic. In this subject a neuron adaptive PID controller with feedforward and adjustable gain was designed. The feedforward control was able to accelerate the response of controller, the weight of neuron was adaptively adjusted by self-study function, and PSD algorithm was proposed to adjust its gain. The clutch position tracking experiments showed that the controller could adapt the nonlinear change of clutch load and target engaging speed with small position error. This indicated that the controller had good robustness and can meet position tracking control command.
6) The electronic control unit (ECU) of automatic clutch was developed for the sample car based on infineon XC164CS microcontroller. According to vehicle’s running conditions and control strategy, the control software was developed. Moreover, an auxiliary debugging software was developed based on VB for convenience to debug. The control system starting and shift experiments under diverse condition were carried out on the sample car. The experiments showed that the vehicle can start successfully on no matter flat road or slope road. While starting on flat road, the vehicle started smoothly according to driver’s intention with low engine speed fluctuating; while starting on slope it can prevent vehicle from countermarching and engine halting. This indicates that the automatic clutch control system has good performance. Until now the sample car has traveled over 15,000 km, and the comfort and safety is satisfying, which indicates that the control strategy is effective.
引文
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