Dual-clutch automatic electronically controlled clutch actuator

Abstract

A dual-clutch automatic electronically controlled clutch actuator includes: a housing and a dual-winding motor stator, a sensor mechanism, a controller, an inner winding mechanism and an outer winding mechanism arranged on the housing. The dual-winding motor stator is composed of an inner winding mechanism and an outer winding mechanism. The controller is integrated in the vehicle TCU. The sensor mechanism is arranged at the bottom of the inner winding mechanism and the outer winding mechanism. The sensor mechanism includes: a dual-winding rotary transformer stator and a dual-winding rotary transformer rotor. The dual-winding rotary transformer stator is arranged at the bottom of the dual-winding motor stator. The dual-winding rotary transformer rotor is arranged on both sides of the dual-winding rotary transformer stator. The present invention integrates the dual-winding motor, the dual-winding rotary transformer, the ball screw mechanism and the clutch release bearing on the housing, so that the overall structure is more compact, the volume is smaller, the transmission efficiency is higher, the precision is high and the cost is lower. The controller effectively compensates for the wear of the clutch driven disc by adjusting the number of turns, angle and speed of the inner and outer rotors, reduces the jitter in the dual-clutch shifting process, and reduces the matching difficulty.

Description

Technical Field

[0001] The present invention relates to a technology in the field of motor vehicle power and transmission, in particular to a dual-clutch automatic electronically controlled clutch actuator. Background Art

[0002] The existing manual clutch actuator is a hydraulic system composed of a master cylinder, a slave cylinder, an oil pot, a high-pressure oil pipe, a low-pressure oil pipe, an air release valve, etc. The master cylinder drives the rigid medium to form high pressure and transfers the rigid medium in its cavity to the slave cylinder. The high-pressure medium is formed in the slave cylinder and drives the dynamic sealing ring to move the piston and the bearing forward. The bearing contacts the clutch diaphragm spring to form a lever principle to make the clutch pressure plate and the driven plate engage / separate; when it needs to be released, the high pressure of the rigid medium inside the cavity is released, and the diaphragm spring uses elastic force to push the bearing and the piston to return to their original position, thereby realizing the separation / engagement of the clutch pressure plate and the driven plate.

[0003] The dual-clutch automatic actuator uses two independent hydraulic clutch actuators corresponding to the C1 and C2 diaphragm springs of the dual clutch, and the two hydraulic clutch actuators control the odd / even gears respectively. Usually, it is achieved by combining a motor with a plunger pump or an electronic pump with a solenoid valve as an operating mechanism to control the actuator. The operating mechanism and the actuator are generally independent structures, resulting in a large size, complex piping, low transmission efficiency, slow response speed, low precision and high cost. Summary of the invention

[0004] In view of the above-mentioned deficiencies in the prior art, the present invention proposes a dual-clutch automatic electronically controlled clutch actuator, which integrates a dual-winding motor, a dual-winding rotary transformer as a sensor mechanism, a ball screw mechanism and a clutch release bearing into a housing, thereby reducing the weight of the actuator, eliminating the need for regular maintenance, eliminating leakage problems, and providing a fast response speed, high precision and lower cost; and the service life of the automatic electronically controlled clutch actuator is effectively improved by providing an external dustproof shaft seal and a self-lubricating support ring; the controller can effectively compensate for the wear of the clutch driven plate by adjusting the number of revolutions, angles and speeds of the inner and outer rotors, thereby reducing the jitter during the dual-clutch shifting process and reducing the difficulty of matching.

[0005] The present invention is achieved through the following technical solutions:

[0006] The present invention includes: a shell and a double-winding motor stator arranged on the shell, a sensor mechanism, a controller, an inner winding mechanism and an outer winding mechanism, wherein: the double-winding motor stator consists of an inner winding mechanism and an outer winding mechanism, the controller is arranged in the TCU of the whole vehicle, and the sensor mechanism is arranged at the bottom of the inner winding mechanism and the outer winding mechanism.

[0007] The inner winding mechanism includes: an inner rotor, an inner sleeve, an inner ball screw, an inner clutch release bearing and an inner support bearing, wherein: the inner sleeve is arranged on one side of the inner rotor and rotates synchronously with it, the inner ball screw is arranged on one side of the inner sleeve and moves axially forward and backward with it, the inner clutch release bearing is interference fit with the inner ball screw, and the inner support bearing is arranged at the bottom of the inner rotor.

[0008] The outer winding mechanism includes: an outer rotor, an outer sleeve, an outer ball screw, an outer clutch release bearing and an outer support bearing, wherein: the outer sleeve is arranged on one side of the outer rotor and rotates synchronously with it, the outer ball screw is arranged on one side of the outer sleeve and moves axially forward and backward when it rotates with it, the outer clutch release bearing is interference fit with the outer ball screw, and the outer support bearing is arranged at the bottom of the outer rotor.

[0009] The sensing mechanism comprises: a double-winding rotary transformer stator and a double-winding rotary transformer rotor, wherein: the double-winding rotary transformer stator is arranged at the bottom of the double-winding motor stator, and the double-winding rotary transformer rotor is arranged on both sides of the double-winding rotary transformer stator.

[0010] The inner ball screw is provided with an inner dustproof shaft seal for preventing dust and water, wherein the inner dustproof shaft seal is connected to the housing.

[0011] The outer ball screw is provided with an outer dustproof shaft seal for preventing dust and water, wherein the outer dustproof shaft seal is connected to the shell.

[0012] The inner ball screw is provided with an inner self-lubricating support ring for reducing friction, wherein the inner self-lubricating support ring is connected to the housing and is arranged at the bottom of the inner dustproof shaft seal.

[0013] The outer ball screw is provided with an outer self-lubricating support ring for reducing friction, wherein the outer self-lubricating support ring is connected to the housing and is arranged at the bottom of the outer dustproof shaft seal.

[0014] The controller includes: a dual-winding motor controller and a sensor processor, wherein: the sensor processor is connected to the sensor mechanism and collects angle, number of turns, and rotation direction information, and outputs the information to the dual-winding motor controller after decoding. The dual-winding motor controller outputs the dual-winding motor speed, torque and commutation instructions to the dual-winding motor.

[0015] Technical Effects

[0016] The present invention solves the problems in the prior art of large volume, dispersed components, low transmission efficiency, difficulty in realizing whole vehicle electrification, and great difficulty in integration.

[0017] Compared with the prior art, the present invention integrates a dual-winding motor, a dual-winding rotary transformer, a ball screw mechanism and a clutch release bearing into a housing, and uses a set of dual-winding motors to independently control the opening / closing function of the odd / even gear clutch of the dual clutch; the structure of the actuator can be more compact, smaller in size, with higher transmission efficiency, faster response speed, higher precision and lower cost; and the service life of the automatic electronically controlled clutch actuator can be effectively improved by setting an external dustproof shaft seal and a self-lubricating support ring.

[0018] In order to save space, the present invention also uses an integrated acquisition mechanism solution in the sensor mechanism. The preferred reluctance dual-winding rotary transformer has the advantages of long life and high precision. At the same time, in order to reduce the volume, the dual-winding motor, Hall sensor and magnetic steel or dual-winding rotary transformer, ball screw mechanism and clutch release bearing are all integrated on the housing in structure. At the same time, the screw reduction mechanism is used to effectively reduce the torque demand for the dual-winding motor and reduce the output loss. At the same time, an independent controller is used to control a set of dual-winding motors to independently control the odd / even gear clutch opening / closing of the dual clutch. The positive and negative speeds of the rotor can be adjusted independently to reduce the power interruption time when the odd / even clutch is opened / closed, thereby reducing the jitter during the dual clutch shifting process. At the same time, the forward and reverse speeds and strokes can be dynamically adjusted and compensated according to the wear state of the dual clutch driven disk, thereby improving the continuity of power output and improving the driving comfort of the car. In addition, the maximum and minimum extension positions of the clutch actuator can be adjusted by adjusting the number of turns and angles of the dual-winding motor, covering more types of clutches and reducing the difficulty of vehicle matching. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is the front view of the overall structure of the present invention;

[0020] Figure 2 It is a top view of the overall structure double-winding motor of the present invention;

[0021] Figure 3 It is a schematic diagram of the structure of the sensor mechanism of the present invention;

[0022] In the figure: double-winding motor stator 1, inner rotor 2, inner sleeve 3, outer rotor 4, outer sleeve 5, controller 6, double-winding rotary transformer rotor 7, double-winding rotary transformer stator 8, inner ball screw 9, outer ball screw 10, inner clutch release bearing 11, outer clutch release bearing 12, inner support bearing 13, outer support bearing 14, housing 15, inner self-lubricating support ring 16, outer self-lubricating support ring 17, inner dustproof shaft seal 18, outer dustproof shaft seal 19, sensor mechanism 20, inner winding structure 21 and outer winding mechanism 22. DETAILED DESCRIPTION

[0023] like Figure 1-Figure 3 As shown, a dual-clutch automatic electronically controlled clutch actuator involved in this embodiment comprises: a housing 15 and a dual-winding motor stator 1 arranged on the housing 15, a sensor mechanism 20, a controller 6, an inner winding structure 21 and an outer winding mechanism 22, wherein: the dual-winding motor stator 1 is composed of an inner winding mechanism 21 and an outer winding mechanism 22, the controller 6 is integrated in the vehicle TCU, and is used to control the angle, number of turns and speed of the winding rotor, and the sensor mechanism 20 is arranged at the bottom of the inner winding mechanism and the outer winding mechanism.

[0024] The inner winding mechanism 21 includes: an inner rotor 2, an inner sleeve 3, an inner ball screw 9, an inner clutch release bearing 11 and an inner support bearing 13, wherein: the inner sleeve 3 is arranged on one side of the inner rotor 2 and rotates synchronously with the inner rotor 2, the inner ball screw 9 is arranged on one side of the inner sleeve 3 and generates independent axial advance and retreat when rotating with the inner ball screw 9, the inner clutch release bearing 11 is interference fit with the inner ball screw 9 and advances and retreats axially with the inner ball screw 9, and the inner support bearing 13 is arranged at the bottom of the inner rotor 2 to provide support and reduce the rotational torque.

[0025] The outer winding mechanism 22 includes: an outer rotor 4, an outer sleeve 5, an outer ball screw 10, an outer clutch release bearing 12 and an outer support bearing 14, wherein: the outer sleeve 5 is arranged on one side of the outer rotor 4 and rotates synchronously with it, the outer ball screw 10 is arranged on one side of the outer sleeve 5 and generates independent axial advance and retreat when rotating with it, the outer clutch release bearing 12 is interference fit with the outer ball screw 10 and advances and retreats axially with it, and the outer support bearing 14 is arranged at the bottom of the outer rotor 4 to provide support and reduce the rotational torque.

[0026] The sensing mechanism 20 comprises: a double-winding rotary transformer rotor 7 and a double-winding rotary transformer stator 8 , wherein: the double-winding rotary transformer stator 8 is arranged at the bottom of the double-winding motor stator 1 , and the double-winding rotary transformer rotor 7 is arranged on both sides of the double-winding rotary transformer stator 8 .

[0027] The sensing mechanism can also be implemented by using a Hall sensor and a magnet, wherein: the Hall sensor is arranged at the bottom of the stator of the dual-winding motor, and the magnet is arranged on both sides of the stator of the dual-winding rotary transformer.

[0028] The controller 6 is integrated into the TCU of the vehicle. By adjusting the number of revolutions and angles of the inner rotor 2 and the outer rotor 4, the maximum and minimum extension positions of the actuator are dynamically adjusted to achieve dynamic compensation for the wear of the dual-clutch driven plate. By controlling the speed and angle of the inner rotor 2 and the outer rotor 4, rapid response is achieved to ensure accurate and dynamic adjustment of the axial position and movement speed of the actuator during the gear shifting process, thereby reducing the jitter during the dual-clutch gear shifting process and reducing the matching difficulty.

[0029] The inner ball screw 9 is provided with an inner dustproof shaft seal 18 for preventing dust and water, wherein the inner dustproof shaft seal 18 is connected to the housing 15 .

[0030] The outer ball screw 10 is provided with an outer dustproof shaft seal 19 for preventing dust and water, wherein the outer dustproof shaft seal 19 is connected to the housing 15 .

[0031] The inner ball screw 9 is provided with an inner self-lubricating support ring 16 for reducing friction, wherein the inner self-lubricating support ring 16 is connected to the housing 15 and is arranged at the bottom of the inner dustproof shaft seal 18 .

[0032] The outer ball screw 10 is provided with an outer self-lubricating support ring 17 for reducing friction, wherein the outer self-lubricating support ring 17 is connected to the housing 15 and is arranged at the bottom of the outer dustproof shaft seal 19 .

[0033] In summary, the present invention, for the first time, uses a dual-winding motor as the power drive mechanism of the dual-clutch actuator, and a dual-winding rotary transformer as the sensing mechanism of the dual-clutch actuator, and integrates the dual-winding motor, Hall sensor and magnetic steel or dual-winding rotary transformer, ball screw mechanism and clutch release bearing on the housing, and increases the life of the dual-clutch actuator by setting an external dustproof shaft seal and a self-lubricating support ring. An independent controller is used to formulate a control strategy to control a set of dual-winding motors to reduce power interruption time, dynamically compensate for friction plate wear, and adjust the maximum and minimum elongation. Compared with existing conventional technical means, it has a more centralized and compact structure, higher transmission efficiency, faster response speed, higher control accuracy, a wider range of applications, good comfort and lower cost.

[0034] The above-mentioned specific implementation can be partially adjusted in different ways by those skilled in the art without departing from the principle and purpose of the present invention. The protection scope of the present invention shall be based on the claims and shall not be limited by the above-mentioned specific implementation. Each implementation scheme within its scope shall be subject to the constraints of the present invention.

Claims

1. A dual-clutch automatic electronically controlled clutch actuator, characterized in that: include: A housing and a double-winding motor stator, a sensor mechanism, a controller, an inner winding mechanism and an outer winding mechanism arranged on the housing, wherein: the double-winding motor stator is composed of an inner winding mechanism and an outer winding mechanism, the controller is arranged in the housing, and the sensor mechanism is arranged at the bottom of the inner winding mechanism and the outer winding mechanism; The sensing mechanism comprises: a dual-winding rotary transformer stator and a dual-winding rotary transformer rotor, wherein: the dual-winding rotary transformer stator is arranged at the bottom of the dual-winding motor stator, and the dual-winding rotary transformer rotor is arranged at both sides of the dual-winding rotary transformer stator; The controller includes: a dual-winding motor controller and a sensor processor, wherein: the sensor processor is connected to the sensor mechanism and collects angle, number of turns, and rotation direction information, and outputs the information to the dual-winding motor controller after decoding, and the dual-winding motor controller outputs the dual-winding motor speed, torque and commutation instructions to the dual-winding motor; The inner winding mechanism includes: an inner rotor, an inner sleeve, an inner ball screw, an inner clutch release bearing and an inner support bearing, wherein: the inner sleeve is arranged on one side of the inner rotor and rotates synchronously with it, the inner ball screw is arranged on one side of the inner sleeve and moves axially forward and backward with it, the inner clutch release bearing is interference fit with the inner ball screw, and the inner support bearing is arranged at the bottom of the inner rotor.

2. The actuator according to claim 1, characterized in that: The outer winding mechanism includes: an outer rotor, an outer sleeve, an outer ball screw, an outer clutch release bearing and an outer support bearing, wherein: the outer sleeve is arranged on one side of the outer rotor and rotates synchronously with it, the outer ball screw is arranged on one side of the outer sleeve and moves axially forward and backward when it rotates with it, the outer clutch release bearing is interference fit with the outer ball screw, and the outer support bearing is arranged at the bottom of the outer rotor.

3. The actuator according to claim 1, characterized in that: The inner ball screw is provided with an inner dustproof shaft seal for preventing dust and water, wherein the inner dustproof shaft seal is connected to the housing.

4. The actuator according to claim 2, characterized in that: The outer ball screw is provided with an outer dustproof shaft seal for preventing dust and water, wherein the outer dustproof shaft seal is connected to the shell.

5. The actuator according to claim 1 or 3, characterized in that: The inner ball screw is provided with an inner self-lubricating support ring for reducing friction, wherein the inner self-lubricating support ring is connected to the housing and is arranged at the bottom of the inner dustproof shaft seal.

6. The actuator according to claim 2 or 4, characterized in that: The outer ball screw is provided with an outer self-lubricating support ring for reducing friction, wherein the outer self-lubricating support ring is connected to the housing and is arranged at the bottom of the outer dustproof shaft seal.

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