A method and system for physical simulation of a double clutch transmission fork

Abstract

The application discloses a double-clutch transmission fork physical simulation method and system. The pressure valve current, the flow valve current and the rotational speed difference of the double-clutch transmission obtained are jointly simulated by a pre-established fork physical model, and simulation results are obtained. The simulation results are used to represent the fork hydraulic cylinder pressure change information and the fork motion information at different stages when the fork is shifted. The simulation results are verified. The verification operation is used to verify the function of the fork. Through the above scheme, the fork physical model jointly simulates various data by the flow valve model, the pressure valve model, the hydraulic cylinder model and the fork gear engagement resistance model, obtains the fork hydraulic cylinder pressure change information and the fork motion information at different stages when the fork is shifted, improves the accuracy of the fork physical simulation, verifies the simulation results, improves the quality of the fork function logic strategy and the diagnostic strategy test of the TCU software, and shortens the development cycle of the TCU software.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of shift forks, and more particularly to a double-clutch transmission shift fork physical simulation method and system. BACKGROUND

[0002] The double-clutch automatic transmission is a complex system jointly acting by a mechanism, an electronic device and a hydraulic system. In the process of gear shifting of a vehicle, the shift fork pre-engages a gear position and the clutch interacts, so that the power of an engine is transmitted to wheels without interruption, and power shifting is realized.

[0003] The shift fork control of the double-clutch automatic transmission is realized by pushing the synchronizer to achieve speed synchronization under the joint action of a pressure electromagnetic valve, a flow electromagnetic valve and a logic valve, and finally the shift fork engages and disengages gears. The shift fork control strategy is an important part of the software of a control unit (TCU).

[0004] In the process of software development, unit testing, model-in-loop testing and hardware-in-loop testing are needed. In addition to formulating a scientific and reasonable testing scheme, a relatively accurate shift fork physical model needs to be built, that is, the working process of the shift fork synchronizer and the physical characteristics of the shift fork hydraulic cylinder hydraulic system can be simulated, so as to support the testing and verification of the shift fork function logic strategy and the diagnosis strategy.

[0005] However, since the existing shift fork physical model is established by modeling the motion of the shift fork through engagement force and engagement resistance, the engagement resistance is obtained through experimental data, and some experimental data cannot accurately reflect the engagement resistance of the shift fork in some stages, so that the existing shift fork physical model is not accurate enough and cannot well represent the physical characteristics of the mechanical structure and the hydraulic system of the shift fork, thereby reducing the quality of the shift fork function logic strategy and the diagnosis strategy testing of the TCU software, and making it impossible to expose the vulnerabilities of the shift fork control strategy in the TCU software development stage, resulting in the extension of the TCU software development cycle. SUMMARY

[0006] Therefore, the present application discloses a double-clutch transmission shift fork physical simulation method and system,

[0007] The first aspect of the present application discloses a double-clutch transmission shift fork physical simulation method, which comprises the following steps:

[0008] obtaining the pressure valve current, the flow valve current and the speed difference of the double-clutch transmission;

[0009] The pressure valve current, the flow valve current and the rotational speed difference of the double clutch transmission are jointly simulated by using the pre-established shifter physical model to obtain simulation results; the simulation results are used to represent the shifter hydraulic cylinder pressure change information and the shifter motion information in different stages during shifter shifting;

[0010] The simulation results are verified; the verification is used to verify the function of the shifter.

[0011] Preferably, the simulation results are obtained by jointly simulating the pressure valve current, the flow valve current and the rotational speed difference of the double clutch transmission through the pre-established shifter physical model, including:

[0012] The flow valve flow is calculated by using the pre-established flow valve model to calculate the flow valve current;

[0013] The pressure valve pressure is calculated by using the pre-established pressure valve model to calculate the pressure valve current;

[0014] The synchronizer synchronization force, the shifter ring resistance and the detent force are calculated by using the pre-established shifter gear engagement resistance model to calculate the rotational speed difference of the double clutch transmission;

[0015] The synchronizer synchronization force, the shifter ring resistance and the detent force are calculated by using the pre-established shifter gear engagement resistance model to calculate the rotational speed difference of the double clutch transmission;

[0016] The shifter position information, the shifter velocity information, the piston two-end pressure value and the synchronization torque information are obtained by jointly simulating the pressure valve pressure, the flow valve flow, the synchronization stage shifting force, the shifter ring stage shifting force and the shifter gear engagement shifting force through the pre-established hydraulic cylinder model.

[0017] Preferably, the construction process of the flow valve model includes:

[0018] The electromagnetic valve spool mass, the electromagnetic valve spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state liquid power and the electromagnetic force are obtained;

[0019] The electromagnetic valve spool mass, the electromagnetic valve spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state liquid power and the electromagnetic force are modeled by using the modeling tool Matlab / Simscape to obtain the flow valve model.

[0020] Preferably, the construction process of the pressure valve model includes:

[0021] acquire the output oil pressure of the proportional pressure valve, the cross-sectional area of the pressure valve spool, the mass of the pressure valve spool, the elastic damping coefficient of the hydraulic oil, the stiffness of the return spring, the change amount of the compression amount of the return spring, the initial compression amount of the return spring, the current force gain coefficient of the electromagnet, and the excitation current;

[0022] model creation is performed on the output oil pressure of the proportional pressure valve, the cross-sectional area of the pressure valve spool, the mass of the pressure valve spool, the elastic damping coefficient of the hydraulic oil, the stiffness of the return spring, the change amount of the compression amount of the return spring, the initial compression amount of the return spring, the current force gain coefficient of the electromagnet, and the excitation current by using a modeling tool Matlab / Simscape, to obtain the pressure valve model.

[0023] Preferably, the construction process of the hydraulic cylinder model comprises:

[0024] acquire the piston area, the piston displacement, the piston speed, the piston acceleration, the volume sum of the oil cylinder and the clutch oil passage when the piston displacement is zero, the bulk modulus of the oil, the surface pressure of the piston, the mass of the active part of the clutch, the viscous damping coefficient of the piston movement, the stiffness of the return spring, and the initial deformation of the return spring;

[0025] model creation is performed on the piston area, the piston displacement, the piston speed, the piston acceleration, the volume sum of the oil cylinder and the clutch oil passage when the piston displacement is zero, the bulk modulus of the oil, the surface pressure of the piston, the mass of the active part of the clutch, the viscous damping coefficient of the piston movement, the stiffness of the return spring, and the initial deformation of the return spring by using a modeling tool Matlab / Simscape, to obtain the hydraulic cylinder model.

[0026] The second aspect of the application discloses a double-clutch transmission fork physical simulation system, the system comprising:

[0027] an acquisition unit configured to acquire a pressure valve current, a flow valve current, and a speed difference of a double-clutch transmission;

[0028] a simulation unit configured to jointly simulate the pressure valve current, the flow valve current, and the speed difference of the double-clutch transmission by using a pre-established fork physical model, to obtain a simulation result; the simulation result is used to represent fork hydraulic cylinder pressure change information and fork movement information at different stages during fork gear shifting;

[0029] a verification unit configured to perform a verification operation on the simulation result; the verification operation is used to verify the function of the fork.

[0030] Preferably, the simulation unit comprises:

[0031] The first calculation module is configured to calculate the flow valve current by using a pre-established flow valve model to obtain a flow valve flow;

[0032] The second calculation module is configured to calculate the pressure valve current by using a pre-established pressure valve model to obtain a pressure valve pressure;

[0033] The third calculation module is configured to calculate the speed difference of the dual-clutch transmission by using a pre-established shift fork gear engagement resistance model to obtain a synchronizer synchronization force, a shift ring resistance and a detent force;

[0034] The fourth calculation module is configured to perform stress analysis and calculation on the synchronizer synchronization force, the shift ring resistance and the detent force to obtain a shift fork gear engagement stress curve; the shift fork gear engagement stress curve is composed of a synchronization stage gear shifting force, a shift ring stage gear shifting force and a shift ring gear tooth gear shifting force;

[0035] The simulation module is configured to perform joint simulation on the pressure valve pressure, the flow valve flow, the synchronization stage gear shifting force, the shift ring stage gear shifting force and the shift ring gear tooth gear shifting force by using a pre-established hydraulic cylinder model to obtain shift fork position information, shift fork speed information, piston two-end pressure values and synchronization torque information.

[0036] Preferably, the first calculation module in the construction process of the flow valve model comprises:

[0037] The first acquisition submodule is configured to acquire the electromagnetic valve spool mass, the electromagnetic valve spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state hydraulic force and the electromagnetic force;

[0038] The first creation submodule is configured to create a model of the electromagnetic valve spool mass, the valve spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state hydraulic force and the electromagnetic force by using a modeling tool Matlab / Simscape to obtain the flow valve model.

[0039] Preferably, the second calculation module in the construction process of the pressure valve model comprises:

[0040] The second acquisition submodule is configured to acquire the proportional pressure valve output oil pressure, the pressure valve spool cross-sectional area, the pressure valve spool mass, the hydraulic oil elastic damping coefficient, the return spring stiffness, the return spring compression amount change, the return spring initial compression amount, the electromagnetic current force gain coefficient and the excitation current;

[0041] The second creating submodule is configured to create a model by using a modeling tool Matlab / Simscape, and the model is created based on the output oil pressure of the proportional pressure valve, the cross-sectional area of the pressure valve spool, the mass of the pressure valve spool, the elastic damping coefficient of the hydraulic oil, the spring stiffness of the return spring, the change amount of the compression amount of the return spring, the initial compression amount of the return spring, the current force gain coefficient of the electromagnet, and the excitation current, so as to obtain the pressure valve model.

[0042] Preferably, the simulation module in the construction process of the hydraulic cylinder model comprises:

[0043] The third obtaining submodule is configured to obtain the piston area, the piston displacement, the piston speed, the piston acceleration, the volume sum of the oil cylinder and the clutch oil passage when the piston displacement is zero, the bulk modulus of the oil, the piston surface pressure, the mass of the driving part of the clutch, the viscous damping coefficient of the piston movement, the spring stiffness of the return spring, and the initial deformation of the return spring.

[0044] The third creating submodule is configured to create a model by using a modeling tool Matlab / Simscape, and the model is created based on the piston area, the piston displacement, the piston speed, the piston acceleration, the volume sum of the oil cylinder and the clutch oil passage when the piston displacement is zero, the bulk modulus of the oil, the piston surface pressure, the mass of the driving part of the clutch, the viscous damping coefficient of the piston movement, the spring stiffness of the return spring, and the initial deformation of the return spring, so as to obtain the hydraulic cylinder model.

[0045] According to the technical solution, the pressure valve current, the flow valve current, and the speed difference of the dual-clutch transmission are obtained, the pressure valve current, the flow valve current, and the speed difference of the dual-clutch transmission are jointly simulated by using the pre-established shift fork physical model, the simulation result is obtained, the simulation result is used to represent the shift fork hydraulic cylinder pressure change information and the shift fork movement information in different stages of the shift fork gear shifting, and the simulation result is verified to verify the function of the shift fork. According to the above scheme, the shift fork physical model jointly simulates various data by using the flow valve model, the pressure valve model, the hydraulic cylinder model, and the shift fork gear engagement resistance model, the shift fork hydraulic cylinder pressure change information and the shift fork movement information in different stages of the shift fork gear shifting are obtained, the accuracy of the shift fork physical simulation is improved, the simulation result is verified, the quality of the shift fork function logic strategy and the diagnostic strategy test of the TCU software is improved, and the development cycle of the TCU software is shortened. BRIEF DESCRIPTION OF DRAWINGS

[0046] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description only constitute a part of the embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of the provided drawings.

[0047] Figure 1 A flowchart of a double-clutch transmission fork physical simulation method disclosed by the embodiments of the present application is shown in the figure.

[0048] Figure 2 A schematic diagram of a fork hydraulic system disclosed by the embodiments of the present application is shown in the figure.

[0049] Figure 3 A schematic diagram of a simulation result based on a fork physical model disclosed by the embodiments of the present application is shown in the figure.

[0050] Figure 4 A structural schematic diagram of a double-clutch transmission fork physical simulation system disclosed by the embodiments of the present application is shown in the figure. DETAILED DESCRIPTION

[0051] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments only constitute a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0052] In the present application, the term "comprising", "containing" or any other variant thereof is intended to cover non-exclusive containing, so that the process, method, article or equipment including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or equipment. Without more limitations, the element defined by the sentence "including a…" does not exclude the presence of other identical elements in the process, method, article or equipment including the element.

[0053] As known from the background art, the existing fork physical model is not accurate enough, resulting in low accuracy of the fork physical simulation, and causing the TCU software development cycle to be prolonged.

[0054] To solve the above problems, the embodiment of the application discloses a double clutch transmission fork physical simulation method and system. Since the fork physical model jointly simulates various data by combining the flow valve model, the pressure valve model, the hydraulic cylinder model and the fork gear engagement resistance model, the fork hydraulic cylinder pressure change information and the fork movement information at different stages during the fork gear shifting are obtained, the accuracy of the fork physical simulation is improved, the simulation results are verified, the quality of the fork function logic strategy and the diagnostic strategy test of the TCU software is improved, and the development cycle of the TCU software is shortened. The specific implementation mode is described by the following embodiment.

[0055] Reference Figure 1 As shown in the figure, the embodiment of the application discloses a flowchart of a double clutch transmission fork physical simulation method, which mainly includes the following steps:

[0056] S101: Obtain the pressure valve current, the flow valve current and the speed difference of the double clutch transmission.

[0057] The speed difference of the double clutch transmission is the speed difference between the intermediate shaft corresponding to the gear of the double clutch transmission and the input shaft corresponding to the gear. The speed difference of the double clutch transmission is related to the speed ratio of the current gear.

[0058] The double clutch automatic transmission is a complex system jointly acting by a mechanical system, an electronic system and a hydraulic system. During the gear upshift and downshift of the vehicle, the pre-gear engagement of the fork and the interaction of the clutch make the power of the engine transmitted to the wheels without interruption, so as to realize power gear shifting.

[0059] S102: Jointly simulate the pressure valve current, the flow valve current and the speed difference of the double clutch transmission by the pre-established fork physical model, and obtain the simulation results; the simulation results are used to represent the fork hydraulic cylinder pressure change information and the fork movement information at different stages during the fork gear shifting.

[0060] In S102, by establishing the mathematical model (fork physical model) of the fork hydraulic system, the fork hydraulic cylinder pressure change information and the fork movement displacement information and speed information at different stages during the gear downshift / gear upshift can be simulated more accurately.

[0061] The specific principle diagram of the fork hydraulic system can be referred to as shown in the figure. Figure 2

[0062] Figure 2 In the figure, the oil pump pumps oil to input the pressure source, the pressure electromagnetic valve is electrified to input the pressure to the flow valve, and the flow valve changes the current size after being electrified, so as to change the movement direction of the hydraulic cylinder piston. The piston is connected to the fork structure, so as to realize the gear engagement and disengagement of the fork.

[0063] ​The shift fork is a component on the automobile gearbox, connected with the gear handle, located at the lower end of the handle, and moves the intermediate gear to change the input / output speed ratio. The shift fork is mainly used for shifting the clutch.

[0064] The simulation results include shift fork position information, shift fork speed information, piston pressure value at both ends, and synchronizing torque information.

[0065] The different stages include a pre-synchronization stage and a locking stage.

[0066] The pre-synchronization stage is the process of synchronizing the speed and the shift fork.

[0067] The locking stage is the process of the tooth sleeve contacting the combination teeth, causing the tooth sleeve to lock the combination teeth.

[0068] To facilitate understanding of the process of jointly simulating the pressure valve current, the flow valve current, and the speed difference of the dual-clutch transmission through the pre-established shift fork physical model to obtain the simulation results, the process can be combined with Figure 3 for explanation.

[0069] Figure 3 In the process, the pressure valve current is input into the pressure valve model for calculation to obtain the pressure valve pressure; the flow valve current is input into the flow valve model to obtain the flow valve flow; the speed difference of the dual-clutch transmission is input into the shift fork gear engagement resistance model for calculation to obtain the synchronizer synchronization force, the detent force, and the detent force, and the synchronizer synchronization force, the detent force, and the detent force are subjected to force analysis and calculation to obtain the shift fork gear engagement force curve, which is composed of the synchronizer synchronization force, the detent force, and the detent force. The pressure valve pressure, the flow valve flow, the synchronizer synchronization force, the detent force, and the detent force are input into the hydraulic cylinder model for joint simulation to output the shift fork position information, the shift fork speed information, the piston pressure value at both ends, and the synchronizing torque information.

[0070] The process of jointly simulating the pressure valve current, the flow valve current, and the speed difference of the dual-clutch transmission through the pre-established shift fork physical model to obtain the simulation results is shown in A1-A5.

[0071] A1: Calculate the flow valve flow through the pre-established flow valve model.

[0072] The flow valve in the flow valve model is a four-position four-way electromagnetic valve, which is composed of a valve body, a valve core, a pre-tightening spring, an electromagnetic coil, and an electromagnet. The force analysis is shown in formula (1).

[0073]

[0074] Where, m sol is the mass of the electromagnetic valve core; xsol is the spool displacement; c sol is the spool damping coefficient permeability; k sol is the spring stiffness of electro-hydraulic proportional valve; x s0 is the initial compression of the solenoid valve spring; F s (x) is the steady-state fluid power; F m is the electromagnetic force.

[0075] The specific flow valve model is constructed as follows:

[0076] The solenoid valve spool mass, solenoid valve spool displacement, solenoid valve spool damping coefficient permeability, electro-hydraulic proportional valve spring stiffness, solenoid valve spring initial compression, steady-state fluid power and electromagnetic force are obtained.

[0077] The solenoid valve spool mass, solenoid valve spool displacement, solenoid valve spool damping coefficient permeability, electro-hydraulic proportional valve spring stiffness, solenoid valve spring initial compression, steady-state fluid power and electromagnetic force are modeled by the modeling tool Matlab / Simscape to obtain the flow valve model.

[0078] In the process of building the mathematical model of the flow valve, the relationship between the flow area of each orifice and the spool displacement is calculated, the dynamic balance equation of the spool is analyzed, and the electromagnetic force, spring force, damping force, etc. are comprehensively considered. The passage conditions of the flow valve and the flow of each passage under different currents are simulated.

[0079] A2: Calculate the pressure valve current by the pre-established pressure valve model to obtain the pressure valve pressure.

[0080] The pressure valve model is constructed as follows:

[0081] The proportional pressure valve output oil pressure, pressure valve spool cross-sectional area, pressure valve spool mass, hydraulic oil elastic damping coefficient, return spring stiffness, return spring compression change, return spring initial compression, electromagnetic iron current force gain coefficient and excitation current are obtained.

[0082] The excitation current can be controlled by a pulse width modulation (PWM) signal.

[0083] The proportional pressure valve output oil pressure, pressure valve spool cross-sectional area, pressure valve spool mass, hydraulic oil elastic damping coefficient, return spring stiffness, return spring compression change, return spring initial compression, electromagnetic iron current force gain coefficient and excitation current are modeled by the modeling tool Matlab / Simscape to obtain the pressure valve model.

[0084] A3: The speed difference of the double clutch transmission is calculated by a pre-established shifting fork gear shifting resistance model to obtain the synchronizer synchronization force, the shift ring resistance and the detent force.

[0085] The speed difference of the double clutch transmission is calculated by a pre-established shifting fork gear shifting resistance model to obtain the gear shifting resistance, which includes the synchronizer synchronization force, the shift ring resistance and the detent force.

[0086] A4: The synchronizer synchronization force, the shift ring resistance and the detent force are analyzed and calculated to obtain the shifting fork gear shifting force curve; the shifting fork gear shifting force curve is composed of the synchronization stage shifting force, the shift ring stage shifting force and the shift ring gear stage shifting force.

[0087] The calculation formula of the synchronization stage shifting force is shown in formula (2).

[0088] Fa1 = (J * Δω / t + T D * Ratio) / synchronization capacity formula (2)

[0089] Wherein, Fa1 is the synchronization stage shifting force; J is the rotational inertia; Δω is the speed difference; T D is the system resistance torque; Ratio is the speed ratio of the gear to be engaged; and the synchronization capacity is the friction torque generated by the unit axial force, which is related to the parameters of the synchronizer ring itself.

[0090] The calculation formula of the shift ring stage shifting force is shown in formula (3).

[0091] Fa2 = (T D * Ratio * (tan β + μ β ) / 1 - μ β * tan β) / R B + slider force + detent force formula (3)

[0092] Wherein, Fa2 is the shift ring stage shifting force; T D is the system resistance torque; Ratio is the speed ratio of the gear to be engaged; β is the angle of the angle; μ β is the friction coefficient between the synchronizer ring angle surface and the gear sleeve angle surface; and R B is the radius of the synchronizer ring spline pitch circle.

[0093] The calculation formula of the shift ring gear stage shifting force is shown in formula (4).

[0094] Fa3 = (T D * Ratio * (tan β + μ β ) / 1 - μ β * tan β) / R B formula (4)

[0095] Wherein, Fa3 is the shifting force of the shift knob; T D System resistance torque; Ratio is the speed ratio of the gear to be engaged; β is the angle of the synchro ring; μ β Friction coefficient between the synchro ring angle surface and the sleeve angle surface; R B The radius of the synchro ring spline pitch circle.

[0096] A5: The pressure valve pressure, the flow valve flow, the shifting force in the synchronization stage, the shifting force in the shift knob stage, and the shifting force in the shift knob stage are simulated jointly by the pre-established hydraulic cylinder model to obtain the shift fork position information, the shift fork speed information, the piston two-end pressure value, and the synchronization torque information.

[0097] The construction process of the hydraulic cylinder model is as follows:

[0098] The piston area, the piston displacement, the piston speed, the piston acceleration, the volume sum of the oil cylinder and the clutch oil passage when the piston displacement is zero, the oil volume elastic modulus, the piston surface pressure, the clutch driven part mass, the piston motion viscous damping coefficient, the return spring stiffness, and the return spring initial deformation are obtained.

[0099] The piston area, the piston displacement, the piston speed, the piston acceleration, the volume sum of the oil cylinder and the clutch oil passage when the piston displacement is zero, the oil volume elastic modulus, the piston surface pressure, the clutch driven part mass, the piston motion viscous damping coefficient, the return spring stiffness, and the return spring initial deformation are modeled by the modeling tool Matlab / Simscape to obtain the hydraulic cylinder model.

[0100] S103: The simulation results are verified. The verification operation is used to verify the function of the shift fork.

[0101] The force condition of the shift fork in each stage of gear engagement is analyzed, the resistance curve of the gear engagement process is calculated, the flow valve model, the hydraulic cylinder model, and the shift fork gear engagement resistance model are built by Matlab / Simscape, and the shift fork physical model is established. The shift fork hydraulic cylinder pressure change information and the shift fork moving displacement information and speed information in different stages during gear shifting / engagement can be accurately simulated, which can meet the verification test of the TCU shift fork function strategy and the diagnosis strategy.

[0102] The shift fork control strategy is an important part of the TCU software, which needs to be tested in the software development process, such as unit testing, model-in-the-loop testing, and hardware-in-the-loop testing. In addition to formulating a scientific and reasonable test scheme, the shift fork physical model can simulate the working process of the shift fork synchronizer, the physical characteristics of the shift fork hydraulic cylinder hydraulic system, and the like, which can be used to support the test and verification of the shift fork function logic strategy and the diagnosis strategy.

[0103] In the embodiments of the present application, the shift fork physical model is jointly simulated on various data by the flow valve model, the pressure valve model, the hydraulic cylinder model and the shift fork gear engagement resistance model, so as to obtain the shift fork hydraulic cylinder pressure change information and the shift fork movement information in different stages during the shift fork gear shifting, improve the accuracy of the shift fork physical simulation, verify the simulation results, improve the quality of the shift fork function logic strategy and the diagnostic strategy test of the TCU software, and shorten the development cycle of the TCU software.

[0104] Based on the above embodiments Figure 1 The disclosed shift fork physical simulation method of the dual-clutch transmission also discloses a shift fork physical simulation system of the dual-clutch transmission, as shown in the accompanying drawings. Figure 4 The shift fork physical simulation system of the dual-clutch transmission mainly includes an acquisition unit 401, a simulation unit 402 and a verification unit 403.

[0105] The acquisition unit 401 is configured to acquire the pressure valve current, the flow valve current and the rotational speed difference of the dual-clutch transmission.

[0106] The simulation unit 402 is configured to jointly simulate the pressure valve current, the flow valve current and the rotational speed difference of the dual-clutch transmission by the pre-established shift fork physical model, so as to obtain a simulation result; the simulation result is used to represent the shift fork hydraulic cylinder pressure change information and the shift fork movement information in different stages during the shift fork gear shifting.

[0107] The verification unit 403 is configured to perform a verification operation on the simulation result; the verification operation is used to verify the function of the shift fork.

[0108] Further, the simulation unit 402 includes a first calculation module, a second calculation module, a third calculation module, a fourth calculation module and a simulation module.

[0109] The first calculation module is configured to calculate the flow valve current by the pre-established flow valve model, so as to obtain the flow valve flow.

[0110] The second calculation module is configured to calculate the pressure valve current by the pre-established pressure valve model, so as to obtain the pressure valve pressure.

[0111] The third calculation module is configured to calculate the rotational speed difference of the dual-clutch transmission by the pre-established shift fork gear engagement resistance model, so as to obtain the synchronizer synchronization force, the shift ring resistance and the detent force.

[0112] The fourth calculation module is configured to perform stress analysis and calculation on the synchronizer synchronization force, the shift ring resistance and the detent force, so as to obtain a shift fork gear engagement stress curve; the shift fork gear engagement stress curve is composed of a synchronization stage shifting force, a shift ring stage shifting force and a shift ring gear tooth shifting force.

[0113] The simulation module is configured to jointly simulate the pressure valve pressure, the flow valve flow, the synchronous stage shifting force, the ring shifting stage shifting force and the ring gear shifting force through a pre-established hydraulic cylinder model to obtain the shift fork position information, the shift fork speed information, the piston two-end pressure value and the synchronous torque information.

[0114] Further, the first calculation module of the flow valve model construction process comprises a first acquisition submodule and a first creation submodule.

[0115] The first acquisition submodule is configured to acquire the electromagnetic valve spool mass, the electromagnetic valve spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state hydraulic force and the electromagnetic force.

[0116] The first creation submodule is configured to create a model of the electromagnetic valve spool mass, the spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state hydraulic force and the electromagnetic force through a modeling tool Matlab / Simscape to obtain the flow valve model.

[0117] Further, the second calculation module of the pressure valve model construction process comprises a second acquisition submodule and a second creation submodule.

[0118] The second acquisition submodule is configured to acquire the proportional pressure valve output oil pressure, the pressure valve spool cross-sectional area, the pressure valve spool mass, the hydraulic oil elastic damping coefficient, the return spring stiffness, the return spring compression amount change, the return spring initial compression amount, the electromagnetic iron current force gain coefficient and the excitation current.

[0119] The second creation submodule is configured to create a model of the proportional pressure valve output oil pressure, the pressure valve spool cross-sectional area, the pressure valve spool mass, the hydraulic oil elastic damping coefficient, the return spring stiffness, the return spring compression amount change, the return spring initial compression amount, the electromagnetic iron current force gain coefficient and the excitation current through a modeling tool Matlab / Simscape to obtain the pressure valve model.

[0120] Further, the simulation module of the hydraulic cylinder model construction process comprises a third acquisition submodule and a third creation submodule.

[0121] The third acquisition submodule is configured to acquire the piston area, the piston displacement, the piston speed, the piston acceleration, the oil cylinder and the clutch oil passage volume when the piston displacement is zero, the oil volume elastic modulus, the piston surface pressure, the clutch driving part mass, the piston movement viscous damping coefficient, the return spring stiffness and the return spring initial deformation.

[0122] The third creating sub-module is configured to create a model of the hydraulic cylinder by modeling tool Matlab / Simscape, and the model is created based on piston area, piston displacement, piston speed, piston acceleration, volume of the cylinder and clutch oil channel when the piston displacement is zero, oil volume elastic modulus, piston surface pressure, clutch driving part mass, piston movement viscous damping coefficient, return spring stiffness and return spring initial deformation.

[0123] In the embodiments of the present application, the shift fork physical model is jointly simulated by the flow valve model, the pressure valve model, the hydraulic cylinder model and the shift fork gear engagement resistance model, so as to obtain the shift fork hydraulic cylinder pressure change information and the shift fork movement information at different stages during the shift fork gear shifting, improve the accuracy of the shift fork physical simulation, verify the simulation results, improve the quality of the shift fork function logic strategy and the diagnostic strategy test of the TCU software, and shorten the development cycle of the TCU software.

[0124] For each method embodiment described above, in order to simply describe, it is expressed as a series of action combinations, but those skilled in the art should know that the present application is not limited by the action sequence described, because according to the present application, some steps can be performed in other order or simultaneously. Secondly, those skilled in the art should know that the embodiments described in the specification are all preferred embodiments, and the actions and modules involved are not necessarily required by the present application.

[0125] It should be noted that each embodiment in the specification is described in a progressive manner, and each embodiment focuses on the difference from other embodiments. The same and similar parts of each embodiment can be referred to. For system embodiments, since they are basically similar to method embodiments, the description is relatively simple, and the relevant parts can be referred to the part of the method embodiment.

[0126] The steps in the method of each embodiment of the present application can be adjusted, combined and reduced in sequence according to actual needs.

[0127] Finally, it should be noted that in this paper, relationship terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between the entities or operations.

[0128] The above description of disclosed embodiments enables one of ordinary skill in the art to make or use the application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0129] The above description is merely illustrative of the preferred embodiments of the present application and is not intended to limit the scope of the application. Many variations in the embodiments described herein will be readily apparent to those of ordinary skill in the art and the generic principles defined herein can be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method of physically simulating a dual clutch transmission fork, the method comprising: The method comprises: acquiring a pressure valve current, a flow valve current and a rotational speed difference of the dual clutch transmission; performing joint simulation processing on the pressure valve current, the flow valve current and the rotational speed difference of the dual clutch transmission through a pre-established fork physical model to obtain a simulation result; the simulation result is used to represent fork hydraulic cylinder pressure change information and fork movement information in different stages during fork gear shifting; performing a verification operation on the simulation result; the verification operation is used to verify the function of the fork; the joint simulation processing on the pressure valve current, the flow valve current and the rotational speed difference of the dual clutch transmission through the pre-established fork physical model to obtain the simulation result comprises: calculating the flow valve current through a pre-established flow valve model to obtain flow valve flow; calculating the pressure valve current through a pre-established pressure valve model to obtain pressure valve pressure; calculating the rotational speed difference of the dual clutch transmission through a pre-established fork gear engagement resistance model to obtain synchronizer synchronization force, fork ring resistance and mechanical resistance; performing stress analysis and calculation on the synchronizer synchronization force, the fork ring resistance and the mechanical resistance to obtain a fork gear engagement stress curve; the fork gear engagement stress curve is composed of a synchronization stage gear shifting force, a fork ring stage gear shifting force and a fork combined gear gear shifting force; performing joint simulation on the pressure valve pressure, the flow valve flow, the synchronization stage gear shifting force, the fork ring stage gear shifting force and the fork combined gear gear shifting force through a pre-established hydraulic cylinder model to obtain fork position information, fork speed information, piston two-end pressure values and synchronization torque information.

2. The method of claim 1, wherein, The construction process of the flow valve model comprises: acquiring electromagnetic valve spool mass, electromagnetic valve spool displacement, electromagnetic valve spool damping coefficient magnetic permeability, electro-hydraulic proportional valve spring stiffness, electromagnetic valve spring initial compression amount, steady-state hydraulic force and electromagnetic force; performing model creation on the electromagnetic valve spool mass, the spool displacement, the electromagnetic valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the electromagnetic valve spring initial compression amount, the steady-state hydraulic force and the electromagnetic force through a modeling tool Matlab / Simscape to obtain the flow valve model.

3. The method of claim 1, wherein, The construction process of the pressure valve model comprises: acquiring proportional pressure valve output oil pressure, pressure valve spool cross-sectional area, pressure valve spool mass, hydraulic oil elastic damping coefficient, return spring stiffness, return spring compression amount change, return spring initial compression amount, electromagnetic iron current force gain coefficient and excitation current; performing model creation on the proportional pressure valve output oil pressure, the pressure valve spool cross-sectional area, the pressure valve spool mass, the hydraulic oil elastic damping coefficient, the return spring stiffness, the return spring compression amount change, the return spring initial compression amount, the electromagnetic iron current force gain coefficient and the excitation current through a modeling tool Matlab / Simscape to obtain the pressure valve model.

4. The method of claim 1, wherein, The construction process of the hydraulic cylinder model comprises: acquire piston area, piston displacement, piston speed, piston acceleration, piston displacement is zero when the volume of the cylinder and clutch oil, oil volume elastic modulus, piston surface pressure, clutch active part mass, piston motion viscous damping coefficient, return spring stiffness and return spring initial deformation; Through the modeling tool Matlab / Simscape, model creation is performed on the piston area, the piston displacement, the piston speed, the piston acceleration, the volume of the cylinder and clutch oil when the piston displacement is zero, the oil volume elastic modulus, the piston surface pressure, the clutch active part mass, the piston motion viscous damping coefficient, the return spring stiffness and the return spring initial deformation, to obtain the hydraulic cylinder model.

5. A dual clutch transmission fork physical simulation system, characterized in that, The system comprises: An acquisition unit is configured to acquire a pressure valve current, a flow valve current, and a rotational speed difference of a dual-clutch transmission. An emulation unit is configured to perform joint emulation processing on the pressure valve current, the flow valve current, and the rotational speed difference of the dual-clutch transmission by using a pre-established fork physical model, to obtain an emulation result. The emulation result is used to represent fork hydraulic cylinder pressure change information and fork motion information at different stages during fork gear shifting. A verification unit is configured to perform a verification operation on the emulation result. The verification operation is used to verify the function of the fork. The emulation unit comprises a first calculation module, a second calculation module, a third calculation module, a fourth calculation module, and an emulation module. The first calculation module is configured to calculate the flow valve current by using a pre-established flow valve model, to obtain a flow valve flow. The second calculation module is configured to calculate the pressure valve current by using a pre-established pressure valve model, to obtain a pressure valve pressure. The third calculation module is configured to calculate the rotational speed difference of the dual-clutch transmission by using a pre-established fork gear engagement resistance model, to obtain a synchronizer synchronization force, a fork ring resistance, and a mechanical resistance.

6. The system of claim 5, wherein, The fourth calculation module is configured to perform stress analysis and calculation on the synchronizer synchronization force, the fork ring resistance, and the mechanical resistance, to obtain a fork gear engagement stress curve. The fork gear engagement stress curve is composed of a synchronization stage gear shifting force, a fork ring stage gear shifting force, and a fork gear tooth gear shifting force. The emulation module is configured to perform joint emulation on the pressure valve pressure, the flow valve flow, the synchronization stage gear shifting force, the fork ring stage gear shifting force, and the fork gear tooth gear shifting force by using a pre-established hydraulic cylinder model, to obtain fork position information, fork speed information, piston two-end pressure values, and synchronization torque information. The first calculation module of the flow valve model construction process comprises: A first acquisition submodule is configured to acquire a solenoid spool mass, a solenoid spool displacement, a solenoid spool damping coefficient magnetic permeability, an electro-hydraulic proportional valve spring stiffness, a solenoid spring initial compression amount, a steady-state hydraulic force, and an electromagnetic force. The first creating submodule is used for creating a model of the flow valve by modeling tool Matlab / Simscape on the solenoid valve spool mass, the spool displacement, the solenoid valve spool damping coefficient magnetic permeability, the electro-hydraulic proportional valve spring stiffness, the solenoid valve spring initial compression amount, the steady-state liquid dynamic force and the electromagnetic force, so as to obtain the flow valve model.

7. The system of claim 5, wherein, The second calculating module of the construction process of the pressure valve model comprises: The second acquiring submodule is used for acquiring the proportional pressure valve output oil pressure, the pressure valve spool cross-sectional area, the pressure valve spool mass, the hydraulic oil elastic damping coefficient, the return spring stiffness, the return spring compression amount change, the return spring initial compression amount, the electromagnetic iron current force gain coefficient and the excitation current. The second creating submodule is used for creating a model of the pressure valve by modeling tool Matlab / Simscape on the proportional pressure valve output oil pressure, the pressure valve spool cross-sectional area, the pressure valve spool mass, the hydraulic oil elastic damping coefficient, the return spring stiffness, the return spring compression amount change, the return spring initial compression amount, the electromagnetic iron current force gain coefficient and the excitation current, so as to obtain the pressure valve model.

8. The system of claim 5, wherein, The simulation module of the construction process of the hydraulic cylinder model comprises: The third acquiring submodule is used for acquiring the piston area, the piston displacement, the piston speed, the piston acceleration, the sum of the oil cylinder and the clutch oil channel volume when the piston displacement is zero, the oil volume elastic modulus, the piston surface pressure, the clutch driving part mass, the piston movement viscous damping coefficient, the return spring stiffness and the return spring initial deformation. The third creating submodule is used for creating a model of the hydraulic cylinder by modeling tool Matlab / Simscape on the piston area, the piston displacement, the piston speed, the piston acceleration, the sum of the oil cylinder and the clutch oil channel volume when the piston displacement is zero, the oil volume elastic modulus, the piston surface pressure, the clutch driving part mass, the piston movement viscous damping coefficient, the return spring stiffness and the return spring initial deformation, so as to obtain the hydraulic cylinder model.

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