Synchronizer structure adaptive optimization method driven by multiple parameters

Abstract

The present application provides a method for adaptive optimization of synchronizer structure driven by multiple parameters, which relates to the technical field of synchronizer structure optimization, including: establishing an integrated simulation model; collecting scenes of gear shifting jamming under high load for the target synchronizer; inputting multiple high-load test scenes into the integrated simulation model for gear shifting test, and performing impact analysis of gear meshing according to the test results; judging whether the anti-meshing impact index meets the preset anti-impact index, if not, activating the structure optimization module; optimizing the multiple structural design parameters, and generating recommended structural design parameters that meet the preset anti-impact index. The present application can solve the technical problem in the prior art that the synchronizer cannot completely eliminate the impact of gear meshing, jamming occurs during the gear shifting process, and the gear shifting process is not smooth. The actual operation under high load is simulated by integrated simulation, which improves the smoothness of the synchronizer shifting process.

Description

Technical Field

[0001] The present application relates to the technical field of synchronizer structure optimization, and in particular to a synchronizer structure adaptive optimization method driven by multiple parameters. Background Art

[0002] The automotive synchronizer is a key component in the automotive transmission system. It is mainly used to coordinate the vehicle's engine speed and the speed of the transmission input shaft to ensure the smoothness and smoothness of the gear shifting process. The synchronizer can eliminate the problem of gear collision or poor engagement caused by speed mismatch, thereby improving the smoothness of gear shifting and driving experience. The synchronizer gradually synchronizes the gears to be meshed through friction torque, but in actual operation, due to the influence of factors such as wear of mechanical parts, surface roughness, and lubrication conditions, the synchronization process may not be able to completely eliminate the speed difference, resulting in impact and stagnation during gear shifting, which not only affects the smoothness of gear shifting, but may also cause gear surface wear, excessive temperature rise, and even damage.

[0003] In summary, the prior art has a technical problem that the synchronizer cannot completely eliminate the impact of gear meshing, resulting in a jamming phenomenon during the gear shifting process, which leads to an unstable gear shifting process. Summary of the invention

[0004] The purpose of this application is to provide a multi-parameter driven synchronizer structure adaptive optimization method to solve the technical problem in the prior art that the synchronizer cannot completely eliminate the impact of gear meshing, resulting in sticking during the gear shifting process and causing an unstable gear shifting process.

[0005] In view of the above problems, the present application provides a synchronizer structure adaptive optimization method driven by multiple parameters, wherein the synchronizer structure adaptive optimization method driven by multiple parameters includes: determining the input shaft and the output shaft for speed difference adjustment through the target synchronizer, performing integrated simulation of the input shaft, the target synchronizer and the output shaft, and establishing an integrated simulation model; performing gear shift jamming scenario collection under high load for the target synchronizer, and establishing multiple high-load test scenarios; inputting the multiple high-load test scenarios into the integrated simulation model for gear shift testing, and performing gear meshing impact analysis based on the test results to generate an anti-meshing impact index; judging whether the anti-meshing impact index meets the preset anti-impact index, and if not, activating the structural optimization module; optimizing the multiple structural design parameters of the target synchronizer through the structural optimization module to generate recommended structural design parameters that meet the preset anti-impact index.

[0006] The technical solution provided in this application has at least the following technical effects or advantages:

[0007] By determining the input shaft and output shaft for speed difference adjustment through the target synchronizer, an integrated simulation of the input shaft, the target synchronizer and the output shaft is performed to establish an integrated simulation model; the gear shifting jamming scene collection under high load is performed for the target synchronizer, and multiple high load test scenes are established; the multiple high load test scenes are input into the integrated simulation model for gear shifting test, and the impact analysis of gear meshing is performed according to the test results to generate an anti-meshing impact index; it is determined whether the anti-meshing impact index meets the preset anti-impact index, if not, the structure optimization module is activated; the multi-structure design parameters of the target synchronizer are optimized through the structure optimization module to generate recommended structural design parameters that meet the preset anti-impact index. In other words, through the integrated simulation model, the working process of the input shaft, synchronizer and output shaft is simulated, the gear shifting jamming scene under high load conditions is tested, the performance of the synchronizer is evaluated under extreme conditions, the gear meshing impact analysis is performed according to the test results, and the multi-design parameters of the target synchronizer are optimized to better adapt to high load and high speed conditions, reduce the jamming problem under high load, and improve the stability of the synchronizer shifting process.

[0008] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented according to the contents of the specification, and in order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are specifically cited below. It should be understood that the content described in this section is not intended to identify the key or important features of the embodiments of the present application, nor is it intended to limit the scope of the present application. Other features of the present application will become easy to understand through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] In order to more clearly illustrate the technical solutions in the present application or the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying any creative work.

[0010] Figure 1 A schematic diagram of the process of the synchronizer structure adaptive optimization method driven by multiple parameters of the present application;

[0011] Figure 2 A flowchart of establishing multiple high-load test scenarios in the synchronizer structure adaptive optimization method driven by multiple parameters of this application. DETAILED DESCRIPTION

[0012] This application solves the technical problem in the prior art that the synchronizer cannot completely eliminate the impact of gear meshing, resulting in a jamming phenomenon during the gear shifting process, which leads to an unsmooth gear shifting process by providing a multi-parameter driven synchronizer structure adaptive optimization method. Through an integrated simulation model, the working process of the input shaft, synchronizer and output shaft is simulated, and the gear shift jamming scenario under high-load conditions is tested. The performance of the synchronizer is evaluated under extreme conditions, and the gear meshing impact analysis is performed based on the test results. The multi-design parameters of the target synchronizer are optimized to better adapt to high-load and high-speed conditions, reduce the jamming problem under high load, and improve the smoothness of the synchronizer shifting process.

[0013] Below, the technical solutions in the present application will be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments of the present application. It should be understood that the present application is not limited to the example embodiments described herein. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present application. It should also be noted that, for the convenience of description, only the parts related to the present application are shown in the accompanying drawings, rather than all of them.

[0014] For examples, please see the attached Figure 1 The present application provides a synchronizer structure adaptive optimization method driven by multiple parameters, wherein the synchronizer structure adaptive optimization method driven by multiple parameters specifically comprises the following steps:

[0015] Step 1: Determine the input shaft and output shaft for speed difference adjustment through the target synchronizer, perform integrated simulation of the input shaft, target synchronizer and output shaft, and establish an integrated simulation model.

[0016] Specifically, in the transmission system, the function of the synchronizer is to adjust the speed difference between the input shaft and the output shaft to ensure smooth meshing of the gears during the gear shifting process. The target synchronizer refers to the specific synchronizer component designed or selected to adjust the speed difference. The input shaft is the shaft connecting the engine and the transmission, which transmits the power of the engine to the transmission. The speed of the input shaft is controlled by the speed of the engine. The output shaft is the shaft connecting the transmission and the wheels, which transmits the power converted by the transmission to the wheels, thereby driving the car to move. The speed of the output shaft is related to the vehicle speed. The speed difference refers to the speed difference between the input shaft and the output shaft. During the gear shifting process, the speed difference may cause the gears to mesh poorly or produce impact, so the synchronizer needs to be adjusted to ensure smooth connection.

[0017] In the transmission, the speed difference between the input shaft and the output shaft is inevitable, especially during the gear shifting process. When switching to different gears, the difference between the speed of the input shaft and the speed of the output shaft may cause the gear to jam or impact. The task of the target synchronizer is to ensure that the input shaft and the output shaft can be synchronized as smoothly as possible by adjusting the speed difference. The entire transmission system of the input shaft, synchronizer and output shaft is modeled and jointly simulated in the simulation environment, fully considering the interaction between the various components, including how the speed of the input shaft affects the work of the synchronizer, how the synchronizer adjusts the speed difference between the input shaft and the output shaft, and how the speed change of the output shaft affects the power transmission of the entire system.

[0018] Use professional simulation software (such as MATLAB / Simulink or AMESim) to build an integrated simulation model. For example, in Simulink, use Simscape Multibody modules to simulate the dynamic behavior of the input shaft, synchronizer, and output shaft, and then perform system-level simulation to observe how to optimize the shifting performance by adjusting the parameters of the synchronizer under different working conditions. Through pre-modeling and simulation tools, establish an overall simulation model including the input shaft, target synchronizer, and output shaft, and combine the dynamics, tribology, thermal and other factors of all components to perform collaborative simulation to simulate the response under different working conditions. Through simulation, the effects of different design schemes can be evaluated without actual manufacturing and testing, thereby accelerating the product development cycle and reducing test costs.

[0019] Step 2: Execute the gear shifting and sticking scene collection under high load for the target synchronizer, and establish multiple high load test scenes.

[0020] Specifically, the specific situations of gear shift jamming of the target synchronizer under high-load environment are collected and analyzed. Through simulation and real vehicle testing, different high-load working conditions are simulated, detailed data of each gear shift is collected, and whether there is jamming is observed. Specific test conditions are collected or created to simulate the problems that the synchronizer may encounter in actual use, such as gear shift jamming. After collecting the gear shift jamming data, multiple high-load test scenarios are established to comprehensively evaluate the performance of the target synchronizer under various high-load conditions, which can not only simulate different driving conditions, but also help optimize the design of the synchronizer to ensure that it can work stably under extreme conditions.

[0021] Set a high-frequency shift frequency to configure the first high-load scenario to simulate a working condition that requires frequent shifting. The synchronizer must be able to complete the speed difference adjustment in a very short time. During frequent shifting, the synchronizer must ensure that each shift is smooth and without impact. Set a larger speed difference between the input shaft and the output shaft, and configure the second high-load scenario to simulate the responsiveness and stability of the synchronizer under large speed difference conditions, ensuring that gear jamming or impact can be avoided even under extreme conditions. Generate multiple high-load test scenarios through cross-variation processing, including different combinations, to simulate the performance of the synchronizer under various working conditions, covering a variety of situations from high-speed driving, rapid acceleration to low-speed and high-load.

[0022] Use the Simulink simulation platform in MATLAB to simulate these high-load scenarios. By creating a simulation model that includes the input shaft, output shaft, synchronizer, and load, it is possible to simulate the shifting process under different working conditions and collect jamming data in the simulation. The simulation tool can also perform multiple iterations to test the adaptability of different synchronizer designs to high-load scenarios. After generating these scenarios, more in-depth tests can be performed to evaluate the performance of the target synchronizer under extreme conditions. By collecting and generating multiple high-load test scenarios, the performance of the target synchronizer under different load conditions is evaluated. Based on the data from the test scenarios, the design of the synchronizer can be optimized, and parameters such as friction materials and gear meshing accuracy can be adjusted. The performance and possible problems of the synchronizer can be predicted during the design stage, thereby improving the overall reliability of the synchronizer.

[0023] Step three: input the multiple high-load test scenarios into the integrated simulation model to perform a gear shift test, and perform an impact analysis of gear meshing based on the test results to generate an anti-meshing impact index.

[0024] Specifically, multiple high-load test scenarios are sequentially input into the integrated simulation model for gear shifting tests, including high speed difference scenarios, frequent gear shifting scenarios, etc. The integrated simulation model integrates the physical characteristics and motion behaviors of multiple components, including the input shaft, target synchronizer, and output shaft. By modeling the dynamic coupling of these components, the operating state and gear shifting process of the synchronizer in actual work are accurately simulated. By inputting different test scenarios (high load, high speed difference, etc.) to simulate the real working environment, dynamic response data under different working conditions are obtained, including speed matching, friction change, and vibration characteristics. After completing the simulation and simulating different high-load test scenarios, a series of test results are generated, including speed matching test results, friction change test results, vibration generation test results, etc.

[0025] The speed matching test results reflect the speed difference and matching between the input shaft and the output shaft. If the speed matching effect is too poor, it is meaningless to have strong impact resistance, and the adjustment parameters of the synchronizer need to be readjusted. According to the test results, the impact analysis of gear meshing is carried out to identify the impact force generated during the gear shifting process and analyze how these impacts affect the performance of the synchronizer. Evaluate the error of speed matching to determine whether it is within the acceptable range. Calculate the stability index of friction force to determine whether the friction force fluctuates within the safe range. According to the vibration test results, evaluate the impact of vibration on the performance and structure of the synchronizer. Combine the analysis results of speed matching, friction force change and vibration generation, evaluate the impact of gear meshing, generate anti-meshing impact index, and evaluate the performance of the synchronizer under different high load conditions. Through the analysis of the test results, optimize the structural design of the synchronizer so that it can effectively reduce the impact generated by gear meshing during the gear shifting process and improve the smoothness of the gear shifting.

[0026] Step 4: Determine whether the anti-meshing impact index meets the preset anti-impact index, if not, activate the structure optimization module.

[0027] Specifically, the anti-meshing impact index is used to measure the ability of the synchronizer to withstand the impact force generated when the gears are meshing during the gear shifting process. It combines multiple factors, such as speed matching, friction change and vibration intensity, to quantify the impact characteristics during gear shifting. The higher the anti-meshing impact index, the better the synchronizer's ability to buffer the impact during gear meshing, and the smoother the gear shifting process. The preset anti-impact index is a target indicator set during the design phase. It is used to measure the impact resistance that the synchronizer should achieve in actual use. It is usually determined by factors such as performance standards, comfort standards and durability standards. For example, the preset anti-impact index may stipulate that the speed difference during the gear shifting process shall not exceed a certain range, the friction change shall not exceed a certain fluctuation value, and the vibration intensity shall be controlled within a certain comfortable range.

[0028] Determine whether the anti-meshing impact index meets the preset anti-impact index. If the anti-meshing impact index meets these preset requirements, it means that the design of the synchronizer can effectively withstand the gear meshing impact under high load, and the shifting process is stable and comfortable, and no further optimization is required. If the test results show that the anti-meshing impact index fails to meet the preset standard, it means that there is a design problem with the synchronizer, which may cause excessive impact force, vibration or friction fluctuation during shifting, and the structure optimization module needs to be automatically activated. By activating the structure optimization module, the synchronizer design is adjusted to reduce gear meshing impact, optimize shifting stability, and reduce shifting jams.

[0029] Step 5: Optimize the multi-element structural design parameters of the target synchronizer through the structural optimization module to generate recommended structural design parameters that meet the preset anti-shock index.

[0030] Specifically, the structural optimization module is an automated design tool used to optimize the design of the synchronizer based on test results and performance standards, and adjust the structure and parameters of the synchronizer based on the information fed back from simulation and test results to achieve better performance, including changing the synchronizer's gear design, friction plate material, and transmission shaft stiffness. The historical structural design parameters of the target synchronizer are retrieved, that is, the historical structural design parameters of the past, and the structural design parameter optimization space is constructed, including multiple structural design parameters. The current multivariate design parameters of the target synchronizer are determined, including friction rings, gears, etc. The material of the friction ring affects the change in friction force, thereby affecting the speed matching and impact resistance. The gear module affects the size and meshing accuracy of the gear, which directly affects the vibration and impact during gear shifting. The number of teeth determines the meshing characteristics of the gear, affecting the gear's load-bearing capacity and impact absorption capacity.

[0031] Iteratively optimize the current multivariate design parameters in the structural design parameter optimization space, and use optimization algorithms (such as particle swarm optimization, genetic algorithm, etc.) to search and optimize the multivariate design parameters of the target synchronizer with the preset impact resistance index as the target. Analyze the iteratively optimized multivariate design parameters through an integrated simulation model and multiple high-load test scenarios to evaluate their impact resistance under high load. According to the current evaluation results, adjust the design parameters (such as friction ring material, gear module, number of teeth, etc.) so that the impact resistance index gradually approaches the preset standard. The optimization process stops when the anti-meshing impact index meets the preset impact resistance index.

[0032] If the maximum number of iterations is reached and the structural design parameters whose iterative anti-meshing impact index meets the preset anti-impact index are not output, the optimized structural parameter sequence is recorded. The optimized structural parameter sequence means that in the process of multiple iterative optimizations, although some design parameters fail to immediately meet the preset anti-meshing impact index, their impact index shows a trend of gradual improvement (gain). By analyzing the optimized structural parameter sequence, the relationship and change law between various parameters (such as friction ring material, gear module, number of teeth, etc.) are found. According to the change law, any two sets of parameters are randomly generated and enter the optimization cycle for simulation testing. If the maximum number of repeated optimizations is reached and the design parameters that meet the preset anti-impact index are still not obtained, the design parameters corresponding to the current minimum anti-meshing impact index are output as the recommended structural design parameters, and a reminder message is generated to inform the designer that although the current optimized design has improved the anti-impact performance, it still does not fully meet the target requirements.

[0033] After multiple rounds of optimization and simulation, a set of design parameters are finally output to make the synchronizer meet the preset anti-shock index as much as possible, as the final structural design scheme for implementation. Through the structural optimization module, the recommended structural design parameters finally obtained significantly improve the anti-shock performance of the target synchronizer. The optimized synchronizer can effectively reduce the gear meshing shock and vibration under high load and high speed difference working conditions, meet the preset anti-shock index, ensure that the target synchronizer has better anti-shock ability under high load, thereby improving the stability of the synchronizer.

[0034] Further, as attached Figure 2 As shown, step 2 of this application includes:

[0035] A frequent shifting scenario is configured for the target synchronizer according to a preset high-frequency shifting frequency to generate a first high-load test scenario; a shifting scenario is configured for the target synchronizer according to a target switching amplitude to generate a second high-load test scenario; cross-variation processing is performed on the first high-load test scenario and the second high-load test scenario to generate a third high-load test scenario; the multiple high-load test scenarios are generated with the first high-load test scenario, the second high-load test scenario and the third high-load test scenario.

[0036] Specifically, high-frequency shifting frequency refers to the number of gear shifts per unit time, and the preset high-frequency shifting frequency is the frequency of the shifting operation pre-set in the simulation or test. According to the preset high-frequency shifting frequency, set the shifting operation scenario in the simulation or test to simulate the frequent shifting in reality. The simulation cycle, shifting frequency, and synchronizer response speed are set through the simulation software to generate the first high-load test scenario, that is, the high-frequency shifting frequency scenario that requires frequent shifting. In this scenario, the target synchronizer needs to be able to respond quickly and adjust the speed difference between the input shaft and the output shaft to avoid shifting or jamming.

[0037] The switching amplitude refers to the range of the speed difference between the input shaft and the output shaft during the gear shifting process, and the target switching amplitude refers to the target value of the speed difference or torque difference that the synchronizer needs to achieve during the gear shifting process. According to the target switching amplitude, set up a second high-load test scenario, namely the target switching amplitude scenario. Simulate the responsiveness and stability of the synchronizer under the condition of large speed difference to ensure that the gears can avoid jamming or impact under extreme conditions.

[0038] The first high-load test scenario and the second high-load test scenario are cross-mutated, that is, the characteristics of the two scenarios are combined to generate a third high-load test scenario. In simulation and testing, cross-mutation is an operation method used to generate new scenarios or new designs. Through cross-mutation, the characteristics of different test scenarios can be combined to generate new and more challenging test scenarios. Assuming that the first scenario has a high shift frequency and the second scenario has a large speed difference range, the result of the cross-mutation processing is the third test scenario, in which the shift frequency is high and the speed difference is also large. Test the performance of the synchronizer under extreme conditions, such as whether it can still maintain smooth shifting when high frequency and large speed difference exist at the same time.

[0039] The first high-load test scenario, the second high-load test scenario, and the third high-load test scenario are combined to form a series of multiple high-load test scenarios, including different combinations, to evaluate the performance of the synchronizer under different working conditions. By simulating different high-load scenarios, the responsiveness and stability of the synchronizer can be tested under extreme conditions, ensuring smooth shifting under high loads and high frequencies, and obtaining detailed data of the synchronizer under different loads. Testing and optimizing the synchronizer design can effectively reduce the risk of failures such as jamming and impact, and improve the reliability of the synchronizer.

[0040] Further, step three of this application includes:

[0041] The multiple high-load test scenario inputs are tested in sequence through the integrated simulation model to obtain multiple test results, wherein any test result at least includes a speed matching test result, a friction change test result, and a vibration generation test result; an impact analysis of gear meshing is performed based on the speed matching test result, the friction change test result, and the vibration generation test result among the multiple test results to generate the anti-meshing impact index.

[0042] Specifically, the integrated simulation model is used to test multiple high-load test scenarios one by one. Each test scenario will simulate different working conditions to help evaluate the performance of the synchronizer. Based on the simulation test, multiple test results are obtained, each of which includes speed matching test results, friction change test results, and vibration generation test results. The speed matching test results are used to measure the degree to which the input shaft and output shaft speed of the synchronizer are consistent during the shifting process. The friction change test results are used to record the size and change of the friction during the operation of the synchronizer. The vibration generation test results are used to evaluate the vibration level generated during the operation of the synchronizer.

[0043] When the synchronizer is working, especially under high load or high speed difference, the impact force generated when the gears mesh will affect the smoothness of the shift and the durability of the synchronizer. When the impact force is too large, it will not only affect the driving experience of the vehicle, but also accelerate the wear of the gears and other transmission parts. Generate the target adjustment coefficient based on the speed matching test results to ensure that the speed difference between the input shaft and the output shaft is within the acceptable range. Check the change of friction. If the friction fluctuates greatly, it means that the performance of the synchronizer in adjusting the speed difference is unstable and the impact will increase. When the friction change stability is poor, the impact resistance index is low. If the vibration amplitude is large, it means that the impact when the gears mesh is strong, and the impact resistance index will be correspondingly low. The speed matching test results, friction change test results and vibration generation test results are comprehensively considered and integrated into an anti-meshing impact index. If the index is lower than the preset standard, it may be necessary to optimize the design of the synchronizer or adjust the working parameters. Through the comprehensive analysis of speed matching, friction change and vibration, reduce the gear meshing impact and improve the smoothness of the shift.

[0044] Furthermore, the present application also includes the following steps:

[0045] Based on the speed matching test result, an anti-impact feedback adjustment coefficient is configured to generate a target adjustment coefficient; based on the friction force change test result, a friction force change stability analysis is performed to generate a friction force stability index; based on the vibration generation test result, a vibration impact index is performed; the friction force stability index and the vibration impact index are integrated, and feedback adjustment is performed through the target adjustment coefficient to generate the anti-engagement impact index.

[0046] Specifically, speed matching is the main function of the synchronizer. If the speed matching effect is not good, it is meaningless to have strong shock resistance. According to the speed matching test results, configure the shock resistance feedback adjustment coefficient. By configuring the feedback adjustment coefficient, the synchronizer design is optimized to make the speed matching more accurate and reduce the shock caused by excessive speed difference. The actual speed difference between the input shaft and the output shaft is obtained through the speed matching test results. The speed difference is compared with the set speed matching error range to determine whether the current speed matching is effective. The target adjustment coefficient is an adjustment coefficient set according to the speed matching test results and requirements, and is used to control the performance of the synchronizer.

[0047] If the speed matching error is within the set range, it means that the speed matching is good and the target adjustment coefficient is 1. If the speed matching error is not within the set range, it means that the speed matching function of the synchronizer fails to meet the requirements. At this time, the target adjustment coefficient is reset to zero, which means that there is a problem with the speed matching performance of the synchronizer and the working state of the synchronizer needs to be redesigned or adjusted, because if the speed matching is not well controlled, then the anti-shock adjustment will lose its meaning.

[0048] According to the test results of friction force change, the stability analysis of friction force change is carried out. The change of friction force during the gear shifting process is analyzed using statistical analysis methods (such as standard deviation, fluctuation amplitude, etc.). The stability of friction force is evaluated by the degree of fluctuation of friction force data. For example, the standard deviation of friction force change is calculated. The smaller the standard deviation, the smaller the friction force fluctuation and the better the stability. According to the stability analysis results of friction force change, the friction force stability index is generated. The friction force stability index can be obtained by 1 / (1+standard deviation), which is used to quantify the degree of fluctuation of friction force during gear shifting. If the friction force changes relatively smoothly and the amplitude is moderate, it means that the synchronizer is working stably; if the friction force changes violently or irregularly, it may cause uneven gear shifting, which in turn affects the driving experience.

[0049] Vibration is an inevitable part of the gear shifting process, especially in high-load gear shifting scenarios, where vibration is often more significant. Based on the vibration test results, the vibration test intensity is obtained. According to the vehicle design standards, comfort requirements or driver feedback, a threshold is pre-set, that is, the preset comfortable vibration intensity, which represents the maximum acceptable vibration intensity during the gear shifting process. The ratio between the vibration test intensity and the preset comfortable vibration intensity is calculated to obtain the vibration impact index, which reflects the gap between the actual vibration intensity and the comfortable vibration intensity. If the vibration impact index is greater than 1, it means that the vibration intensity exceeds the comfort range, causing discomfort to the driver or vibration interference inside the vehicle. It is necessary to reduce vibration by optimizing the gear shifting system, synchronizer design, shock absorption system, etc. If the vibration impact index is less than 1, it means that the vibration intensity is within the acceptable range, the vehicle's gear shifting process is comfortable, and the driver will not feel excessive vibration.

[0050] Combine the friction stability index and the vibration impact index, assign weights to the two indexes according to the design objectives and actual application requirements of the synchronizer, and generate a comprehensive index through weighted average or other fusion methods. Through the target adjustment coefficient of the speed matching test results, the friction stability and vibration impact are feedback-adjusted to obtain the anti-meshing impact index. The anti-meshing impact index combines factors such as speed matching, friction stability and vibration intensity to quantify the impact intensity that may be generated during the gear shifting process. Through the optimization of speed matching, friction stability and vibration control, the jamming phenomenon and unnecessary vibration are reduced, the structure and function of the synchronizer are timely optimized, and the gear shifting performance and durability are improved.

[0051] Furthermore, the present application also includes the following steps:

[0052] Establish a speed matching error range; determine whether the speed matching error is within the speed matching error range according to the speed matching test result; if so, configure the target adjustment coefficient to 1; if not, reset the target adjustment coefficient to zero.

[0053] Specifically, a speed matching error range is set to define the maximum acceptable speed difference between the input shaft and the output shaft. Based on the performance standards and design requirements of the synchronizer, an acceptable speed matching error range is determined to determine whether the speed matching degree of the synchronizer during gear shifting is acceptable. For example, if the design of the synchronizer requires the speed matching error to not exceed ±50RPM, then this range is -50RPM to +50RPM.

[0054] Based on the speed matching test results, determine whether the speed difference between the input shaft and the output shaft is within the predetermined error range, and decide whether the target adjustment coefficient needs to be adjusted. If the test result (actual speed difference) is within the error range, the speed matching is considered normal, and the target adjustment coefficient is configured to 1, indicating that the synchronizer does not need any adjustment and maintains the current working state. Continue to use the current design without additional adjustments. Factors such as speed matching, friction changes, and vibration will continue to be optimized according to the design parameters and no further adjustments are required.

[0055] If it exceeds this range, the speed matching is considered to have failed, indicating that the synchronizer cannot effectively complete the speed matching task. At this time, the target adjustment coefficient needs to be configured to zero, which means that the anti-shock function fails, because if the speed matching is not done well, the subsequent impact adjustment and optimization measures are meaningless. If the speed matching fails, the process of redesigning or optimizing the synchronizer is triggered, and the gear meshing angle, friction material, lubrication scheme, etc. of the synchronizer are adjusted to ensure that the speed matching can meet the requirements, thereby restoring the anti-shock function. By ensuring that the speed matching error is within a reasonable range, the impact caused by excessive speed difference during the gear shifting process can be avoided, thereby improving the smoothness of the gear shifting, and by judging in real time whether the speed matching error is within the tolerance range, the invalid adjustment of the synchronizer can be reduced.

[0056] Furthermore, the present application also includes the following steps:

[0057] Acquire a preset comfortable vibration intensity; calculate a ratio of the vibration test intensity to the preset comfortable vibration intensity based on the vibration generation test result, and generate the vibration impact index.

[0058] Specifically, the preset comfortable vibration intensity is a threshold value set according to the driving comfort standard or experimental data during vehicle design, which indicates the maximum acceptable vibration intensity during the gear shifting process. If the vibration intensity exceeds this value, the driver may feel uncomfortable, which is usually defined through user surveys, experimental data or comfort standards. The test results generated based on vibration, including vibration intensity, vibration frequency, vibration waveform, etc., reflect the actual vibration generated by the vehicle during the gear shifting process. The vibration test intensity is compared with the preset comfortable vibration intensity, and the ratio between the two is calculated to quantify the impact of the vibration generated during the gear shifting process on comfort.

[0059] If the vibration test intensity is greater than the preset comfortable vibration intensity, the vibration impact index will be greater than 1, indicating that the vibration during gear shifting exceeds the comfortable range; if it is less than 1, it means that the vibration is relatively comfortable. Based on the calculated ratio (the ratio of the vibration test intensity to the preset comfortable vibration intensity), a vibration impact index is generated. If the index is greater than 1, it means that the vibration intensity has a greater impact on comfort; if it is less than 1, it means that the vibration is within an acceptable range. By calculating and analyzing the vibration impact index, it is possible to identify whether the vibration generated during the gear shifting process exceeds the comfortable range, and then take measures to optimize the gear shifting process and improve the driver's comfort experience.

[0060] Further, step five of this application includes:

[0061] Perform historical structural design parameter retrieval for the target synchronizer and construct a structural design parameter optimization space; determine current multivariate design parameters of the target synchronizer; iteratively optimize the current multivariate design parameters based on the structural design parameter optimization space, and call the integrated simulation model and the multiple high-load test scenarios to analyze the iteratively optimized structural design parameters until the recommended structural design parameters whose iterative anti-meshing impact index meets the preset anti-impact index are obtained.

[0062] Specifically, the existing design parameters, including the geometry of friction rings, gears, and synchronizers, material properties, manufacturing tolerances, etc., are extracted from the historical structural design of the target synchronizer as a reference in the optimization process. According to the historical data and the current design requirements, the optimization space of the design parameters is determined, that is, the structural design parameter optimization space, which is a multidimensional space containing all possible combinations of design parameters. Each design parameter (such as the material of the friction ring, the shape and size of the gear, etc.) has a certain range of values, and the structural design parameter optimization space represents the combination of all these parameters. The optimization process is to find the optimal solution in this space, that is, those design parameters that can meet the performance requirements (such as anti-meshing impact, comfort, etc.) and meet the manufacturing and cost requirements.

[0063] Determine the current design of the target synchronizer, including multiple parameters such as the material of the friction ring, the module and tooth shape of the gear, and the geometric dimensions of the synchronizer. The current multivariate design parameters are the current design parameters of the target synchronizer, including but not limited to the design characteristics of each part such as the friction ring, gear, and synchronizer structure. The design parameters of each part may affect the overall performance of the synchronizer.

[0064] According to the optimization space of structural design parameters, the current multivariate design parameters are iteratively optimized, and a suitable optimization algorithm is selected for multi-parameter adjustment, such as genetic algorithm, particle swarm optimization, simulated annealing algorithm, etc. The optimal solution is searched in the multidimensional space. Each iteration will optimize the current design parameters once to improve the anti-meshing impact performance of the design so as to gradually approach the optimal design. For example, a particle swarm optimization algorithm is selected to initialize a group of particles, and the position and speed of each particle are random. Each position of a particle is a parameter of a design scheme (such as friction ring material, gear module, number of teeth, etc.), and the speed of each particle represents the change of the parameter. The fitness of each particle is evaluated, that is, the anti-meshing impact index is calculated according to the design parameters. Each particle will update the individual optimal position according to its own fitness value, that is, if the fitness of the current particle is better than the previous optimal value, the individual optimal position will be updated. All particles in the entire particle swarm will compare their own fitness values ​​and update the position of the particle with the best fitness to the global optimal position. The speed and position of the particle are updated according to the fitness to move it towards the individual optimal and global optimal positions. Repeat this process until the optimal solution that meets the anti-impact standard is found.

[0065] After each optimization, the new design parameters will be input into the integrated simulation model for verification. The simulation model will simulate the shifting process according to the new design, obtain the speed matching test results, friction change test results, vibration generation test results, etc., and generate new anti-meshing impact indicators. In order to ensure the reliability of the synchronizer under high load conditions, the simulation model will test each optimization result under multiple high-load test scenarios to evaluate the performance of the iteratively optimized structural design parameters in actual use, especially under difficult working conditions.

[0066] After each optimization, the anti-meshing impact index is evaluated according to the test results to determine whether it meets the preset anti-impact standard. Once the anti-meshing impact index reaches the preset anti-impact index, the optimization process ends and the recommended structural design parameters are output. Through the iterative optimization process of structural design parameters, combined with historical design data, integrated simulation models and high-load test scenarios, the design of the synchronizer is optimized to improve its anti-meshing impact performance, gear shifting smoothness and durability, which not only improves the design efficiency, but also ensures that the final synchronizer design can work reliably under various working conditions and meet the requirements of driving comfort and durability.

[0067] Furthermore, the present application also includes the following steps:

[0068] If the number of iterative optimization reaches the preset number of iterations, and the structural design parameters whose iterative anti-meshing impact index meets the preset anti-impact index have not been output, obtain an optimized structural parameter sequence with an increasing trend of iterative anti-meshing impact index according to the iterative optimization record; analyze the change law of multivariate structural design parameters based on the optimized structural parameter sequence to generate a multivariate parameter change law; randomly generate between any two groups of parameters in the optimized structural parameter sequence based on the multivariate parameter change law, optimize the optimization space of the structural design parameters and then repeat the iterative optimization; if the number of repeated iterative optimization reaches the preset number of repetitions, and the structural design parameters whose iterative anti-meshing impact index meets the preset anti-impact index have not been output, use the structural design parameters with the smallest iterative anti-meshing impact index obtained by the current optimization as the recommended structural design parameters, and generate a reminder message with the smallest iterative anti-meshing impact index.

[0069] Specifically, the number of iterative optimization refers to the number of times the design parameters are adjusted during the optimization process. The preset number of iterations refers to the maximum number of iterations allowed during the optimization process. After reaching this number, even if the optimization result has not yet met the preset anti-impact index, it will be further processed according to the current optimization status. In each optimization process, if the anti-meshing impact index of the design parameters does not fully meet the preset requirements, a set of design parameter sequences with gradually increasing impact indicators can be obtained by recording the results of each iteration. For example, suppose that during the optimization process, it is found that with the adjustment of the friction ring material, the impact index has improved. Although it has not fully met the standard, it still shows a good improvement trend.

[0070] Analyze the sequence of structural parameter optimization with increasing trend to find out the relationship and change rules between various parameters (such as friction ring material, gear modulus, number of teeth, etc.). For example, suppose that in multiple optimization processes, it is found that the increase of gear modulus can linearly reduce the anti-meshing impact index, while the change of friction ring material is nonlinear, and there is a certain threshold for the improvement of anti-impact performance, and infer which parameter combinations may produce the best effect in further optimization.

[0071] According to the obtained change rules, any two sets of parameters are randomly generated in the design space to generate new design solutions. By calling the integrated simulation model and high-load test scenario, the newly generated design parameters are evaluated, the anti-meshing impact index is updated, and multiple rounds of optimization are continued. Repeated iterative optimization means that when the first optimization fails to meet the preset anti-impact index, iterative optimization is continued according to the optimization results of the previous round. After each iteration, the new design parameters are adjusted based on the simulation test results until the expected performance standard is achieved or the maximum number of repetitions is reached.

[0072] If the number of repeated optimizations reaches the preset value and the design parameters that meet the preset anti-impact index are still not obtained, the design parameters corresponding to the current minimum anti-meshing impact index will be output as the recommended structural design parameters. The minimum iterative anti-meshing impact index refers to the scheme with the minimum anti-meshing impact index in the final selected design scheme during the optimization process. The minimum index means that the design exhibits the best anti-impact performance in all iterations. Even if the preset anti-impact index is still not fully met after multiple optimizations, a reminder message will be generated to inform the designer of the minimum anti-meshing impact index of the current scheme, prompting the designer that although the anti-impact performance has been improved, it has not yet fully met the expected standard. The reminder message can include the current minimum anti-meshing impact index, the reason for not meeting the standard, and suggestions for further optimization. By randomly generating parameter combinations and analyzing the law of multivariate parameter changes, it is avoided to fall into the local optimal solution too early in the optimization process, and the probability of the global optimal solution is increased. Multiple iterative optimizations and random combination generation can eventually obtain design parameters close to the optimal one. Although the preset standard is not fully met, design parameters with the minimum impact index will be generated, ensuring the performance improvement of the synchronizer.

[0073] In summary, the multi-parameter driven synchronizer structure adaptive optimization method provided in this application has the following technical effects:

[0074] By determining the input shaft and output shaft for speed difference adjustment through the target synchronizer, an integrated simulation of the input shaft, the target synchronizer and the output shaft is performed to establish an integrated simulation model; the gear shifting jamming scene collection under high load is performed for the target synchronizer, and multiple high load test scenes are established; the multiple high load test scenes are input into the integrated simulation model for gear shifting test, and the impact analysis of gear meshing is performed according to the test results to generate an anti-meshing impact index; it is determined whether the anti-meshing impact index meets the preset anti-impact index, if not, the structure optimization module is activated; the multi-structure design parameters of the target synchronizer are optimized through the structure optimization module to generate recommended structural design parameters that meet the preset anti-impact index. In other words, through the integrated simulation model, the working process of the input shaft, synchronizer and output shaft is simulated, the gear shifting jamming scene under high load conditions is tested, the performance of the synchronizer is evaluated under extreme conditions, the gear meshing impact analysis is performed according to the test results, and the multi-design parameters of the target synchronizer are optimized to better adapt to high load and high speed conditions, reduce the jamming problem under high load, and improve the stability of the synchronizer shifting process.

[0075] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

[0076] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application belong to the scope of the present application and its equivalent technology, the present application is also intended to include these modifications and variations.

Claims

1. A multi-parameter driven synchronizer structure adaptive optimization method, characterized in that: include: Determine the input shaft and output shaft for speed difference adjustment through the target synchronizer, perform integrated simulation of the input shaft, target synchronizer and output shaft, and establish an integrated simulation model; Execute the gear shifting jamming scenario collection under high load for the target synchronizer, and establish a plurality of high load test scenarios, wherein the plurality of high load test scenarios include a high speed difference scenario and a frequent gear shifting scenario; Inputting the multiple high-load test scenarios into the integrated simulation model to perform a gear shift test, and performing an impact analysis of gear meshing according to the test results to generate an anti-meshing impact index; Determine whether the anti-meshing impact index meets the preset anti-impact index, and if not, activate the structure optimization module; Optimizing the multi-element structural design parameters of the target synchronizer by means of the structural optimization module to generate recommended structural design parameters that meet the preset anti-shock index; The multiple high-load test scenarios are input into the integrated simulation model to perform a gear shift test, and an impact analysis of gear meshing is performed based on the test results to generate an anti-meshing impact index, including: Testing the multiple high-load test scenario inputs in sequence through the integrated simulation model to obtain multiple test results, wherein any test result at least includes a speed matching test result, a friction force change test result, and a vibration generation test result; Performing gear meshing impact analysis according to the speed matching test result, the friction force change test result and the vibration generation test result among the multiple test results to generate the anti-meshing impact index; The gear meshing impact analysis is performed according to the speed matching test result, the friction force change test result and the vibration generation test result among the multiple test results to generate the anti-meshing impact index, including: Based on the speed matching test result, an anti-shock feedback adjustment coefficient is configured to generate a target adjustment coefficient; Based on the friction force change test results, friction force change stability analysis is performed to generate a friction force stability index; Performing a vibration shock index based on the vibration generation test result; The friction force stability index and the vibration impact index are integrated, and feedback adjustment is performed through the target adjustment coefficient to generate the anti-meshing impact index.

2. The method for adaptive optimization of synchronizer structure driven by multiple parameters as claimed in claim 1, characterized in that: Based on the speed matching test result, the anti-shock feedback adjustment coefficient is configured to generate a target adjustment coefficient, including: Establish speed matching error range; Determining whether the speed matching error is within the speed matching error range according to the speed matching test result; If yes, set the target adjustment coefficient to 1; If not, the target adjustment coefficient is reset to zero.

3. The method for adaptive optimization of synchronizer structure driven by multiple parameters as claimed in claim 1, characterized in that: Based on the vibration test results, vibration shock indicators are generated, including: Get the preset comfortable vibration intensity; The ratio of the vibration test intensity to the preset comfortable vibration intensity is calculated based on the vibration generation test result to generate the vibration impact index.

4. The method for adaptive optimization of synchronizer structure driven by multiple parameters as claimed in claim 1, characterized in that: Gear shifting and sticking scenarios under high load are collected for the target synchronizer, and multiple high load test scenarios are established, including: Performing a frequent shifting scenario configuration for the target synchronizer according to a preset high-frequency shifting frequency to generate a first high-load test scenario; Performing a gear shifting scenario configuration for the target synchronizer according to the target switching amplitude to generate a second high load test scenario; Performing cross-mutation processing on the first high-load test scenario and the second high-load test scenario to generate a third high-load test scenario; The multiple high-load test scenarios are generated using the first high-load test scenario, the second high-load test scenario, and the third high-load test scenario.

5. The method for adaptive optimization of synchronizer structure driven by multiple parameters as claimed in claim 1, characterized in that: The multi-element structural design parameters of the target synchronizer are optimized by the structural optimization module to generate recommended structural design parameters that meet the preset anti-shock index, including: Retrieving historical structural design parameters for the target synchronizer and constructing a structural design parameter optimization space; determining current multivariate design parameters of the target synchronizer; Based on the structural design parameter optimization space, the current multivariate design parameters are iteratively optimized, and the integrated simulation model and the multiple high-load test scenarios are called to analyze the iteratively optimized structural design parameters until the recommended structural design parameters whose iterative anti-meshing impact index meets the preset anti-impact index are obtained.

6. The method for adaptive optimization of synchronizer structure driven by multiple parameters as claimed in claim 5, characterized in that: Also includes: If the number of iterative optimizations reaches the preset number of iterations, and the structural design parameters whose iterative anti-meshing impact index satisfies the preset anti-impact index have not been output, an optimized structural parameter sequence whose iterative anti-meshing impact index is increasing is obtained according to the iterative optimization record; Based on the optimized structural parameter sequence, a change law analysis of multivariate structural design parameters is performed to generate a change law of multivariate parameters; Based on the multivariate parameter variation rule, randomly generate between any two groups of parameters in the optimized structural parameter sequence, optimize the structural design parameter optimization space, and then repeatedly perform iterative optimization; If the iterative optimization is repeated for a preset number of times, and the structural design parameters whose iterative anti-meshing impact index satisfies the preset anti-impact index have not been output, the structural design parameters with the smallest iterative anti-meshing impact index obtained by the current optimization are used as the recommended structural design parameters, and a reminder message is generated with the smallest iterative anti-meshing impact index.

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