Automatic rebound compensation device of dog clutch in electric gearbox

Abstract

A method for controlling dog clutch engagement in an electrified driveline includes locking a shaft of a transmission; positioning an actuator of the transmission at a specified position; commanding the motor to rotate at a certain speed; when the motor stops rotating, the engagement threshold position is updated according to the specified position of the actuator.

Description

Technical Field The present invention relates to a method for controlling clutch engagement in an electric transmission. Background Art

[0001] A vehicle (e.g., an electrified vehicle) may be equipped with a transmission to change gears with different gear ratios to produce different output torques and speeds with the same input torque. The electrified vehicle may have an electric motor coupled to the input end of the transmission. The transmission may include a gear member and a dog clutch driven by a transmission, the transmission being shifted to an engaging member of the clutch.

[0002] For electric transmissions, where the torque input to the transmission is provided by an electric motor, dog clutches can be used in place of synchronizers to provide the desired dynamic performance.

[0003] However, the use of a dog clutch may result in shifting complications. Compared to synchronizers, components of a dog clutch (such as teeth or components of gears) may experience a higher degree of grinding during the engagement process. This wear may increase the noise and vibration generated by the transmission during gear shifting, making it more uncomfortable for the driver, passengers or other users of the vehicle when driving and operating the vehicle. In addition, grinding may increase wear and other forms of degradation of the teeth and other components of the clutch assembly. Grinding may also increase wear and other forms of degradation of the teeth and other components of the gears or rotating elements to which the clutch assembly can selectively connect. In addition, the vibrations generated by grinding may exacerbate the degradation of other components within the transmission (such as gear sets and shafts).

[0004] Control methods can be used to determine the different positions at which teeth engage or disengage during clutch operation. However, this method may have uncertainty because axial clearance allows relative movement between components while preventing wear and other degradation. For example, in different gear sets of multiple transmissions, the engagement position may have a normal distribution at specific engagement and disengagement positions. If the normal distribution is applied to the entire transmission population, then some transmission populations may have an increased chance of grinding compared to other populations. In addition, some transmissions may also have an increased chance of missing engagement with dog clutches. Missed engagement may increase shift time. Although individual calibration can reduce such problems, calibration may increase manufacturing time. Special equipment can also be used to calibrate controllers, such as ECUs, actuators, and dog clutch components. In addition, if a component of the transmission (such as a component that is rotationally coupled to the dog clutch) is misaligned or recalibrated, the effectiveness of this method in engaging the dog clutch may be reduced, thereby increasing the chance of grinding and / or missing engagement. Summary of the invention

[0005] The inventors of the present invention have recognized these and other problems with such systems and have developed methods that at least partially address these problems. In one example, a method for controlling engagement of a dog clutch in an electrified transmission system is developed, comprising: locking a shaft of a transmission; positioning an actuator of the transmission at a prescribed position; commanding an electric motor to rotate at a certain speed; and when the electric motor is stalled, updating an engagement threshold position based on the prescribed position of the actuator.

[0006] The method enables an ECU and an actuator (such as a shift actuator (RSA)) to automatically compensate for degradation, backlash and other variations in the clutch system, thereby improving the accuracy of the teeth entering the engagement zone before and during engagement. Improving engagement accuracy can reduce grinding or lack of engagement of the first and second teeth of the dog clutch during the engagement process. During the engagement phase, the gap between the first and second teeth can be reduced so that the engagement can be closer to the engagement threshold position relative to the first tooth and each second tooth. During the calibration of the position (such as the disengagement position) for the dog clutch and actuator, the actuator can be operated without the use of special equipment. Similarly, the algorithm on the controller (such as an ECU) and the method working in conjunction with the algorithm can also be separately calibrated without the use of special equipment.

[0007] In one example, a dedicated end device can be used to lock the transmission to prevent the output shaft from rotating. In addition, the parking brake can also lock the transmission to prevent the output shaft from rotating. A controller that controls the position of the transmission and the position of the dog clutch components can use the method of the present disclosure to automatically provide the disengaged position, neutral position and engaged position of the transmission and dog clutch components. Calibration of the actuator and dog clutch can be performed at the end of the production line through automatic calibration by the controller. Similarly, the actuator and dog clutch can also be calibrated by the controller when the transmission is installed on the vehicle. Automatic calibration of the actuator and dog clutch can be performed when the output shaft of the transmission is locked and cannot rotate, such as when the parking brake is engaged.

[0008] It should be understood that the above summary is intended to introduce in a simplified form the concepts that are further described in the detailed description. It is not intended to identify key or essential features of the claimed subject matter, the scope of which is uniquely determined by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 An example schematic diagram of a vehicle is shown which may include a transmission of the present disclosure.

[0010] Figure 2 A schematic diagram of a transmission gear assembly is shown, which may include a clutch of the present disclosure.

[0011] Figure 3 A schematic diagram of the clutch system is shown.

[0012] Figure 4 A schematic diagram showing the clutch system component model, including simplified representations of the teeth and forces.

[0013] Figure 5A A schematic diagram of a neutral position is shown with the first and second teeth engaged.

[0014] Figure 5B A schematic diagram of the engagement threshold position at which the first tooth and the second tooth engage is shown.

[0015] Figure 6 A schematic diagram of the tooth is shown, including the angle and its complementary surface.

[0016] Figure 7 A plurality of schematic diagrams of the first tooth and the second tooth at various positions relative to the distance (s) on the axis are shown.

[0017] Figure 8 The force versus engagement collar tooth position curves are shown relative to different distances from the collar tooth starting position at disengagement.

[0018] Fig. 9A A first position of the component model parts in a first stage is shown, including the teeth and their respective sleeves and engaging rings.

[0019] Fig. 9B A second position of the element model components in the second stage is shown, including the teeth and their respective sleeves and engaging rings.

[0020] Fig. 9C A second position of the element model components, including the teeth and their respective sleeves and engagement rings, is shown in the third stage.

[0021] Fig.10 The positions of the first and second teeth in the first event that could occur when using this algorithm to search for a repulsive zone are shown.

[0022] Fig.11 The positions of the first and second teeth are shown for a second event that may occur when using the algorithm to search for the repulsive zone.

[0023] Fig.12 The positions of the first and second teeth are shown for a third event that may occur when using this algorithm to search for the repulsive zone.

[0024] Fig.13 A first method of engaging the clutch of the present invention is shown.

[0025] Fig.14 A second method of accessing a clutch repulsion zone using the first tooth of the present disclosure is shown.

[0026] Fig.15 A third method is shown for bringing the first tooth into close engagement with the second tooth after identifying and passing through the repulsive zone. DETAILED DESCRIPTION

[0027] The following description relates to a method for calibrating a transmission and a clutch assembly having components coupled to a transmission shift. The actuator and the clutch components may be part of a vehicle transmission. The vehicle may be an electrified vehicle, wherein the vehicle has at least one electric motor as a source of rotational energy. The transmission may be an electrified transmission, such that the transmission may have at least one input from an electric motor that can transmit rotational energy in the form of torque. The actuator may be a shift actuator (RSA). The transmission may also include a gear assembly comprising a plurality of gear sets. Each gear set may have a different gear ratio and may input rotational energy in the form of the same torque to achieve different output speeds. The transmission may include at least two gear sets. At least one of the gear sets may include an idler gear. A controller in the form of a control unit, such as an electronic control unit (ECU), may send instructions to control the actuator to shift to different positions. The control unit may control the shift position of the actuator and thereby control the position of the clutch component between the plurality of phases. The control unit may be operated and used by the method to calibrate components of the clutch assembly and components responsible for driving the clutch assembly. The clutch component may rotationally couple the gears of the gear set to a shaft. A gear that is selectively coupled to a shaft by a clutch member may be an idler gear of a gear set. When selectively coupled to a shaft, the idler gear may be rotationally coupled to the shaft. When rotationally coupled to the shaft, the idler gear may be drivingly coupled, transferring rotational energy to the shaft via torque. When rotationally coupled to the shaft, the idler gear may achieve an additional specific gear ratio, such that the same input to the complementary gear set may produce a different speed when the idler gear is rotationally coupled to the shaft than when the idler gear is not rotationally coupled to the shaft.

[0028] The clutch member may include a clutch device of a dog clutch. The dog clutch may include an engagement member, such as an engagement sleeve. As the engagement sleeve, the engagement member may be an engagement ring. The dog clutch may also include a coupling member, such as a coupling ring. The engagement sleeve includes at least one first tooth and may include a plurality of first teeth. The coupling member may include at least one first tooth and a plurality of second teeth. The RSA may be driven in a direction referred to as a shift direction. The shift direction may be a one-dimensional direction along the axis. When the RSA is driven to a first position, the engagement sleeve and the first tooth may be driven to a second position complementary and proportional to the first position on the shaft. The RSA may drive the engagement sleeve and the first tooth to a plurality of positions. When the clutch is in a starting position, the first tooth of the engagement sleeve may not contact the second tooth of the coupling member. When in a neutral threshold position, the first tooth and the second tooth may contact but not lock. When in an engaged position, such as an engagement threshold position, the first tooth and the second tooth may contact and lock, thereby engaging the engagement sleeve with the coupling member.

[0029] The method can be an algorithm or a search method. The method searches for a position at the start of the repulsive zone and the end of the neutral zone, which is referred to as the neutral threshold position. In addition, the method can also search for a position between the repulsive zone and the attractive zone, that is, the starting position of the attractive zone, which is referred to as the engagement threshold position. The engagement threshold position can be determined using this method. The control unit can use the engagement threshold position to calibrate the engagement position positioned by an actuator (such as an RSA). The method can use a variety of heuristic methods. For example, the first embodiment of the method can be a linear method. For the linear version of the method, the new candidate position is monotonically increased by a predetermined step size at each iteration. For another example, the second embodiment of the method can be a binary search method. For the binary version of the method, the new candidate position is set to the midpoint at each iteration, thereby halving the range position. For example, the value of S1 is the last test position where the RSA did not move, and the value of S2 is the last test position where the RSA moved. The new candidate position is S3 = (S1 + S2) / 2. If the RSA does not move at S3, then in the next iteration, S1 will be set to S3. If at S3, RSA is moving, then in the next iteration, S2 will be set to S3.

[0030] The method can search for the position of each first tooth of the first tooth and each second tooth of the second tooth, such as the neutral position and the engagement position. The method can be divided into three stages: a first stage of preparing the engagement components and the coupling components for engagement, a second stage of searching for the neutral threshold position, and a third stage of searching for the engagement threshold position. The second stage can also search for the end point of the neutral area and the starting point of the repulsion area defined by the neutral threshold position. The third stage can also search for the end point of the repulsion area and the starting point of the attraction area defined by the engagement threshold position. When searching for the neutral threshold position and / or the engagement threshold position, the first tooth can be positioned at a distance from the disengagement position to the second tooth position.

[0031] In the preparation phase, the clearance between the engagement member and the shift fork is minimized, and the clearance between the coupling member and the driven shaft is minimized. The speed and torque of the motor are zero, and the driven shaft of the transmission is locked. The driven shaft can be locked by a dedicated device at the end of the line or by engaging the parking brake. The dog clutch is in the neutral position, referred to here as S0. The clearance between the engagement member and the shift fork is minimized by the shift force driving the RSA. When the clearance between the coupling member and the driven shaft is minimized, the clearance between the idler gear and the complementary shoulder of the idler gear is also minimized. The coupling member is coupled to the idler gear in rotation. When the idler gear is positioned on the shaft, the shoulder of the idler gear matches the groove of the shaft. Minimizing the clearance between the engagement member and the shift fork minimizes the backlash when the clutch is engaged and looking for an engagement position. Similarly, minimizing the clearance between the coupling member and the shaft also minimizes the backlash when the clutch is engaged and looking for an engagement position. When meshing, the helix angle of the idler gear teeth can be used in conjunction with the torque to minimize the clearance between the gear and the shoulder. For example, the motor can be driven to a set speed and produce a constant torque. The torque can be transmitted to a gear set consisting of gears. The helix angle of each tooth of the gear can transmit and guide part of the tangential force generated by the torque and rotation as an axial force. The helix angle can also be called the helix angle. The axial force can act on the gear to push the gear in the axial direction. The axial force can push the gear towards the shoulder when rotating. When the gear is pushed close to the shoulder, the clearance between the gear and the shoulder is minimized. Similarly, the clearance between the coupling part and the shaft is minimized because the coupling part can be physically coupled to the gear and the shaft includes a shoulder as a feature. After the operation is completed, the motor is stopped (torque and speed are zero). The gear is a gear that can be engaged by an actuator and a coupling part, for example, by locking the coupling part with the coupling part by the coupling part. The clearance minimized above can be the clearance in the direction of the shoulder. When the clearance is minimized, the actuator can be moved along the axis and in the same direction relative to the axis. In other stages of the method described below, the actuator can be moved along the axis and in the same direction relative to the axis. The position to which the actuator is moved can be represented as a point on the shaft. The speed profile and speed magnitude applied can vary depending on the design of the transmission, but the goal is to minimize the clearance.

[0032] In the second stage, when the method searches for the neutral position and the engaged position of the engagement member and the first tooth relative to the second tooth, the first tooth may be located in multiple regions, such as a non-contact zone, a repulsive zone, or an attractive zone. Each region may correspond to a different event that may occur between the engagement member and the first tooth. When the engagement member is in the non-contact zone, a first event may occur, that is, the first tooth and the second tooth are not in contact and the RSA does not move. When the engagement member is in the repulsive zone, an axial force may be transmitted from the engagement member (such as an engagement ring) to the coupling member. The axial force may be greater than the force of the RSA or may be opposite to the force of the RSA. The axial force from the engagement member may be a part of the tangential force on the coupling member or may come from the tangential force. When the engagement member is in surface-sharing contact with the coupling member, the axial force may be transmitted to the engagement member. The tangential force may come from a torque transmitted to the coupling member, where the torque is generated by the output of a motor such as a motor. In the repulsive zone, when the first tooth and the second tooth are in contact, the first tooth and the engagement member are pushed away from the second tooth and the coupling member. The force from the engagement zone may push the engagement member, which in turn pushes the RSA to move in a direction opposite to the displacement direction. The controller unit can use a communicative coupling sensor on the RSA to detect the distance the RSA moves in the opposite direction of the shift. The algorithm can use the detected change in the RSA distance to adjust the neutral position, the engaged position, and the test position of the first tooth and the engagement member.

[0033] When the coupling component is in the attraction zone, the clutch can be engaged so that the first tooth and the second tooth can be locked with each other. The tangential force of the second tooth and the force of the RSA can press the first tooth toward the second tooth so that their surfaces share contact. The tangential force of the coupling component and the negative angle of the second tooth can lock the first tooth with the second tooth. In the attraction zone, when the first tooth and the second tooth are in contact, the first tooth and the coupling component can be locked with the second tooth and the coupling component. When the controller calibrates the RSA and clutch components and correctly calculates the repulsion zone search, the third event may not occur during the repulsion zone search. For example, when the coupling component contacts the coupling component surface, axial force may be transmitted to the coupling component.

[0034] Regardless of whether the first, second or third event occurs, the speed of the motor is controlled to zero and the RSA is moved back to a stationary position, such as the S0 position. If the third event occurs, the first tooth and the second tooth are disengaged, and the engaging part and the coupling part are disengaged. Once the engaging part moves back to S0, the gap between the engaging part and the coupling part is minimized as in the first stage, and then the second stage is repeated for the new candidate position. The second stage can be repeated. The control unit can perform detection and stop the motor if it is below a minimum time threshold, thereby minimizing grinding, wear, noise and other forms of degradation during the second stage. Each new test position is selected by the linear search method of the first embodiment or the binary search method of the second embodiment. The minimum distance between the two candidate positions is below a first minimum distance threshold that depends on the last measurement result. Iteration can continue until the difference between the larger position and the smaller position is equal to or below a second minimum distance threshold, such as a maximum allowable error or error value.

[0035] In the third stage, the first tooth and the coupling member may be positioned in multiple areas, such as the repulsion zone or the attraction zone described above. In the third stage, the first event may not occur because the neutral threshold position becomes the lowest position in the test position. The second event may occur when the coupling member is in the repulsion zone. In the second event, an axial force from the coupling member is transmitted to the coupling member. The axial force is opposite to the displacement direction and may push the coupling member, such as pushing the RSA back in the direction opposite to the displacement direction and away from the coupling member. The second event may cause grinding of the first tooth and the second tooth, thereby causing grinding of the clutch gear. The third event may occur when the coupling member is in the attraction zone. When the coupling member is in the attraction zone, the clutch is engaged. The tangential force of the coupling member and the negative angle of the second tooth may lock the first tooth with the second tooth, thereby locking the coupling member to the coupling member. The electric motor may be stopped, and the locking state of the coupling member and the coupling member is recorded by the controller unit.

[0036] Regardless of whether the second or third event occurs, the motor is commanded to adjust the speed to zero and the RSA is moved back to a stationary position, such as the S0 position. Once moved back to the S0 position, the gap between the engaging component and the coupling component will be minimized as in the first stage, and the third stage is then repeated for the new candidate position. The third stage can be repeated. The control unit can perform detection and stop the motor if it is below a minimum time threshold, thereby minimizing grinding, wear, noise and other forms of degradation during the third stage. Each new test position is selected by the linear search method of the first embodiment or the binary search method of the second embodiment. The minimum distance between the two candidate positions is below a first minimum distance threshold that depends on the last measurement result. Iterations can continue until the difference between the larger position and the smaller position is equal to or below a second minimum distance threshold, such as a maximum allowable error or error value.

[0037] During operation of the clutch, the control unit can be programmed to set the RSA in a neutral position when the clutch is not engaged, and by extension to set the engaging component in a neutral position when engaged. The neutral position can be a position as close to the neutral threshold as possible in the no-contact zone. Alternatively, the neutral position can be a starting neutral position when starting to look for the engaging position. The engaging position can be a position as close to the neutral threshold position as possible when in the attraction zone. As described above, arranging the neutral position and the engaging position can minimize the operating distance when engaging the clutch. The program closes the clutch in the same direction, where the engaging component moves along the displacement direction of the axis (e.g., the s direction) to engage with the coupling component.

[0038] Figure 1 An example schematic diagram of a vehicle that may include the transmission of the present disclosure is shown. Figure 1 The vehicle in the system may be an electrified vehicle such as an electric vehicle or a hybrid vehicle, having multiple torque sources, which may include an electric motor, a hydrogen fuel cell, and / or an internal combustion engine (ICE). Figure 1 An example schematic diagram of a vehicle that may include the disclosed transmission is shown. Figure 2 A schematic diagram of a transmission gear assembly is shown, which may include a clutch of the present disclosure. The clutch of the present disclosure may be used Figure 2 Idler gear shown. Figure 3 A schematic diagram of a clutch system of the present disclosure is shown. The clutch system may include an engaging ring and an engaging ring for rotationally or drivingly coupling an idler gear to a shaft via a complementary hub, a shift rod, and a shift fork. Figure 4 A schematic diagram of the clutch system component model is shown, with simplified representations of the clutch component teeth and forces. Figure 4 A first tooth representing a plurality of teeth on the engagement ring and a second tooth representing a plurality of teeth on the engagement ring are shown. The first tooth and the second tooth complement each other and are locked and engaged with each other. Figure 5A A schematic diagram of the neutral threshold position where the first and second teeth are engaged is shown. Figure 5B A schematic diagram of an engagement threshold position at which the first tooth and the second tooth engage is shown. When in the neutral position and the engagement threshold position, the first tooth and the second tooth may be in a surface sharing contact state. Figure 6 A schematic diagram of a tooth is shown, including relative geometry such as angles and its complementary surfaces. Figure 7 A plurality of schematic diagrams showing the first tooth and the second tooth at a plurality of positions relative to the distance (s) on the track are shown. Figure 8 Schematic diagram showing force and position of the engagement collar teeth at different distances relative to the collar teeth starting position when disengaged. Fig. 9A Shown are first positions of the component model parts during the first and second steps of a larger operation, including the teeth and their respective sleeves and engaging rings. Fig. 9BA second position of the elemental model components, including the teeth and their respective sleeves and engaging rings, is shown at the beginning of the third step of the larger operation. Fig. 9C A second position of the elemental model components, including the teeth and their respective sleeves and engaging rings, is shown at the end of the third step of the larger operation. Figures 9A-9C The steps in the figure are the operational steps for the preparation stage.

[0039] Fig.10 The positions of the first and second teeth in the first event that may occur when using this algorithm to search for the repulsive zone are shown. Fig.11 The positions of the first and second teeth are shown for the second event that may occur when using the algorithm to search for repulsive and attractive regions. Fig.12 The positions of the first and second teeth for a possible third event when using the algorithm to search for repulsive and attractive regions are shown. Fig.13 A first method of the clutch of the present disclosure is shown searching for a neutral threshold position and an engaged threshold position and engaging at the engaged threshold position. Fig.13 The various steps of the first method shown may include sub-methods, e.g. Figure 14-15 The method shown. Fig.14 A second method of approaching the first tooth clutch repulsion zone of the present disclosure is shown. Fig.14 The method can also be used to estimate the neutral threshold position. Fig.15 A third method is shown for bringing the first tooth into close engagement with the second tooth after identifying and passing through the repulsive zone. Fig.15 The method can also be used to estimate the engagement threshold position.

[0040] It should also be understood that the specific components and systems illustrated in the drawings and described in the following specification are exemplary embodiments of the inventive concepts defined herein. For ease of discussion, the drawings are collectively referred to. Therefore, like elements are generally represented by like reference numerals herein and will not be repeated.

[0041] Figure 1-7 and Figure 9A-12 An example configuration schematic diagram showing the relative positioning of various components. As used herein, the term "approximately" means within plus or minus 5 percent of a range, unless otherwise specified.

[0042] also, Figure 1-7 and Figure 9A-12An example configuration of relative positioning of various elements is shown. If the elements shown in the figure are in direct contact or directly coupled to each other, then at least in one example, these elements can be referred to as direct contact or direct coupling, respectively. Similarly, at least in one example, the elements shown as adjacent or adjacent to each other can be adjacent or adjacent to each other, respectively. For example, elements that are in face-to-face contact with each other can be referred to as face-to-face contact elements. Another example is that, at least in one example, the elements are placed separately from each other, with only space in the middle and no other elements, which can be referred to as being placed separately from each other. For example, relative to each other, the elements displayed above / below each other, relative to both sides of each other, or relative to the left / right side of each other can be referred to as such elements. In addition, as shown in the figure, in at least one example, the topmost element or element point can be referred to as the "top" of the element, and the bottommost element or element point can be referred to as the "bottom" of the element. The top / bottom, upper / lower, upper / lower used in this article can be relative to the vertical axis in the figure to describe the positioning of each element in the figure relative to each other. Therefore, in one example, the element displayed above other elements is vertically positioned above other elements. For another example, the shapes of elements depicted in the figures may be referred to as having these shapes (e.g., circular, linear, flat, curved, rounded, chamfered, beveled, or the like). In addition, in at least one example, elements shown intersecting one another may be referred to as intersecting elements or intersecting one another. In addition, in one example, elements that are displayed within another element or displayed outside another element may be referred to as such elements. In addition, when describing each element, it may be associated with a reference axis in the drawings.

[0043] Unless otherwise stated, a feature described as axial may be approximately parallel to a reference axis. Unless otherwise stated, a feature described as anti-axial may be approximately perpendicular to the referenced axis. Unless otherwise stated, a feature described as radial may surround or extend outward from an axis, such as a reference axis, or a component or feature previously described as radial to a reference axis.

[0044] Features described as longitudinal may be approximately parallel to the longitudinal axis. A transverse axis may be parallel to the normal to the longitudinal axis. A transverse feature may be approximately parallel to the transverse axis and parallel to the normal to the longitudinal axis.

[0045] Now watch Figure 1, a vehicle 100 is shown that includes a powertrain 101 and a transmission 103. The vehicle 100 may have a front end 132 and a rear end 134, located on opposite sides of the vehicle 100. Objects, components, and features on the vehicle 100 that are referred to as being closer to the front end may be closest to the front end 132 compared to the rear end 134. Objects, components, and features on the vehicle 100 that are closer to the rear end may be closest to the rear end 134 compared to the front end 132. The powertrain 101 includes a prime mover 106 and a transmission 108. The prime mover 106 may be an internal combustion engine (ICE) or an electric motor, etc., and provides rotational power to the transmission 108 when in operation. The transmission 108 may be an automatic transmission. The transmission 108 receives the rotational power generated by the prime mover 106 as input and outputs the rotational power to the transmission 103 according to the selected gear or setting. In addition, in addition to the prime mover 106, there may be other moving devices in the vehicle. If the prime mover 106 is an internal combustion engine, there may be at least one second prime mover connected to the transmission 108, where the second prime mover can be an electric machine such as an electric motor. In one example, if there are one or more second movers in addition to the prime mover 106, the vehicle 100 can be a hybrid vehicle, where there are multiple torque inputs to the transmission 108. The vehicle 100 can have a longitudinal axis 130. The powertrain 101 and the driveline 103 can have a length parallel to the longitudinal axis 130.

[0046] Prime mover 106 may be powered by energy from energy storage device 105. In one example, energy storage device 105 is a battery for storing electrical energy. Inverter 107 may be installed between energy storage device 105 and prime mover 106 to adjust direct current (DC) to alternating current (AC). Inverter 107 may include various components and circuits, the thermal requirements of which may affect the efficiency of the inverter.

[0047] Vehicle 100 can be a commercial vehicle, a light, medium or heavy vehicle, a passenger vehicle, an off-road vehicle and / or a sport utility vehicle. In addition, vehicle 100 and / or one or more of its components can also be used in industrial, locomotive, military, agricultural and / or aerospace fields. In one example, vehicle 100 is a pure electric vehicle or a vehicle with a pure electric operating mode, such as a plug-in hybrid vehicle. Therefore, prime mover 106 is an electric machine. In one example, prime mover 106 is a motor / generator. In these examples, powertrain 103 can be electrified and is therefore an electrified powertrain.

[0048] In some examples, such as Figure 1As shown, the driveline 103 includes a first axle component 102 and a second axle component 112. The first axle assembly 102 can be configured to drive a first set of wheels 104, and the second axle assembly 112 can be configured to drive a second set of wheels 114. In one example, the first axle component 102 is arranged near the front of the vehicle 100 and thus comprises a front axle, while the second axle component 112 is arranged near the rear of the vehicle 100 and thus comprises a rear axle. The driveline 103 is shown as a four-wheel drive configuration, but other configurations may also be used. For example, the driveline 103 may include a rear-wheel drive or an all-wheel drive configuration. In addition, the driveline 103 may also include one or more tandem axle components. Therefore, the driveline 103 may also have other configurations without departing from the scope of the present disclosure, Figure 1 The configuration shown in is for illustration only and is not limiting. In addition, the vehicle 100 may also include other wheels that are not connected to the transmission system 103.

[0049] In some 4WD configurations, such as Figure 1 As shown, the powertrain 103 includes a transfer case 110 configured to receive the rotational power output by the transmission 108. A first transmission shaft 113 is drivingly connected to a first output end 111 of the transfer case 110, and a second transmission shaft 122 is drivingly connected to a second output end 121 of the transfer case 110. The first transmission shaft 113 (e.g., a front transmission shaft) transmits the rotational power from the transfer case 110 to a first differential 116 of a first axle assembly 102 to drive a first set of wheels 104, and the second transmission shaft 122 (e.g., a rear transmission shaft) transmits the rotational power from the transfer case 110 to a second differential 126 of a second axle assembly 112 to drive a second set of wheels 114. For example, the first differential 116 is drivingly coupled to a first set of axle shafts 118 coupled to the first set of wheels 104, and the second differential 126 is drivingly coupled to a second set of axle shafts 128 coupled to the second set of wheels 114. It is understood that each of the first set of shafts 118 and the second set of shafts 128 can be disposed in a housing. The first transmission shaft 113 and the second transmission shaft 122 can be positioned to extend parallel to the longitudinal axis 130. In the configuration example of the vehicle 100, the second transmission shaft 122 can be centered around the longitudinal axis 130.

[0050] The first differential 116 can provide all-wheel drive to the vehicle 100 to some extent as part of the rotational power transmitted through the first transmission shaft 113. Similarly, the second differential 126 can provide all-wheel drive to the vehicle 100 as part of the rotational power transmitted through the second transmission shaft 122. The first differential 116 and the second differential 126 can provide all-wheel drive and all-wheel drive, respectively, as part of an all-wheel drive mode of the vehicle 100.

[0051] The parking brake may be provided on one or more drive shafts of the vehicle 100. For example, the parking brake 142 may be installed on the second drive shaft 122 so as to engage with the second drive shaft 122. When engaged, the parking brake 142 may prevent the rotation of the second drive shaft 122, thereby stalling the second drive shaft 122. When the second drive shaft 122 stalls, the rotating elements in the transmission 108 and the transfer case 110 may also stall. In addition, the parking brake may also be installed on the first drive shaft 113, for example, to engage with the first drive shaft 113.

[0052] The adjustment of the powertrain system 103 between various modes and the control of the operation within each mode can be performed based on the vehicle control system 154, which includes a controller 156. The controller 156 can be a microcomputer, including a microprocessor unit, input / output ports, an electronic storage medium (such as a read-only memory chip, a random access memory, a survivability memory, and a data bus) for executable programs and calibration values. The storage medium is programmable to computer-readable data, representing instructions executable by the processor for performing the methods described below and other variants that are expected but not specifically listed. In one example, the controller 156 can be a powertrain control module (PCM).

[0053] The controller 156 may receive various signals from sensors 158 coupled to different areas of the vehicle 100. For example, the sensors 158 may include sensors on the prime mover 106 or another prime mover for measuring the speed and temperature of the prime mover; pedal position sensors for detecting the degree of depression of a pedal operated by an operator (such as an accelerator pedal or a brake pedal); speed sensors on the first and second sets of wheels 104, 114, etc. The vehicle acceleration is proportional to the accelerator pedal position (e.g., the degree of depression). Figure 1 After receiving signals from various sensors 158, the controller 156 processes the received signals and adjusts the operation of the transmission system using various actuators 160 of the vehicle 100 based on the received signals and the instructions stored in the memory of the controller 156. For example, the controller 156 may receive an indication that the brake pedal is depressed, indicating a desire to reduce the vehicle speed. In response, the controller 156 may instruct an operation, such as a shifting mode of the transmission 108.

[0054] In some examples, additionally or alternatively, the vehicle 100 may be a hybrid vehicle including an engine and an electric machine, each configured to provide power to one or more of the first axle assembly 102 and the second axle assembly 112. For example, one or both of the first axle assembly 102 and the second axle assembly 112 may be driven by power from the engine in a first operating mode in which the electric machine is not operated to provide power (e.g., an engine-only mode); driven by power from the electric machine in a second operating mode in which the engine is not operated to provide power (e.g., an electric-only mode); and driven by power from both the engine and the electric machine in a third operating mode (e.g., an electric-assist mode). As another example, one or both of the first axle component 102 and the second axle component 112 may be an electric axle component configured to be driven by an integrated electric machine.

[0055] In certain embodiments, the gearbox 108 may also be a first gearbox further including a second gearbox disposed on the second set of shafts 128. The gearbox 108 may be interchangeably referred to herein as a gearbox.

[0056] Please see Figure 2 , the figure shows the reference Figure 1 Schematic diagram 200 of a transmission 108 and a gearbox cover 203 is shown. The gearbox 203 can be surrounded and formed by the housing of the gearbox 108. In one example, the gearbox 203 includes a gear component 202. The gearbox (such as the gearbox 108) can be a multi-stage reduction gearbox, and the gear component 202 can be a system of multiple reduction kits. The gear component 202 can be composed of at least two reduction groups, which can reduce the speed (such as revolutions per minute (RPM)) and increase the torque. The reducer can be referred to as stages herein. These stages can be gear sets. There can be a first stage 204 and a second stage 206. The first stage 204 and the second stage 206 can include gears, such as fixed gears. The gearbox 108 can be input from a motor 207. The motor 207 can be Figure 1 The prime mover 106 in, for example Figure 1 The vehicle 100 in the embodiment is an electric vehicle. The motor 207 may be another prime mover, for example, the vehicle 100 is a hybrid vehicle.

[0057] For example, the housing 203 of the gearbox 108 may include a first shaft 208, a second shaft 210, and a third shaft 212. The first stage 204 may be supported by the first shaft 208 and the second shaft 210. The second stage 206 may be supported by the first shaft 208 and the second shaft 210. The first shaft 208 may serve as an input to the first stage 204 and the second stage 206. The second shaft 210 may serve as an output to the first stage 204 and the second stage 206. The first stage 204 may rotationally and drivingly couple the first shaft 208 to the second shaft 210. The second stage 206 may rotationally and drivingly couple the first shaft 208 to the second shaft 210. The first shaft 208 may be centered on the first shaft 216. The second shaft 210 may be centered on the second shaft 218. The first stage 204 may also be rotationally and drivingly coupled to the third shaft 212. The third shaft 212 may be centered on the third shaft 220. The first shaft 216, the second shaft 218, and the third shaft 220 may be parallel to each other. The first stage 204 may pass through the first shaft 216 to the second shaft 218. The second stage 206 may pass through the first shaft 216 to the third shaft 220.

[0058] The first shaft 208 may drivingly couple the first input shaft to the gear member 202. In the example shown in the schematic diagram 200, the first input shaft may be the output shaft 214 of the motor 207. The output shaft 214 may be referred to herein as the transmission output shaft 214. Shafts and other components that may be drivingly coupled but not in direct contact may be represented by dashed lines 219.

[0059] However, the gearbox may have other configurations. For example, the first input shaft may be a shaft that is drivingly connected to the output shaft 214 or the output end of another reduction device. In addition, for other configurations, there may be only one shaft, such as the second shaft 210, that can be selectively drivingly connected to the first shaft 208 through a reduction ratio. For example, the first stage 204 and the second stage 206 can selectively drive couple the first shaft 208 to the second shaft 210.

[0060] The second shaft 210 and the third shaft 212 may be drivingly connected to the first output shaft. In the example shown in the schematic diagram 200, the first output shaft may be a drive shaft, such as the second drive shaft 122. However, the gear component 202 and the housing 203 may also adopt other configurations. For example, the first output shaft may be a shaft drivingly connected to a drive shaft (such as the second drive shaft 122) or other reduction gear. In addition, in other examples, the second shaft 210 and / or the third shaft 212 may be drivingly connected to a separate output shaft. For example, the second shaft 210 may be drivingly connected to the first output shaft, such as Figure 3 In this example, the third shaft 212 can be drivingly connected to the second output shaft (such as the second transmission shaft 122). In addition, in other examples, the second shaft 210 and / or the third shaft 212 can be an output shaft.

[0061] The actuator 222 can be used to selectively drive the first stage 204 or the second stage 206 to the first shaft 208. The actuator 222 can be in driving connection with the shift rod 224. The actuator 222 can be mounted to the transmission 108 or a component of the transmission 108, such as a wall and surface of the housing 203. For example, the actuator 222 can be mounted by a plurality of fasteners (such as screws). As another example, the actuator can be mounted in a groove or void in the surface and material of the transmission 108. The actuator 222 can be Figure 1 One of the actuators 160 in. The actuator 222 can move the shift rod 224 along the fourth axis 226 by translation. When moving in a first direction, such as toward the front end 132, the shift rod 224 can drive couple the first stage 204 with the first axis 208. When moving in a second direction, such as toward the rear end 134, the shift rod 224 can drive couple the second stage 206 with the first axis 208. The shift rod 224 can be guided by the housing of the transmission 108 and / or the housing 203. For example, the actuator 222 can be an RSA. The actuator 222 can be an electric actuator, a hydraulic actuator, or an electro-hydraulic actuator. The actuator 222 can also be Figure 1 One of the actuators 160 in.

[0062] The housing 203 may form a pan 228 for the working fluid 230. The working fluid 230 may be a lubricant, such as engine oil. The gears of the first stage 204 and the second stage 206 may be lubricated by splashes of the working fluid 230. The sump 228 may be located below the component 202 so that the working fluid 230 may return to the sump 228 by gravity 260 as indicated by the arrow.

[0063] The first stage 204 and the second stage 206 can be composed of a plurality of gears. The first stage 204 and the second stage 206 can each be composed of at least two gears. For example, the first stage 204 can include a first gear 232 and a second gear 234. In this example, the second stage 206 can include a third gear 236 and a fourth gear 238. At least one of the gear sets can have an idler gear, such as an idler gear 235. For example, the first stage 204 can include an idler gear 235. The idler gear 235 can transfer rotational energy from the first shaft 208 to the second shaft 210 across the first stage 204 in the same direction through torque. The idler gear 235 can be located between the first gear 232 and the second gear 234 and mesh with them.

[0064] The shift lever 224 and the actuator 222 may use a plurality of arms and engagements to drive coupled reducers. There may be at least one arm and two engagements drivingly coupled to the shift lever 224 to select a reducer set. The number of arms and engagements drivingly coupled to the shift lever 224 may depend on the number of reducer sets to be engaged. The first stage 204 may be drivingly coupled to the first shaft 208 via a first engagement member 240 and a first coupling 244. Similarly, the second stage 206 may be drivingly coupled to the first shaft 208 via a second engagement member 242 and a second coupling 246. The first engagement member 240 and the second engagement member 242 may be shiftably coupled to the shift lever 224 via a first arm 248 and a second arm 250, respectively.

[0065] The first coupling 244 and the second coupling 246 can be respectively connected to the second gear 234 and the third gear 236. The first coupling 240 and the first coupling 244 can form a clutch, such as a dog clutch. The second coupling 242 and the second coupling 246 can form a clutch, such as a dog clutch. The first coupling 240 and the second coupling 242 can be dog-type couplings.

[0066] The idler gear 235 may be drivingly connected to the third coupling 254. The third coupling 254 may be complementary to the third engagement member 252. The idler gear 235 may be selectively coupled to the third shaft 212 via the third engagement member 252 and the third coupling 254. The third coupling 254 may be shift-coupled to the shift lever 224 via the third arm 256. The actuator 222 and the shift lever may move the third coupling 254 to engage or disengage, for example, couple or uncouple, the third engagement member 252. When the idle gear 235 is selectively coupled via the third engagement member 252 and the third coupling 254, the idle gear 235 may be rotatably and drivingly coupled to the third shaft 212. The third engagement member 252 and the third coupling 254 may form a clutch, such as a dog clutch. The third coupling 254 may be a dog engagement.

[0067] When rotationally coupled to the third shaft 212, the idler 235 can achieve an additional specific gear ratio, so that the same input to the first stage 204 can produce different speeds. The first stage 204 can achieve two gear ratios. For example, when the first coupling 244 and the first engagement member 240 are engaged and the third coupling 254 and the third engagement member 252 are disengaged, the first stage 204 can achieve a first gear ratio. In this example, when the first coupling 244 and the first engagement member 240 are disengaged and the third coupling 254 and the third engagement member 252 are engaged, the first stage 204 can enable a second ratio.

[0068] Schematic diagram 200 shows a single shift rod, i.e., shift rod 224, which can be moved by actuator 222. Shift rod 224 can be physically coupled to first arm 248 and second arm 250 and drive them. However, it is understood that schematic diagram 200 is not limited to this, and there may be multiple shift rods and actuators. For example, actuator 222 can move multiple shift rods. Another example is that there can be multiple shift rods, each of which is shifted by an actuator specifically coupled to each shift rod. In these examples, each shift rod can be matched with an arm (e.g., first or second arm 248, 250), which can be used to drive a joint (e.g., first or second joint member 240, 242).

[0069] The method of the present disclosure may be used to calibrate a control unit for engaging the clutch of the present disclosure, such as a clutch component including the third engagement component 252 and the third coupling 254. When the control unit searches for a neutral threshold position and an engagement threshold position using the method of the present disclosure, the output shaft may be locked to prevent rotation using a dedicated end device or parking brake. For example, when the control unit searches for a neutral threshold position and an engagement threshold position, the output shaft may be locked using an end device or parking brake (such as Figure 1 The parking brake 142 in the second transmission shaft 122 is locked. In addition, or when the control unit searches for the neutral threshold position and the engagement threshold position, another shaft, such as another transmission shaft or output shaft, which is rotationally coupled to the shaft 212 can be locked by the end device or the parking brake.

[0070] Please see Figure 3 , a gear engagement schematic 300 is shown. The gear engagement schematic 300 can be a schematic diagram including a clutch component that can selectively couple the gear rotation to the shaft. The clutch component can be a dog clutch component composed of a dog clutch. However, the gear engagement schematic 300 can also be used for other gear clutch components to engage other gears to the shaft. In another example, the gear engagement schematic 300 can be a clutch component including a first engagement component 240 and a first coupling 244. For an alternative example or another example, the gear engagement schematic 300 can be composed of Figure 2 The clutch component consists of the second coupling component 242 and the second coupling 246.

[0071] The output shaft 214 can be centered on the first axis 312. The first axis 312 can be a rotational axis (e.g., a rotary shaft) about which the output shaft 214 can rotate. The output shaft 214 can be rotationally and drivingly coupled to the partial gear set 314, thereby transferring rotational energy from the output shaft 214 to the partial gear set 314 through torque. The partial gear set 314 can be composed of a larger gear set, such as Figure 2The first stage 204 in the embodiment of the present invention. Part of the gear set 314 can be selectively connected to the shaft 318. The shaft 318 can be Figure 2 The third shaft 212 in the embodiment of the present invention. When selectively coupled to the shaft 318, the partial gear set 314 can be drivingly coupled with the shaft, thereby transferring rotational energy from the partial gear set 314 to the shaft 318 through torque. The shaft 318 can be centered on the second shaft 319. The second shaft 319 can be a rotational shaft (e.g., a rotary shaft), wherein the shaft 318 can rotate around the second shaft 319. The first shaft 312 and the second shaft 319 can be parallel.

[0072] An electronic control unit (ECU) 322 may be communicatively coupled to the actuator 222 and the motor 207. The communicatively coupled 320 between the components of the gear engagement diagram 300 may be represented by dashed lines with arrows. Signals may be sent through the communicatively coupled coupler, such as data read from a sensor or a command to change a condition. Arrows from the communicatively coupled coupler 320 toward the components represent the direction of transmission of the communication signal. The ECU 322 may be Figure 1 ECU 322 may be part of the control system 154. For example, ECU 322 may be Figure 1 Controller 156 in.

[0073] The ECU 322 may control the torque output and speed of the motor 207 using electronic command signals. The motor 207 may output rotational energy through torque to drive the output shaft 214. When the torque is output to the output shaft 214, the output shaft 214 may have a speed (ωd) 324 and a torque (Td) 326 about the first axis 312. The speed 324 may be the speed of the drive gear of the partial gear set 314, wherein the speed 324 may be referred to as the drive speed 324 herein. Likewise, the speed 324 may also be referred to as ωd 324 in the figures and the following description. The torque 326 may be the torque of the drive gear of the partial gear set 314, wherein the torque 326 may be referred to as the drive torque 326 in the following description. Likewise, the torque 326 may also be referred to as Td 326 in the following figures and the description. The drive speed 324 may be represented by a curved arrow about the first axis 312. Td 326 may be represented by a curved arrow about the first axis 312 and a straight arrow coaxial with the axis 312. The curved arrow indicates the rotation direction of the drive speed 324. The curved arrow represents the rotation direction, and the straight arrow represents the torque magnitude of Td 326.

[0074] The ECU 322 may use electronic signal commands to control the position and translation of the shift lever 224 through the actuator 222. Line 328 may represent the position of the engagement component connected to the shift lever 224. The shift direction (s) 330 may be the direction in which the shift lever 224 and the engagement component shift to engage the gears of the partial gear set. The shift direction may be parallel to an axis such as the first shaft 312 or the second shaft 319. Figure 3In the embodiment, the shift direction 330 can be represented by an arrow and an s symbol. The shift direction 330 can also be referred to as the s-direction 330. When executing in the s-direction 330, the shift lever 224 can approach the partial gear set 314.

[0075] The partial gear set 314 may include at least a first gear 332 and a second gear 334. The first gear 332 is a driving gear that can drive the second gear 334. The second gear 334 is a driven gear. For example, the second gear 334 is an idler gear, such as Figure 2 Similarly, the first gear 332 can be Figure 2 The first gear 232 in. The second gear 334 can be positioned around the shaft 318, radially around the shaft 318 relative to the centerline of the shaft 318.

[0076] The engagement member may include a plurality of members that can be shifted by an actuator, such as a shift fork 336 and a member of a clutch member 338. The shift fork 336 may shift-couple the member of the clutch member 338 to the shift lever 224. When driven in the S direction 330, the shift fork 336 may engage the clutch member 338 with a gear of the partial gear set 314. When engaged with the partial gear set 314, the clutch member 338 may be selectively connected with the second gear 334. When selectively coupled to the second gear 334, the clutch member 338 may selectively rotationally couple the second gear 334 to the shaft 318.

[0077] The second gear 334 may mate with the first groove 340 of the shaft 318. The first groove 340 may radially surround the shaft 318 and be pressed into the material of the shaft 318. A first gap 344 may exist between the wall of the first groove 340 and the feature of the second gear 334. The first gap 344 is approximately the minimum distance that the shift fork 336 and the components of the clutch member 338 engage with the second gear 334 when shifting. The position sensor 342 may be communicatively coupled to the ECU 322. The position sensor 342 may estimate the position of the shift lever 224 and / or the actuation of the actuator 222. The ECU 322 may use the data from the position sensor to estimate the position of the shift fork 336, and the components of the clutch member 338 may be shifted by the shift fork 336. Using the position data from the position sensor 342, the ECU 322 may estimate the distance that the shift lever 224 moves in the s-direction 330, and the speed at which the actuator 222 drives the clutch member 338 to engage with the second gear 334.

[0078] A first axial force (fa) 346 may be exerted on the second gear 334. fa346 is a force parallel to the second axis 319. fa may be transmitted through the axis 318. fa346 may be generated by the torque (Td) 326 as the torque (Td) 326 is transmitted from the first gear 332 to the second gear 334. The magnitude of fa346 may be parallel to and in the same direction as the s-direction 330. fa346 may increase the distance of the gap 344 as the second gear 334 may translate closer to the wall of the first groove 340 opposite the gap 344. The first groove 340 and the gap 344 may allow the second gear 334 to rotate freely about the axis 318.

[0079] The clutch member 338 can be a dog clutch structure. The clutch member 338 can include an engagement sleeve, such as an engagement ring 352. The clutch member can also include a hub 354 and an engagement ring 356. The engagement ring 352 can be positioned around and supported by the hub 354. The hub 354 can be positioned around the shaft 318. The hub 354 can also be physically and rotationally coupled to the shaft 318. The engagement ring 352 can be rotationally coupled to the shaft 318, such as when supported by the hub 354. The engagement ring 352 can be shiftably connected to the shift rod 224 via the shift fork 336. The shift fork can be positioned around the second groove 360 ​​of the engagement ring 352. The shift fork 336 can cooperate with the second groove 360 ​​to form a second gap 358 between the groove wall and the shift fork 336. The engagement ring 356 can be physically and rotationally coupled to the second gear 334. For example, the second gear 334 can include the engagement ring 356. The engagement ring 356 can be positioned about the first groove 340, for example, when physically coupled with the second gear 334. When positioned about the first groove 340, the gap 344 can be located between the engagement ring 356 and the nearest wall of the first groove 340. The first groove 340 and the gap 344 can allow the engagement ring 356 to rotate with the second gear 334 about the shaft 318.

[0080] When the engagement ring 352 is selectively coupled to the engagement ring 356, the clutch member 338 can engage with the second gear 334. When the shift lever 224 and the shift fork 336 are shifted in the S direction 330, the engagement ring 352 can be selectively coupled to the engagement ring 356. When selectively coupled to the engagement ring 356, the engagement ring 352 can selectively rotationally couple the engagement ring 356 to the hub 354.

[0081] The first gear 332 may include a plurality of first teeth 372. The second gear 334 may include a plurality of second teeth 374. The first gear 332 and the second gear 334 may be meshed with the first teeth 372 and the second teeth 374. The first teeth 372 and the second teeth 374 may be meshed to drive couple the first gear 332 and the second gear 334. The first teeth 372 and the second teeth 374 may each mesh with a helix angle (γ) 376. The helix angle 376 may be represented in the figure by the symbol γ376 instead. The helix angle 376 in the figure, for example Figure 3 , which can also be represented by the symbol γ applied to the angle diagram. In addition, the helix angle 376 can also be referred to as the helix angle. The helix angle 376 can be greater than a first threshold angle, such as 10 degrees (eg, γ>10°).

[0082] fa346 may act on the second gear 334 and is generated by Td326 applied to the first gear 332. fa346 may be calculated and expressed by the first equation. Formula 1:

[0083] Dd in Formula 1 represents the pitch diameter of the driving gear (eg, the first gear 332 ).

[0084] Figure 4 A simplified schematic diagram 400 is shown. The simplified schematic diagram 400 is Figure 3 Block element model of gear engagement schematic 300 , with engagement ring 352 and engagement ring 356 simplified as lines.

[0085] Axial clearances, such as first clearance 344 and second clearance 358, are represented by two translating hard stop elements. The first hard stop element is comprised of a hard stop element in the fork sleeve coupling, such as second groove 360 ​​of engagement ring 352. The second hard stop element is comprised of an idler gear and a coupling with shaft 318. In the example of simplified schematic 400, the second hard stop may include first groove 340. In simplified schematic 400, the rotational coordinates of the engagement sleeve and coupling components, such as engagement ring 352 and engagement ring 356, are corrected to linear coordinates. The linear coordinates are in a direction perpendicular to the axial coordinate s, and the s direction 330 corresponds to and is parallel to the axis of the axial coordinate s.

[0086] Simplified schematic diagram 400 shows additional forces such as tangential force (ft) 432, secondary axial force (fd) 434, and displacement force (fs) 436. ft 432 may be generated by Td 326 as Td 326 is transferred to shaft 318. fd 434 is a force parallel to the axis of rotation. fd 434 may be generated by Td 326 as Td 326 is transferred to engagement ring 352. fd 434 may be complementary to or opposite to s-direction 330. The direction of fd 434 may depend on the position of shift rod 224 and engagement ring 352 relative to engagement ring 356. fs 436 may be generated by actuator 222 and may move shift rod 224, thereby moving engagement ring 352. fs 436 may be parallel to s-direction 330. fs 436 may also be complementary to or opposite to s-direction 330 depending on how actuator 222 is driven. For example, when operating the shift rod 224 to engage the engagement ring 352 with the engagement ring 356, the fs 436 can be complementary to the s-direction 330. As another example, when operating the shift rod 224 to disengage the engagement ring 352 from the engagement ring 356, the fs 436 can be opposite to the s-direction 330.

[0087] The simplified gear engagement schematic diagram shows a first tooth 442 and a second tooth 444. The engagement ring 352 includes at least one first tooth, such as the first tooth 442. The engagement ring 356 may include at least one second tooth, such as the second tooth 444. The engagement ring 352 may include a plurality of first teeth of the same size as the first tooth 442. The engagement ring 356 may include a plurality of second teeth of the same size as the second tooth 444. In one embodiment, the first tooth 442 and the second tooth 444 may have approximately the same size.

[0088] ft432 may be generated from the same source as fa346. For example, ft432 may act on the second gear 334 and be generated by Td326 applied to and transmitted through the first gear 332. ft432 may be calculated and represented by Td326 and mathematically related to T326 by a second equation. Formula 2:

[0089] Similar to Formula 1, Dd in Formula 2 represents the pitch diameter of the driving gear (eg, the first gear 332 ).

[0090] ft432 can generate different values ​​and directionality for fd434 depending on the position of first tooth 442 relative to second tooth 444. By extension, ft432 can generate different values ​​and directionality for fd434 depending on the position of engagement sleeve (eg, engagement ring 352) relative to engagement ring 356.

[0091] For example, the surface sharing contact between the first feature of the first tooth 442 and the second feature of the second tooth 444 can guide and divert a portion of the ft 432 so that the direction of the fd 434 is opposite to the s-direction 330. When the fd 434 is opposite to the s-direction, the first tooth 442 can be pushed away from the second tooth 444, for example, if the fs 436 is less than the fd 434. When the first tooth 442 is pushed away from the second tooth 444, the engagement ring 352 can be pushed away from the engagement ring 356, opposite to the s-direction 330.

[0092] When the first feature of the first tooth 442 shares contact with the second feature surface of the second tooth 444, if fs436 is greater than fd434, the first tooth 442 may continue to push toward the second tooth 444 along the s-direction 330; however, grinding may occur between the first tooth 442 and the second tooth 444. Similarly, other features of the engagement ring 352, other features of the engagement ring 356, and other features of the gears and gear sets complementary to the engagement ring 356 (such as the second gear 334) may also be ground.

[0093] As another example, the surface sharing contact between the third feature of the first tooth 442 and the fourth feature of the second tooth 444 can guide the ft432 so that the fd434 is complementary to the s-direction 330. When the fd434 is complementary to the s-direction, the first tooth 442 can be pushed toward the second tooth 444 by the fd434 and locked therewith. When the first tooth 442 is pushed toward the second tooth 444 and locked therewith, the engagement ring 352 can be pulled toward the engagement ring 356 along the s-direction 330 and engaged therewith.

[0094] Please see Figure 5A-5B , which schematically represent two locations where the surfaces of the first tooth 442 and the second tooth 444 share contact. Figure 5A The first tooth 442 and the second tooth 444 are shown sharing surface contact in a first position referred to herein as a neutral threshold position 500 . Figure 5B The surfaces of the first tooth 442 and the second tooth 444 are shown sharing contact in a second position, referred to herein as an engagement threshold position 540. When in the neutral threshold position 500, the first tooth 442 and the second tooth 444 may not be selectively coupled. The neutral threshold position 500 may also be referred to as a contact point or contact point position. When in the engagement threshold position 540, the first tooth 442 and the second tooth 444 may be selectively coupled.

[0095] Figure 5A-5B Other features of the first tooth 442 and the second tooth 444 are shown. Figure 5A-5BThe features of the first tooth 442 and the second tooth 444 can be collectively introduced and discussed. As an example, the first tooth 442 includes a first leading surface 504 and a second leading surface 506. The second leading surface 506 can be located above the first leading surface 504. The first tooth 442 can also include at least one first contact edge 512 and at least one third contact edge 522. The first tooth 442 includes a first trailing surface 532 and a second trailing surface 534. The second trailing surface 534 can be located above the first trailing surface 532. The first leading edge surface 504 and the second leading edge surface 506 can meet at the first contact edge 512 and form the first contact edge 512. The first leading edge surface 504 and the first trailing edge surface 532 can meet at the third contact edge 522 and form the third contact edge 522.

[0096] Likewise, the second tooth 444 includes a third leading edge surface 508 and a fourth leading edge surface 510. The third leading edge surface 508 may be located above the fourth leading edge surface 510. The second tooth 444 may also include at least one second contact edge 514 and at least one fourth contact edge 524. The second tooth 444 includes a third trailing edge surface 536 and a fourth trailing edge surface 538. The fourth trailing surface 538 may be located above the third trailing surface 536. The second contact edge 514 may be formed at the intersection of the first leading edge surface 504 and the second leading edge surface 506. The third leading surface 508 and the fourth leading surface 510 may meet at the second contact edge 514 and form the second contact edge 514. The third leading edge surface 508 and the fourth trailing edge surface 538 may meet at the fourth contact edge 524 and form the fourth contact edge 524.

[0097] For example, when the first drag surface 532 shares surface contact with the fourth drag surface 538, the first tooth 442 may lock with the second tooth 444. For another example, when the second drag surface 534 shares surface contact with the third drag surface 536, the first tooth 442 may lock with the second tooth 444.

[0098] Back to Figure 5A, when the first tooth 442 and the second tooth 444 are in the neutral threshold position 500, the first contact edge 512 and the second contact edge 514 may be in surface sharing contact. Alternatively, the first leading edge surface 504 may be in surface sharing contact with the third leading edge surface 508. Alternatively, the second leading edge surface 506 may be in surface sharing contact with the fourth leading edge surface 510. When the first contact edge 512 and the second contact edge 514 are in surface sharing contact, or the first leading surface 504 and the third leading surface 508 are in surface sharing contact, the first tooth 442 may slide upward against the third leading surface 508. Alternatively, when the first contact edge 512 and the second contact edge 514 are in surface sharing contact, or the second leading surface 506 and the fourth leading surface 510 are in surface sharing contact, the first tooth 442 may slide downward to the fourth leading surface 510. The first tooth 442 may engage with the second tooth 444 from the neutral position, for example, when the third contact edge 522 slides over the fourth contact edge 524. However, engagement from the neutral threshold position may result in grinding or vibration during engagement. For example, when the first tooth 442 slides relative to the third leading edge surface 508 or the fourth leading edge surface 510, friction or vibration may occur between the first tooth 442 and the second tooth 444.

[0099] Back to Figure 5B , taking the first example as an example, when the first tooth 442 and the second tooth 444 are in the engagement threshold position 540. When in the engagement threshold position 540, the third contact edge 522 and the fourth contact edge 524 may be in surface sharing contact. Alternatively, the first trailing surface 532 may be in surface sharing contact with the fourth trailing surface 538. When the first contact edge 512 and the second contact edge 514 are in a surface sharing contact state, or the second leading edge surface 506 and the fourth leading edge surface 510 are in a surface sharing contact state, the first tooth 442 may slide downward relative to the fourth leading edge surface 510.

[0100] As another example, when the first tooth 442 and the second tooth 444 are in another engagement threshold position, the mirror contact edge of the first tooth 442 opposite to the third contact edge 522 and the mirror contact edge of the second tooth 444 opposite to the fourth contact edge 524 may be in surface sharing contact. Alternatively, the second drag surface 534 may be in surface sharing contact with the third drag surface 536. Under the above mentioned conditions, the first tooth 442 may slide downward against the third drag surface 536.

[0101] The first tooth 442 and the second tooth 444 are engaged from an engagement threshold position (e.g., engagement threshold position 540). When engaging from the engagement threshold position 540, the engagement ring 352 and the engagement ring 356 and / or Figure 3Grinding occurs between the gears of the partial gear set 314. For example, when the first tooth 442 and the second tooth 444 are engaged at the engagement threshold position 540 instead of the neutral threshold position 500, grinding and / or vibration between the engagement ring 352 and the engagement ring 356 and / or the gears of the partial gear set 314 may be reduced.

[0102] Turn to Figure 6 , which shows a schematic diagram 600 of a tooth 610. The dimensions of the tooth 610 are similar to Figure 4-5B The first tooth 442 or the second tooth 444 in the embodiment is substantially the same. The tooth 610 may be a conical tooth.

[0103] The tooth 610 can have a centerline 612. The centerline 612 can extend through the first contact edge 622 and divide it into two halves. For example, the centerline 612 can divide the tooth 610 into two approximately symmetrical halves. The second contact edge 624 and the third contact edge 626 can be located on opposite sides of the centerline 612. The first contact edge 622 can be Figure 5A-5B The first contact edge 512 or the second contact edge 514 in the embodiment. The second contact edge 624 may be Figure 5A-5B The fourth contact edge 524 in. The third contact edge 626 may be Figure 5A-5B The third contact edge 522 in.

[0104] The first leading surface 632 and the second leading surface 634 may meet at the first contact edge 622 and be connected by the first contact edge 622. The first leading edge surface 632 and the first trailing edge surface 642 may meet at the second contact edge 624 and be connected by the second contact edge 624. The second leading edge surface 634 and the second trailing edge surface 644 may meet at the third contact edge 626 and be connected by the third contact edge 626. The first leading surface 632 may be Figure 5A-5B The first leading surface 504 or the fourth leading surface 510 in the embodiment. The second leading surface 634 may be Figure 5A-5B The second leading surface 506 or the third leading surface 508 in the first trailing surface 642 may be Figure 5A-5B The first trailing surface 532 or the third trailing surface 536 in the embodiment. The second trailing surface 644 may be Figure 5A-5B The second trailing surface 534 or the fourth trailing surface 538 in.

[0105] The tooth 610 may be defined by a first angle, referred to herein as an alpha angle (α) 652, and a second angle, referred to herein as a beta angle (β) 654. The alpha and beta angles 652, 654 may be angled with respect to the centerline 612. The second leading edge surface 634 may extend from the alpha angle 652 of the centerline 612. The second leading surface 634 may be parallel to a first arm 662 of the alpha angle 652 and extend from the centerline 612. The first leading surface 632 may be mirrored on the centerline 612 relative to the second leading surface 634. The second trailing surface 644 may extend at a beta angle 654 from the centerline 612. The second trailing surface 644 may be parallel to and extend from a second arm 664 of the beta angle 654 of the centerline 612. The first trailing surface 642 may be mirrored on the centerline 612 relative to the second trailing surface 644. The alpha angle 652 may be defined by a range. For example, the α angle 652 may be greater than 40° and less than 60° (e.g., 40°<α<60°). The beta angle 654 may be defined by a range. For example, the β angle 654 may be greater than 0° and less than 20° (e.g., 0°≤β<20°).

[0106] The first leading surface 632 may extend from the centerline 612 at a first complementary angle. The first leading surface 632 may extend parallel to the centerline 612 and at an arm of the first complementary angle. The complementary angle of the first leading surface 632 may have the same dimensions as the centerline 612 and be mirrored on the centerline 612 relative to the alpha angle 652. The first trailing surface 642 may extend from the centerline 612 at a second complementary angle. The first trailing surface 642 may extend parallel to and at an arm of the second complementary angle of the centerline 612. The second complementary angle of the first trailing surface 642 may have the same dimensions as the centerline 612 and be mirrored on the centerline 612 relative to the beta angle 654.

[0107] Go to Figure 7 , which shows a plurality of schematic diagrams 700, each illustrating a position. Each position in the schematic diagram 700 may be a position of the first tooth 442 and the second tooth 444 during position search, neutral and engagement operations.

[0108] The diagram may be a portion of a trajectory corresponding to the s-axis 708 representing distance. For the positions shown in the various diagrams, the actuator that moves the first tooth 442, e.g. Figure 2-4 The actuator 222 in the embodiment can be moved to a predetermined position arranged at different points along the s-axis 708. The actuator can be moved to a position parallel to the s-axis. The position to which the actuator can be moved can be referred to as the actuator position, or if the actuator is a range-movement actuator, the range actuator position. The actuator position of the actuator can be recorded by a position sensor, such as Figure 3 The position sensor 342 of the actuator 222 is provided. The actuator position can be continuously recorded and updated by the controller, such as Figure 3ECU 322 for actuator 222. The position of first tooth 442 on s-axis 708 is proportional to and corresponds to the displacement position of the actuator. For ease of discussion, the position of first tooth on s-axis 708 can be considered as the displacement position of the actuator, such as the displacement position of actuator 222.

[0109] The second tooth 444 may remain stationary at substantially the same position along the s-axis 708. The distance of the s-axis may be relative to a value of S0720. S0720 is a zero value corresponding to a starting position in which the first tooth 442 and the corresponding engagement sleeve (e.g., engagement ring 352) are Figure 2-4 The actuator 222 in the gear is retracted to a minimum value. S0720 can be a neutral position in which force is not transmitted from the second tooth 444 to the first tooth 442 and vice versa. The S axis 708 can also have a first threshold position and a second threshold position. The first threshold position is a first tooth contact position (sn) 722. The second threshold position is an engagement threshold position (se) 724. The first tooth contact position 722 can be Figure 5A The first tooth contact position 722 may be a neutral threshold position, which may be referred to herein as the neutral threshold position 722. The engagement threshold position 724 may be a neutral threshold position, which may be referred to herein as the neutral threshold position 722. Figure 5B 724, and may be a position where the engagement threshold position 540 occurs. In all positions shown in the schematic diagram 700, the first tooth 442 and the second tooth 444 are retracted so that their respective gaps (e.g., the second gap 358 and the first gap 344) reach a maximum value. If the first tooth 442 and the second tooth 444 are engaged at the engagement threshold position 724, the backlash can be minimized during the engagement of the engagement ring 352 with the engagement ring 356.

[0110] Schematic diagram 700 may include a schematic diagram showing a first position 710 of first tooth 442 relative to second tooth 444, a schematic diagram showing a second position 712, a schematic diagram showing a third position 714, a schematic diagram showing a fourth position 716, and a schematic diagram showing a fifth position 718. In the first position 710, first tooth 442 may be retracted to a position of s0720, wherein all features of the tooth are located before or at s0720 relative to s-axis 708. Between the first position 710 and the second position 712, the first tooth may be advanced forward a greater distance along the s-axis. When in the second position 712, the first tooth 442 may be advanced along the s-axis 708 and correspond to a first tooth contact position 722. In the second position 712, the first contact edge 512 may contact the second contact edge 514. Between the second position 712 and the third position 714, the first tooth 442 may be further advanced along the s-axis 708 from s0. In the third position 714, the first tooth 442 may be in surface sharing contact with the second tooth 444 through at least one leading edge surface of the first tooth 442 and at least one leading edge surface of the second tooth 444. Likewise, between the second position 712 and the third position 714, the leading edge surface of the first tooth 442 may be in coplanar contact with the leading edge surface of the second tooth 444. Furthermore, between the third position 714 and the fourth position 716, the leading surface of the first tooth 442 in the first position may be in coplanar contact with the leading surface of the second tooth 444. For example, in the third position 714, the first leading edge surface 504 may be in surface sharing contact with the third leading edge surface 508. In the fourth position 716, the first tooth 442 may be advanced along the s-axis 708 and correspond to the engagement threshold position 724. Between the fourth position 716 and the fifth position 718, the first tooth 442 may be further advanced along the s-axis 708. In the fifth position 718, the first tooth 442 may be in surface-sharing contact with the second tooth 444 through at least one trailing surface of the first tooth 442 and at least one trailing surface of the second tooth 444. Likewise, between the fourth position 716 and the fifth position 718, the trailing surface of the first tooth 442 may be in surface-sharing contact with the trailing surface of the second tooth 444. For example, in the fifth position 718, the first dragging surface 532 may be in surface-sharing contact with the fourth dragging surface 538.

[0111] When in the third position 714, Figure 4 The ft432 in the middle and the leading surfaces of the first and second teeth 442, 444 can guide the fd434 in the opposite direction of the s direction 330. The fd434 in the opposite direction of the s direction 330 can be shown as a first axial force (fd1) 742. The first axial force 742 can push the first tooth 442 away from the second tooth 444 and toward s0720. When in the fifth position 718, Figure 4The ft432 in the fourth position 716 and the leading surfaces of the first and second teeth 442 and 444 may guide the fd434 to be complementary to the s-direction 330. The fd434 complementary to the s-direction 330 may be shown as a second axial force (fd2) 744. The second axial force 744 may pull the first tooth 442 toward the second tooth 444 and may lock the first tooth 442 with the second tooth 444 therein. The second axial force 744 may occur in the fourth position 716 and may pull the first tooth 442 toward the fifth position 718.

[0112] The neutral threshold position 722 and the engagement threshold position 724 may serve as boundaries, respectively. The neutral threshold position 722 may serve as a boundary between a neutral zone (the first tooth 442 is not subjected to force) and a repulsive zone (the first tooth 442 is subjected to repulsive force). An s position greater than the neutral threshold position 722 but less than the engagement threshold position 724 may be subjected to a repulsive force (such as the first axial force 742). The engagement threshold position 724 may serve as a boundary between a repulsive zone and an attractive zone, in which an attractive force acts on the first tooth 442. An s position greater than the engagement threshold position 724 may be subjected to an attractive force, such as the second axial force 744. Figure 8 The graph and trajectory of Figure 10-12 The schematic diagram further illustrates this relationship.

[0113] Please see Figure 8 , which shows a graph 800 consisting of a first axis 804 and a second axis 806. Graph 800 includes a force versus position curve. The first axis 804 represents the quantity fd434. The second axis 806 is Figure 4 The value of the first axis 804 may depend on the second axis 806, so when the distance on the second axis 806 changes, the force on the first axis 804 will also change. The second axis 806 may be Figure 7 The s-axis 708 in FIG. 704 may start from S0 720. The first axis 804 includes negative values ​​and positive values, representing negative and positive values ​​of fd 434, respectively. The positive and negative values ​​on the first axis 804 are separated by the second axis 806, where the positive value of the force is located above the second axis 806 and the negative value of the force is located below the second axis 806. Figure 3 When the s-direction 330 in is complementary, a positive value of the force on the first axis 804 may represent fd434. Similarly, when Figure 3 When the s-direction 330 of the first shaft 804 is opposite, the negative value of the force on the first shaft 804 can represent fd434. A positive force on the shaft 804 can pull or push the first tooth 442 away from S0720. A negative force can pull or push the first tooth 442 toward S0720. As previously described, the negative force or positive force on the first tooth 442 can be caused by the ft432 on the second tooth 444 and the position of the first tooth 442 relative to the second tooth 444.

[0114] The trace 810 of the graph 800 represents the function fd(s). fd(s) is generated by increasing the value of s: the distance of the first tooth 442 from the starting point fd434. As the trace 810 increases along the second axis 806, the magnitude of the force may increase or decrease, or may change from negative to positive. The shape of the trace 810 can be used by the algorithm of the present disclosure to detect the engagement threshold position 724. For example, the engagement sleeve (such as the engagement ring 352) carrying the first tooth 442 can be repeatedly positioned from S0720 along the second axis 806 to different static positions, and the effect of the applied motor torque on the actuator (such as the engagement sleeve) coupled to the displacement of the engagement sleeve is observed. Figure 2 In this example, with the test position increasing monotonically, it can be observed that at a certain point, when the torque from the motor is applied, the position sensor of the actuator (such as Figure 3 The position sensor 342 in the embodiment will not show any repulsive force. At the point where there is no repulsive force, the engagement position (such as the engagement threshold position 724) has been exceeded. The new test position can be approximated as the average of the last two test positions.

[0115] A plurality of distances are set along the second axis 806 starting from s0720, including a first distance 812, a second distance 814, a third distance 816, and a fourth distance 818. The distances from closest to s0720 to the largest are the first distance 812, the second distance 814, the third distance 816, and the fourth distance 818. Between s0720 and the first distance 812, the trajectory 810 shows that there is substantially no fd434 from the motor torque on the first tooth 442. At the first distance 812, the first tooth 442 enters the repulsive force zone. The first distance 812 is the same distance as the neutral threshold position 722. Between the first distance 812 and the second distance 814, the repulsive force may increase, resulting in an increasing thrust on the first tooth 442. At the second distance 814, the trajectory 810 is at a minimum and a maximum negative value relative to the first axis 804. At the second distance 814, the repulsive force on the first tooth 442 reaches a maximum. Between the second distance 814 and the third distance 816, fd434 remains approximately constant, wherein fd434 is a negative value and the repulsive force on the first tooth 442 is approximately constant. At the third distance 816, the repulsive force of the second tooth 444 on the first tooth 442 begins to decrease. Between the third distance 816 and the fourth distance 818, fd434 may increase, becoming a smaller negative value and a smaller repulsive force. Between the third distance 816 and the fourth distance 818 may be the engagement threshold position 724. At the engagement threshold position 724, fd434 becomes approximately zero. At distances greater than the engagement threshold position 724, fd434 may be positive and have an attractive force. At the engagement threshold position 724, the first tooth 442 enters the attraction zone. As the distance on the second axis 806 increases from the engagement threshold position 724 to the fourth distance 818, the attractive force may increase, resulting in an increasingly positive pull on the first tooth 442. At the fourth distance 818, the trajectory 810 is at a maximum and most positive value relative to the first axis 804. At the fourth distance 818, the attraction force on the first tooth 442 reaches a maximum. After the fourth distance 818, the trajectory 810 can remain approximately constant relative to the first axis 804.

[0116] The method of the disclosed algorithm can search for a neutral threshold position 500 corresponding to the neutral threshold position 722 and an engagement threshold position 540 corresponding to the engagement threshold position 724. The method can be divided into three different stages: a first stage of preparing the engagement components and the coupling components for engagement, a second stage of searching for the neutral position, and a third stage of searching for the engagement position. The first stage can be referred to as the preparation stage. The second stage can be referred to as the neutral position search stage. The third stage can be referred to as the engagement position search stage. When a force opposite to the shift direction is detected at a specified position, the second stage can end and update the engagement threshold position between the non-contact zone (e.g., the neutral zone) and the repulsion zone. The second stage can update the neutral threshold position to a specified position where the repulsion is detected by the actuator moving opposite to the shift direction. After the motor stops, and the method of the third stage reaches or exceeds the set number of iterations, the third stage can end and update the engagement threshold position between the repulsion zone and the attraction zone. The third stage can update the engagement threshold position to a specified position detected when the motor stops and the method of the third stage reaches or exceeds the set number of iterations.

[0117] In the preparation stage, the first tooth 442, the second tooth 444 and their physical coupling or shift coupling components, such as the engagement ring 352, the shift rod 224, the actuator 222 and the engagement ring 356, can be prepared so that the first tooth 442 can be used to search for the neutral position and the engaged position. The preparation stage can also be used to prepare the first tooth 442, the second tooth 444 and their physical or shift coupling components so that the first tooth 442 can engage with the second tooth 444. Figure 3 The clutch member 338 can be closed. The preparation stage may include a first step, a second step and a third step. Figures 9A-9C A simplified gear engagement diagram showing various possible arrangements of gears during the preparation phase. The preparation phase minimizes the backlash that may occur during the search for the engagement position and during engagement in the engagement position.

[0118] Go to Fig. 9A , which shows a first arrangement 910 of the simplified schematic diagram 400. In the first arrangement 910, the engagement ring 352 can be in a first position 932 relative to the shaft 708, and the engagement ring 356 can be in a second position 934 relative to the shaft 708. In the first arrangement 910, the engagement ring 352 and the first tooth 442 can be in a relaxed state. Similarly, the engagement ring 356 and the second tooth 444 can be in a relaxed state. In the first arrangement 910, the nearest wall of the second groove 360 ​​is adjacent to the second groove 360. Figure 336. Similarly, in the first arrangement 910, there may be a second gap 944 between the nearest wall of the first groove 340 and the engagement ring 356. The first gap 942 may be a gap that is greater than a first minimum gap threshold between the second groove 360 ​​and the shift fork 336. The second gap 944 may be a gap that is greater than a second minimum gap threshold between the first groove 340 and the engagement ring 356. When in the first position 932, the engagement ring 352 and the first tooth 442 may be in a position s=0, for example Figure 7 s0720 in. The first gap 942 and the second gap 944 can be functional gaps of the respective components. In the preparation stage, the first gap 942 and the second gap 944 can be closed. When closed, the first gap 942 can be reduced to a first minimum gap of a smaller distance. The first minimum gap can be approximately zero, or a value that is as close to zero distance as functionally possible. Similarly, when closed, the second gap 944 can be reduced to a second minimum gap of a smaller distance. The second minimum gap can be a distance that is approximately zero, or an approximate value that is as close to zero distance as functionally possible.

[0119] During the first and second steps of the preparation phase, the simplified schematic diagram 400 may be in a first arrangement 910. In the first step, the speed and torque of the motor are zero. Figure 1 The driven shaft of the transmission 108 is locked. In this example, the driven shaft is shaft 318. For example, shaft 318 can be locked by the parking brake of the vehicle 100. In another example, shaft 318 can be locked by a dedicated device at the end of the line. In the second step, the dog clutch (such as Figure 3 338 in the clutch assembly 336 is placed in a neutral position. In the neutral position, the engagement ring 352 is separated from the engagement ring 356. The neutral position can be a first arrangement 910. At the first arrangement 910, the actuator 222 does not transmit force to the shift rod 224. In the first arrangement 910, the motor (such as the motor 207) or other transmission device may not transmit torque to the shaft 318 or the gear rotationally coupled to the engagement ring 356. For example, during the first arrangement 910, the motor may be in an off state, such as not generating and transmitting rotational energy through torque.

[0120] Look again Figure 9B-9C , Fig. 9B A second arrangement 950 of the simplified schematic diagram 400 is shown, Fig. 9CA third arrangement 970 of the simplified schematic diagram 400 is shown. The second arrangement 950 and the third arrangement 970 represent the beginning and end of the third step of the preparation phase, respectively. The third step of the preparation phase restores the clearance between the clutch member and the idler gear so that the clutch member can engage. When the clearance is restored, each clearance is closed and reduced to a minimum value. In the example shown in the second arrangement 950 and the third arrangement 970, the clearances that need to be minimized are the clearances between the second groove 360 ​​and the engagement ring 352 and the clearances between the first groove 340 and the engagement ring 356.

[0121] Go to Fig. 9B In the third step of the preparation phase, as shown in the second arrangement 950, fs436 can be transmitted to the shift rod 224 through the actuator 222. The deflection force generated by the complementary helix angle of the gears physically coupled to the engagement ring 356 can be used to reduce the distance of the second gap 944. s436 can drive the shift rod 224. The drive of the shift rod 224 can drive a coupling connected to the first engagement ring 352, such as the shift fork 336. The movement of the coupling can reduce the distance of the first gap 942. In each iteration of the first stage, fs436 can be moved in the same direction of the s-axis 708 (such as Figure 3 The distance of the first gap 942 is reduced in the s direction 330 in the second arrangement diagram. Similarly, the motor 207 can generate a rotational speed and a torque. The torque from the motor 207 can be transmitted to the engagement ring 356. As shown in the second arrangement diagram 950, the torque can apply ft432 and fa346 to the engagement ring 356. fa346 can be physically coupled to the engagement ring 356 through a gear (e.g. Figure 3 The helix angle of the second gear 334 in the first stage is transmitted and deflected by ft432. fa346 can reduce the distance of the second gap 944. In each iteration of the first stage, fa346 can be moved in the same direction of the s-axis 708 (such as Figure 3 The distance of the second gap 944 is reduced in the s direction 330).

[0122] Go to Fig. 9C, the end of the third step of the preparation phase is shown in the third arrangement 970. In the third arrangement 970, a third gap 972 may exist between the nearest wall of the second groove 360 ​​and the shift fork 336. Similarly, in the third arrangement 970, a fourth gap 974 may exist between the nearest wall of the first groove 340 and the engagement ring 356. The third gap 972 may be a minimum gap threshold of the engagement ring 352, so that the engagement ring 352 can be engaged with the engagement ring 356. The third gap 972 may be a minimum gap threshold of the engagement ring 352, so that the first teeth 442 of the engagement ring can be used in the neutral position search phase and the engagement position search phase. The fourth gap 974 may be a minimum gap threshold of the engagement ring 356, so that the engagement ring 352 can be engaged with the engagement ring 356. The third gap 972 may be a minimum gap threshold of the engagement ring 352, so that the second teeth 444 of the engagement ring 356 can be used in the neutral position search phase and the engagement position search phase. The preparation phase closes the gap in a determined direction, in this way defining a determined measurement origin. The third gap 972 can be the first measurement origin of the engagement ring 352 and the actuator 222, for example, when the engagement ring 352 and the actuator 222 are positioned at s0. The fourth gap 974 can be the first measurement origin of the engagement ring 356. The third gap 972 can be the first measurement origin of the first tooth 442, for example, when the first tooth 442 is positioned at s0. The fourth gap 974 can be the first measurement origin of the second tooth 444.

[0123] When searching for the engagement position or engaging at the engagement position, minimizing the distance between the first gap 942 and the third gap 972 can minimize the backlash of the engagement ring 352. Minimizing the distance between the first gap 942 and the third gap 972 can close the first gap 942. When searching for the engagement position or engaging at the engagement position, minimizing the distance between the second gap 944 and the fourth gap 974 can minimize the backlash of the engagement ring 356. Minimizing the distance between the second gap 944 and the fourth gap 974 can close the second gap 944.

[0124] In the third arrangement 970, the motor 207 can continue to generate speed and torque and transmit it to the engaging ring 356. The fa346 from the torque can be applied to the engaging ring 356 to maintain the fourth gap 974 at approximately the same distance.

[0125] Please see Figure 10-12 , the figure illustrates three events that may occur during the neutral position search phase and the engaged position search phase. Figure 10-12 Included and shared are multiple areas where the first tooth 442 can be positioned relative to the second tooth 444 and the S-axis 708 . Figure 10-12There are three regions, namely, the first region 1012, the second region 1014, and the third region 1016. The first region 1012 is a non-contact region, where no force from the second tooth 444 may be applied to the features of the first tooth 442. In addition, the first region 1012 may also be referred to as a neutral region. The second region 1014 and the third region 1016 are a repulsive region and an attractive region, respectively. In the second region 1014, a repulsive force may be applied from the second tooth 444 to the features of the first tooth 442. In the third region 1016, an attractive force may be applied from the second tooth 444 to the features of the first tooth 442.

[0126] Please see Fig.10 , a first event 1000 is shown. During the first event 1000, the first tooth 442 may be located at a first position 1010 on the S-axis 708. The first position 1010 may be a position where the first tooth 442 is completely located in the first region 1012. During the neutral position search phase and the engagement position search phase, the motor 207 may transmit torque to the Figure 2-3 The tangential force 1020 can generate a torque and apply it to the second tooth 444. The tangential force 1020 can be Figure 4 The tangential force in is 432.

[0127] Fig.11 A second event 1100 is shown. During the second event 1100, the first tooth 442 can be in a second position 1110 on the s-axis 708. The second position 1110 can be where the features and components of the first tooth 442 are located in the second region 1014. When the features of the first tooth 442 are located in the second region 1014, some features of the first tooth 442 can have surface-sharing contact with the second tooth 444; however, the first tooth 442 can be pushed away from the second tooth 444 by the first axial force 1122. The first axial force 1122 can be transmitted from the motor 207 to the Figure 2-3 The torque of the engagement ring 356 is generated. The first axial force 1122 is a repulsive force along the s-axis 708 that is opposite to the s direction. The first axial force 1122 can be mathematically represented as a negative value for use in the algorithm. The first axial force 1122 can be Figure 7 The first axial force 742 in the second zone 1014 can be pushed into the first zone 1012 by the first axial force 1122.

[0128] Fig.12A third event 1200 is shown. During the third event 1200, the first tooth 442 can be in a third position 1210 on the s-axis 708. The third position 1210 can be where the features and components of the first tooth 442 are located in the third zone 1016. When the features of the first tooth 442 are located in the third zone 1016, some features of the first tooth 442 can have surface-sharing contact with the second tooth 444. When in the third zone 1016, the first tooth 442 can be pulled by the second axial force 1222. The second axial force 1222 can be transmitted from the motor 207 to the Figure 2-3 The torque of the engagement ring 356 is generated. The second axial force 1222 can pull the first tooth 442 so that more features of the first tooth 442 share contact with the surface of the second tooth 444. The second axial force 1222 can pull the first tooth 442 to lock with the second tooth 444. Similarly, the tangential force 1020 can push the second tooth 444 toward the first tooth 442 and can lock the second tooth 444 to the first tooth 442. The second axial force 1222 is an attractive force complementary to the s direction along the s-axis 708. The first axial force 1122 can be mathematically shown as a positive value for use in the algorithm. The second axial force 1222 can be Figure 7 The second axial force 744 in.

[0129] Please see Fig.13 , a method 1300 is shown. The method 1300 is a first method of calibrating and engaging a clutch of the present disclosure. The method 1300 may be used to calibrate a clutch assembly, which may be a dog-type clutch structure, such as Figure 3 The method 1300 can calibrate an ECU, such as ECU 322, so that the ECU can selectively couple the engagement member and the coupling member of the clutch member to minimize grinding, vibration, noise, and backlash during engagement. The engagement member can be the engagement ring 352, and the coupling member can be Figure 3 The method 1300 can estimate the neutral threshold position, for example Figure 5A and Figure 7 The neutral threshold position 500, 722 in the method 1300 can estimate the engagement threshold position, for example Figure 5B and 7engagement threshold positions 540, 724 in the method 1300. When the ECU is calibrated, for example, when the neutral threshold position and the engagement threshold position are estimated and recorded by the method 1300, the teeth of the engagement component may engage the teeth of the coupling component at the engagement threshold position. Likewise, when the ECU is calibrated by the method 1300, the teeth of the engagement component may not engage the teeth of the coupling component at the neutral threshold position or at a position between the neutral threshold position and the engagement threshold position. After the method 1300, the ECU or another control unit may prevent the engagement component from being actuated and attempting to engage with the engagement component at or before the neutral threshold position, for example, in a neutral zone or a no-contact zone. After the method 1300, the ECU or another control unit may prevent the engagement component from being actuated and attempting to engage with the coupling component between the neutral threshold position and the engagement threshold position (for example, in a repulsion zone). After the method 1300, the ECU or another control unit may actuate the coupling component to a position greater than the engagement threshold position.

[0130] The teeth of the engaging component may include first teeth 442. The teeth of the coupling component may include second teeth 444. Method 1300 may use a linear heuristic method, wherein each iteration, the new candidate position is monotonically increased by a predetermined step size. However, an alternative method using the steps of method 1300 may use a non-linear heuristic method, such as a binary heuristic method, to determine the new candidate position. If a binary heuristic method is used, the iteration range between the lowest position and the highest position is halved by setting the new candidate position at the midpoint. The counter for iterating the candidate position may be represented by the letters k, j, and i.

[0131] The method 1300 starts and proceeds to 1302. At 1302, operating conditions are determined so that a control system consisting of a controller or controllers (such as ECU 322) can adjust vehicle conditions for subsequent steps of the method 1300. At 1312, the clutch is initialized in a preparatory phase to search for a neutral threshold position and an engaged threshold position.

[0132] The preparation stage shown in 1302 includes multiple sub-steps. 1302 can start from 1314. At 1314, a driven shaft, such as shaft 318, to which the clutch member can be selectively coupled is locked. The driven shaft can be locked by a dedicated device at the end of the line or by engaging a parking brake. At 1314, the speed and torque of the motor (such as motor 207) can be null, so that no torque is transmitted to the gear set selectively coupled to the driven shaft through the clutch member. Starting from 1314, 1302 continues to 1316, where the counters of the iteration candidates are set to their starting values. For example, the first counter k is set to 0, the second counter j is set to 1, and the third counter i is set to 0. At 1318, the clutch member is set to a neutral position. The neutral position can be a position where the distance s is less than the neutral threshold position, such as the neutral threshold position 500 or the neutral threshold position 722, along the shift axis, such as the s axis 708. In the neutral position, the s distance of the engagement member is set to the s0 value. From 1318, 1302 may proceed to 1320. At 1320, the gap between the engagement member and the coupling member is minimized. 1320 includes a plurality of sub-steps. 1320 includes sub-steps 1322 and 1324. At 1322, the gap between the coupling ring, e.g. Fig. 9A The gap 944 in is reduced to a minimum, e.g. Fig. 9C The fourth gap 974 in the middle. At 1322, the motor can generate a rotational speed and torque, and transmit the rotational energy to the engagement ring through the torque. The torque can generate tangential force and axial force, such as Figure 3-4 ft432 and fa346 in. The axial force can reduce the clearance of the joint ring to the minimum clearance. When 1324, the clearance of the joint ring, such as Fig. 9A The gap 942 in is reduced to the minimum gap, such as Fig. 9C The third gap 972 in. At 1324, the gap of the engagement ring can be reduced by a displacement force, e.g. Figure 4 fs436 in.

[0133] The first step of the preparation phase may include 1314, 1316. The second step of the preparation phase may include 1318. The third step of the preparation phase may include 1320. The process of the preparation phase may be performed by Figures 9A-9C The first arrangement 910, the second arrangement 950 and the third arrangement 970 in 1314, 1316 and 1318 can be schematically shown by the first arrangement 910. The clutch components at the beginning of 1320 can be schematically shown by the second arrangement 950. The clutch components at the end of 1320 can be schematically shown by the third arrangement 970.

[0134] After 1312, method 1300 proceeds to 1332. At 1332, method 1300 may approach the repulsion zone. During the process of approaching the repulsion zone at 1332, method 1300 may search and estimate the neutral threshold position. 1332 may include a neutral position search phase. After 1332, method 1300 may proceed to 1342. At 1342, method 1300 searches and estimates the engagement threshold position. 1342 may include an engagement position search phase. The engagement threshold position may be a position where an engagement point is set for engaging the clutch assembly. After 1342, method 1300 may proceed to 1352. At 1352, method 1300 may engage the clutch member so that the clutch member couples the idle gear rotationally to the driven shaft. At 1352, the clutch is engaged in the engagement position. 1352 may include a sub-step 1354. At 1354, the engagement position is calculated and recorded. The engagement position may be based on the position where the engagement threshold position is detected. The engagement position can be calculated according to the third equation. The third equation estimates the specified position of the engagement position according to the sum of P1, P2 multiplied by the value of the k counter minus 1, and P6 multiplied by the value of the j counter. Formula 3: Engagement position = s = P1 + P2*(k-1) + P6*j

[0135] In Formula 3, s is the position of the joint part; P1 is the lower limit of the candidate position; P2 is the first step size; P6 is the second step size. The first step size P2 is a coarse step size based on the initial estimate. The second step size P6 is a smaller step size than P2.

[0136] After 1354, method 1300 can exit 1352 and end.

[0137] 1332 and 1342 comprise sub-methods of method 1300. The steps of 1332 may be performed in Fig.14 Similarly, the steps of 1342 may be performed in Fig.15 The method 1500 is shown and expanded upon.

[0138] See also Figure 13-15 , method 1300, method 1400 and method 1500 use multiple variables, such as P1, P2, P3, P4, P6 and P7. P1, P2 and P6 are described with reference to Equation 3, where P1 is the lower limit of the candidate position; P2 is the first step length, and P6 is the second step length. For method 1400, P1 is determined by stack tolerance analysis, so it is calculated offline rather than by software logic. For one example of method 1500, P1 can be a neutral threshold position determined according to method 1400. In another example of method 1500, P1 can be a value determined by stack tolerance analysis for method 1400. P3 is the motor speed target value, that is, the motor (such as Figure 2 The motor 207 in the embodiment increases the rotational speed to a selected speed to drive the coupling member and the complementary gear (such as Figure 3 356 and the second gear 334 in the engagement ring 356 and the second gear 334). During the engagement process and / or when evaluating the neutral threshold position or the engagement threshold position, the speed of the motor can be increased to the selected speed of P3. P4 can be the time to command the speed of the electric machine to P3. P5 is the torque output by the motor to the gear set, such as a stage including a portion of the gear set 314, which can drive the coupling component and the complementary gear. P6 can be a second stage size. Compared with P2, P6 can be a finer step size. P7 is a fixed value and a set number of iterations that can be performed during the method without resetting the i counter. The first counter k can be a distance-based position counter. The first counter k can be used in combination with P1 and P2 and iterated. The second counter j can be used in combination with P1, P2, P5 and P6 and used repeatedly. The third counter i can be used in combination with P7 to evaluate whether the method 1300 is stopped. If i is less than P7, the engagement point search phase of the method 1300 can continue. If i is greater than P7, the engagement point search phase of the method 1300 can end after completing this instance. Wherein P7 can be used to confirm the engagement point, such as engagement threshold position 540 or engagement threshold position 724. The second stage, i.e., method 1400, can be responsible for finding the repulsive zone and updating the neutral threshold position of the actuator control unit. The third stage, such as method 1500, can be responsible for finding the attractive zone and updating the engagement threshold position of the actuator control unit.

[0139] Fig.14 Method 1400 is shown. Method 1400 is a method of approaching a repulsive zone and finding a neutral point between the clutch teeth and the clutch ring teeth. The neutral point may be a neutral threshold position, such as Figure 5A and Figure 7 The neutral threshold position 500, 722 in the method 1400 starts at 1402. At the position 1402, the RSA of the clutch component, such as Figure 2 The actuator 222 in is placed in a neutral position. The neutral position may place the engagement member at a starting point where s is zero (e.g., about s=0 mm), such as a starting point on the s-axis. For example, the neutral position may be Figure 7 S0720 on the middle s-axis 708. The neutral position may be located in a non-contact zone (e.g., a neutral zone), such as Fig.10 The first zone 1012 in the method 1400. At the start of the method 1400, the neutral position is not the neutral threshold position. When the neutral threshold position is found, the neutral threshold position can be recorded by a control unit, such as an ECU, such as Figure 3 ECU 322 in. After method 1400 and method 1500, the neutral threshold position can be used as the maximum distance of the neutral position when the clutch is engaged.

[0140] After 1402, method 1400 proceeds to 1404. At 1404, the RSA is positioned so that the engagement member is at a first specified position. The first specified position may be a point on the s-axis, such as s-axis 708. The first specified position may be the sum of P1 and P2 expressed in the fourth equation. Formula 4: s1=s=P1+P2*k i

[0141] In Formula 4, s1 is the first test position and ki is the current instance and value of the k counter.

[0142] After 1404, method 1400 proceeds to 1406. At 1406, the torque of the motor is limited to P5, so that the torque generated by the motor may not be greater than P5. The torque of the motor may be limited to P5 by a control system, which may control the motor and clutch components. The control system may include an ECU. If the torque is greater than P5, the control system may reduce the torque of the motor to P5. After 1406, method 1400 proceeds to 1408. At 1408, the control system instructs the motor to a selected speed equal to P3 via a control signal. Similarly, at 1408, the motor is instructed to run at a speed of P3 for a period of time P4 via a control signal.

[0143] After 1408, method 1400 proceeds to 1410. At 1410, the sensor and control system evaluate the motor to determine whether the output is rotating. If the motor rotation is not detected (1410 is NO), the motor is stalled. When the motor is stalled, the coupling component has found and entered the attraction zone. After the motor is stalled, method 1400 proceeds to 1412. The coupling component can be physically coupled to the gear or selectively coupled to the shaft by a clutch including the coupling component and the coupling component. The stalling of the electric machine and the shaft may be caused by locking the output shaft by a device, such as by a parking brake or an end device. Coupling the motor rotation to the locked output shaft (such as by a clutch component) may cause the motor to stall. For example, the locked output shaft can be a shaft on which the gear and the coupling component are mounted. As a shaft, the output shaft can be complementary to the coupling component and the complementary gear of the coupling component, so that the clutch can couple the complementary gear rotation to the output shaft when engaged. Alternatively, the output shaft can also be coupled to the shaft rotation. The shaft is complementary to the complementary gear of the coupling component, so that when the clutch is engaged, the complementary gear is coupled to the shaft rotation. For either of the above examples, a parking brake or endpoint device may prevent rotation of a shaft selectively coupled by a clutch including an engaging component and a coupling component.

[0144] At 1412, the value of P2 is decreased. For example, at 1412, the value of P2 may be decreased by a linear method, where the step size of P2 is decreased by an arbitrary step size. As another example, at 1412, the value of P2 may be decreased in a non-linear manner, such as a binary method. After 1412, method 1400 may proceed to 1414. At 1414, the k counter is reset to zero from the previous value. After 1414, method 1400 returns to 1402.

[0145] Returning to 1410, if the motor is detected to be rotating ("yes" at 1410), the motor is not stalled and method 1400 proceeds to 1422. At 1422, the control system determines whether the RSA and the shift lever are moving backward, such as with Figure 3 The control system may use data from a position sensor, such as position sensor 342, to evaluate the RSA. If the RSA is detected to be moving backward ("yes" at 1422), the repulsion zone has been found and the method 1400 may end. The previous specified value may be used as the neutral threshold position.

[0146] For example, the RSA can be set to a first test position and a second test position. The first test position can be the test position immediately before the second test position (for example, the first test position is the previous specified value and the second position is the specified value). The second test position is an increment P2 larger than the first test position. When in the first test position, the RSA is not detected to move backward, for example, 1422 is NO. In the second test position, the RSA is detected to move backward, for example, 1422 is "yes". Method 1400 can stop and the first test position can be set to a neutral threshold position. Wherein, the neutral threshold position can be the previous test position before the test position where the repulsive force is detected.

[0147] In another example, after detecting that the RSA moves backward (e.g., 1422 is "yes"), an optional step can be performed before the method 1400 ends. In the optional step, the control unit (such as ECU322) can record the previously specified value. The ECU can update the neutral threshold position to the previously specified value. After the optional step, the method 1400 ends.

[0148] The repulsion zone can be Figure 10-12 The position before the position where the repulsive zone is first detected, such as the position of the last specified value, is the neutral threshold position, such as the neutral threshold position 500, 722. The neutral threshold position can be used Fig.15 The next step of method 1500 is to find the repulsive zone and the engagement threshold position. The controller system memory can store and update the neutral threshold position for use in subsequent clutch engagement and / or disengagement, such as in Fig.13The clutch is engaged in 1352. The clutch actuator, such as Figure 2 The actuator 222 in the embodiment may respond to the updated neutral threshold position via a command from the controller system. For example, the updated neutral threshold position may be used as the neutral position during clutch engagement and / or disengagement. In this or another example, the updated neutral threshold position may also be a maximum neutral position that the actuator may not exceed when actuating to the neutral position.

[0149] Returning to 1422, if the RSA is not detected to move backward (1422 is NO), the repulsion zone is not found, and the method 1400 enters 1432. At 1432, the method 1400 instructs the motor to reduce the speed and torque output to zero. The control system can control the motor to zero speed and zero torque through the command signal generated by the controller. After 1432, the method 1400 enters 1434. At 1434, the value of the k counter is increased by 1 unit. Formula 5: k i =k i-1 +1

[0150] In Formula 5, ki is an integer, which is the new instance of the k counter value, and ki-1 is the previous value of the k counter. The value of the k counter increases by a factor for each iteration.

[0151] After 1432, method 1400 returns to 1402. At each adjustment or return to the neutral position in 1402, the third step of the preparation phase can be repeated to minimize the clearance between the engaged and coupled components. For example, the third step of the preparation phase can be repeated after each instance of 1414 and 1434. 1402 of method 1400 can include performing the clutch component clearance reduction step at 1320 of method 1300 at each iteration. Multiple specified positions can be tested by method 1400 for the first specified position.

[0152] Fig.15 Method 1500 is shown. Method 1500 is a method for finding an engagement point between teeth of an engagement sleeve and teeth of an engagement ring. The engagement point may be an engagement threshold position, such as Figure 5A and Figure 7 The engagement threshold positions 540, 724 in.

[0153] After startup, method 1500 proceeds to 1502. At 1502, method 1500 places the RSA in a neutral position. Fig.14 Similarly, the neutral position is Fig.14The neutral position described in . For example, the neutral position can be set to s is 0 mm. The RSA can move the engaging component to different positions by instructions from the control system. Starting from 1502, method 1500 enters 1504. At 1504, the RSA is positioned so that the engaging component is at a second specified position. The second specified position can be a point on the s-axis, such as s-axis 708. The second specified position can be estimated by the sixth equation. The sixth equation estimates the second specified position by multiplying P1, P2 by the value subtracted from the value of the k counter by 1, and P5 by the sum of the value of the j counter. Formula 6: s2=s=P1+P2*(k i -1)+P6*j

[0154] In Formula 6, s2 is the second test position.

[0155] In method 1500, a plurality of specified positions may be tested for the specified position s2. The neutral threshold position found in method 1400, such as neutral threshold position 500, 722, may be the minimum value of the specified position range of s2. As the minimum value of s2, the neutral threshold position may prevent the clutch from engaging in the neutral region. The engaging component may be the engaging component described in method 1400, such as Figure 3 The coupling member may be the coupling member described in method 1400, for example Figure 3 The coupling loop 356 in.

[0156] After 1504, method 1500 proceeds to 1506. At 1506, the torque of the motor is limited to P5, so that the torque generated by the motor may not be greater than P5. The torque of the motor may be limited to P5 by a control system, which may control the motor and clutch components. The control system may include an ECU, such as Figure 3 ECU322 in. If the torque is greater than P5, the control system can reduce the torque of the motor to P5. After 1506, method 1500 enters 1508. At 1508, the control system commands the motor to a selected speed equal to P3 through a control signal. Similarly, at 1508, the control system commands the motor to run at P3 speed for a period of time P4 through a control signal. The command signal can be used to require the motor and the output of the motor to rotate around the axis to start and / or increase the rotation speed of the motor.

[0157] After 1508, method 1500 proceeds to 1512. At 1512, the sensor and control system evaluates the motor to see if the output is rotating. If motor rotation is not detected (1512 is NO), the motor is stalled. Stalling of the motor and shaft may be caused by the output shaft being locked by a device such as a parking brake or an end stop. Coupling the motor rotation to a locked output shaft (e.g., by a clutch component) may cause the motor to stall. The locked output shaft may be a shaft that is complementary to the coupling component, such as Figure 3 The coupling member is a shaft 318 in the embodiment of the present invention, wherein the complementary shaft is provided with a gear and a coupling member. When the clutch member is closed, the coupling member is selectively coupled to the complementary shaft. Similarly, the output shaft can be an independent shaft separated from the complementary shaft of the coupling member, but is rotationally coupled to the complementary shaft of the engagement member by means of a gear set or the like. The coupling member can be physically coupled to the gear. The gear can be positioned around the complementary shaft and supported by the complementary shaft. The coupling member can be selectively coupled to the complementary shaft via the engagement member. When the motor stops, the engagement member finds and enters the attraction zone, and the method 1500 enters 1514. At 1514, the third counter i is increased by one unit 1. Formula 7: i i =i i-1 +1

[0158] In Formula 7, ii is an integer, which is a new instance of the value of the i counter, and ii-1 is the previous value of the i counter. The value of the i counter may increase by 1 for each iteration.

[0159] After 1514, method 1500 may continue to 1516. At 1516, the value of i is compared to P7. If the value of i is greater than or equal to P7 ("yes" at 1516), method 1500 ends. At the end, the control unit may record the values ​​of i, k, and j of the last iteration and use them to calculate the engagement threshold position and Fig.13 Engagement at engagement point 1352 of method 1300. Here, the control unit may record and use the last s2 position of 1504 as the engagement threshold position.

[0160] Returning to 1516, if the value of i is less than P7 (1516 is NO), method 1500 may proceed to 1518. At 1518, method 1500 instructs the motor to reduce the speed and torque output to zero. The control system may control the motor to zero speed and zero torque through the command signal generated by the control unit. After 1518, method 1500 returns to 1502. The steps of method 1500 may be repeated multiple times until i is greater than or equal to P7.

[0161] The controller system's memory can store and update the engagement threshold position and engage and / or disengage the clutch accordingly, e.g. Fig.13The clutch is engaged in 1352. The clutch actuator, such as Figure 2 The actuator 222 in the embodiment may respond to an updated engagement threshold position via a command from a controller system. For example, during clutch engagement and / or disengagement, the updated engagement threshold position may be used as the engagement position. In this or another example, the updated engagement threshold position may also be a minimum engagement position that the actuator may reach or exceed when actuated to the engagement position.

[0162] Returning to 1512, if the electric machine does rotate (1512 is "yes"), the electric machine will not stall. When the motor is not stalled, it means that the engaging member has not been found or has not entered the attraction zone, and method 1500 enters 1532. At 1532, method 1500 instructs the motor to reduce the speed and torque output to zero. The control system can control the motor to zero speed and zero torque through the command signal generated by the controller. After 1532, method 1400 enters 1534. At 1534, the value of the j counter is increased by a unit of 1. The increase of j can be expressed by the eighth equation. Formula 8: j i =j i-1 +1

[0163] In Formula 8, ji is an integer, which is the new instance of the j counter value, and ji-1 is the previous value of the j counter. The value of the j counter increases by 1 for each iteration.

[0164] After 1534, method 1500 may continue to 1536. At 1536, the i value is evaluated and compared to the 0 value to evaluate whether the i value is not equal to 0 (e.g., i!=0). If the i value is equal to 0 (1536 is NO), method 1536 may return to 1502. Returning to 1536, if i is not equal to 0 (e.g., i!=0), (1536 is "yes"), method 1500 will continue to 1538. At 1538, the i counter is reset to equal 0. The steps of method 1500 may be repeated multiple times until i is greater than or equal to P7 and the motor stops, such as when 1516 is "yes".

[0165] Each time the neutral position in 1502 is adjusted or returned, the third step of the preparation phase can be repeated to minimize the gap between the engaging component and the coupling component. For example, the third step of the preparation phase can be repeated after each instance of 1536, 1538, and 1518. 1502 of method 1500 can include Fig.13 Each iteration of method 1300 at 1320 performs a clutch component lash reduction step.

[0166] The method disclosed herein, for example Fig.13The method 1300 can search for the position of each first tooth of the first tooth and each second tooth of the second tooth, such as the neutral position and the engaged position. The method can be divided into three stages: the first stage is used to prepare for the engagement of the engagement component and the coupling component, the second stage is used to search for the neutral position, and the third stage is used to search for the engaged position. When searching for the neutral position and / or the engaged position, the first tooth can maintain a certain distance from the position of the second tooth relative to the disengaged position.

[0167] During the second phase: neutral zone search, the first tooth may be positioned in multiple zones, such as a no-contact zone, a repulsion zone, or an attraction zone, while the method searches for a neutral position and an engaged position of the engagement member and the first tooth relative to the second tooth. Each zone may correspond to a different event that may occur with the engagement member and the first tooth. When the engagement member is in the no-contact zone (first zone), a first event may occur, i.e., the first tooth and the second tooth are not in contact and the RSA is not moving. When the engagement member is in the repulsion zone, the axial force of the motor is greater than the force of the RSA. In the repulsion zone, when the first tooth and the second tooth are in contact, the first tooth and the engagement member are pushed away by the force from the second tooth and the coupling member. The force pushing the first tooth and the coupling member may push the actuator, causing the actuator to move in a direction opposite to the displacement direction. The movement of the actuator, such as the RCA, may be detected by the control unit, such as by a position sensor monitoring the actuator and communicatively coupled to the control unit. The movement detected by the control unit may indicate that the actuator has entered the repulsion zone and may be used by the algorithm to adjust the neutral and engaged position of the first tooth and the engagement member. When the coupling member is in the attraction zone, the clutch can be engaged so that the first tooth and the second tooth can be locked to each other. The tangential force of the second tooth and the force of the RSA can press the first tooth toward the second tooth so that their surfaces share contact. The tangential force of the coupling member and the negative angle of the second tooth can lock the first tooth with the second tooth. The locking can cause the rotation of the shaft and the rotating element that is rotationally coupled to the coupling member to stop. The stalling of the shaft can be detected by the control unit, such as by a sensor that communicates with the control unit to monitor the rotation of the shaft or the output of the motor. During the search for the neutral zone, the locking condition can be recorded and the controller can adjust the specified position to test the neutral threshold position and the repulsion zone. When the controller calibrates the RSA and clutch components and correctly calculates the repulsion zone search, the third event can be prevented from occurring during the search for the repulsion zone. Regardless of whether the first, second or third event occurs, the speed of the motor is controlled to zero and the RSA is moved back to a static position, such as the S0 position. If the third event occurs, the first tooth and the second tooth are disengaged, and the coupling member and the coupling member are disengaged. Once moved back to the S0 position, the gap between the engaging and coupling parts will be minimized as in the first stage, and then the second stage is repeated for the new candidate position. The second stage can be repeated. The control unit can perform detection and stop the motor if it is below a minimum time threshold, thereby minimizing grinding, warping, noise and other forms of degradation during the second stage. Each new position is selected by the linear search method of the first embodiment or the binary search method of the second embodiment. The minimum distance between the two candidate positions is below a first minimum distance threshold that depends on the last measurement result. Iterations can continue until the difference between the larger position and the smaller position is equal to or below a second minimum distance threshold, such as a maximum allowable error or error value.

[0168] During the third phase: the engagement zone search, the first tooth and the engagement member may be positioned in multiple zones, such as the repulsion zone or the attraction zone described above. During the third phase, either the first event or the second event may occur. In the first event, the engagement member is located in the repulsion zone rather than the attraction zone. In the first event, the axial force generated by the motor overcomes the force that the RSA can apply, and the axial force generated by the motor can push the RSA back and maintain its speed. The first event may cause the first tooth and the second tooth to grind, which in turn causes the clutch gear to grind. The second event may occur when the engagement member is in the attraction zone. When the engagement member is in the attraction zone, the clutch is engaged. The tangential force of the coupling member and the negative angle of the second tooth can lock the first tooth with the second tooth, thereby locking the engagement member to the coupling member. The electric motor may be stopped, and the locking state of the engagement member and the coupling member is recorded by the controller unit. Regardless of whether the first or second event occurs, the speed of the motor is controlled to zero and the RSA is moved back to a stationary position, such as the S0 position. Once moved back to the S0 position, the gap between the engagement member and the coupling member is minimized as in the first phase, and the third phase is repeated for the new candidate position. The third phase may be repeated. The control unit may perform detection and stop the motor if it falls below a minimum time threshold, thereby minimizing grinding, warping, noise and other forms of degradation during the second phase. Each new position is selected by the linear search method of the first embodiment or the binary search method of the second embodiment. The minimum distance between two candidate positions is below a first minimum distance threshold, which depends on the last measurement result. Iterations may continue until the difference between the larger position and the smaller position is equal to or below a second minimum distance threshold, such as a maximum allowed error or error value.

[0169] In another representation, the method of the present disclosure includes a twenty-second example, wherein the driven shaft can be locked by a dedicated end point device. In another representation, the method of the present disclosure includes a twenty-third example, wherein the driven shaft can be locked by a parking brake.

[0170] Thus, a method can calibrate a control unit and a dog clutch so that an engaging component engages a coupling component to prevent or minimize grinding. The preparation phase of the method can reduce the backlash effect of the search phase of the method. When calibrated, the force applied from the engaging component to the coupling component opposite to the shifting direction of the clutch can be prevented. The method can calibrate the control unit and the dog clutch by finding a first threshold position and a second threshold position for the teeth of the dog clutch. The first threshold position is a first point and the second threshold position is a second point on a clutch parallel shiftable axis (referred to as a shift axis). The first threshold position can be a neutral threshold position between a first zone and a second zone along the shift axis. The second threshold position can be an engagement threshold position between a second zone and a third zone. The first zone can be a distance along the shift axis within which a feature of a first tooth may not have surface sharing contact with a second tooth. The second zone and the third zone can be a distance along the shift axis within which a feature of a first tooth may have surface sharing contact with a second tooth. In the second zone, a feature of a first tooth in coplanar contact with a feature of a second tooth may be subject to a repulsive force. The repulsive force can push the first tooth away from the second tooth. In the third zone, the feature of the first tooth that shares a contact surface with the feature of the second tooth can receive an attractive force. The attractive force can pull the first tooth into contact with the second tooth and lock it. The identification of the neutral threshold position and the engagement threshold position can determine the second zone and the third zone, so that when the control unit, the actuator and the clutch member are calibrated by the method, the engagement member can be engaged in the third zone. Not engaging in the second zone, such as forcing engagement from the second zone using an actuator force greater than the axial force, can prevent friction between the clutch member components, such as friction caused directly or indirectly by repulsive forces. In addition, not engaging in the second zone can prevent grinding between rotating elements of the gear set that are complementary to the clutch member. The method can calibrate the control unit and the actuator so that the clutch member is actuated using an end device or a parking brake to lock the driven shaft. The method can be used to recalibrate the control unit and the actuator to actuate the clutch assembly when the characteristics of the clutch assembly change. For example, if the components of the clutch assembly are replaced or degraded, the characteristics of the clutch assembly may change. The control unit can be an electronic control unit (ECU). In another representation method, a system is provided. The system may include a motor, a processor having instructions stored in a memory, a dog clutch of a transmission, and a corresponding actuator controlled by the instructions and the processor based on one or more sensors. For example, the instructions may be configured to perform a method. The method may include locking a shaft of the transmission, positioning an actuator of the transmission in a prescribed position, commanding the motor to rotate at a selected speed; and updating an engagement threshold position when the motor stalls based on the prescribed position of the actuator. Subsequent operation of the clutch actuator may be adjusted based on the updated engagement threshold learned through such operation.

[0171] Although various embodiments are described above, it should be understood that these embodiments are examples only and not limitations. It is obvious to those familiar with the relevant technology that the disclosed subject matter can be embodied in other specific forms without departing from the spirit of the subject matter. Therefore, the embodiments described above should be regarded as illustrative and not restrictive in all respects. Therefore, the configurations and routines disclosed herein are exemplary in nature, and these specific examples should not be regarded as restrictive because there can be many variations. For example, the above-mentioned technology can be applied to power systems containing different types of propulsion sources, including different types of prime movers, internal combustion engines and / or transmissions. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of various systems and configurations, as well as other features, functions and / or attributes disclosed herein.

[0172] Please note that the control and estimation routine examples included herein can be used in various engine, motor, gearbox and / or vehicle system configurations. The control methods and routines disclosed herein can be stored as executable instructions in a non-transitory memory and can be executed by a control system including a controller in combination with various sensors, actuators and other engine hardware. The specific routines described herein may represent one or more of any number of processing strategies, such as event-driven, interrupt-driven, multi-tasking, multi-threading, etc. Therefore, the various actions, operations and / or functions illustrated can be performed in the order shown, can be performed in parallel, or omitted in some cases. Similarly, the processing order is not necessarily required to achieve the features and advantages of the example embodiments described herein, but is only for ease of illustration and description. One or more of the illustrated actions, operations and / or functions can be performed repeatedly, depending on the specific strategy being used. In addition, the described actions, operations and / or functions can graphically represent the code to be programmed into the non-transitory memory of a computer-readable storage medium in an engine control system, wherein the described actions are implemented by executing instructions in a system including various engine hardware components combined with an electronic controller.

[0173] It is understood that the configurations and routines disclosed herein are exemplary in nature, and these specific embodiments are not limiting, as there may be many variations. In addition, unless expressly stated to the contrary, the terms "first", "second", "third", etc. do not indicate any order, position, quantity, or importance, but are merely labels used to distinguish one element from another. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0174] The following claims particularly point out certain combinations and subcombinations regarded as novel and non-obvious. The claims may refer to "an" element or a "first" element or the equivalent. The claims should be understood to include one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amendment of the present claims or by presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, are also deemed to be included in the subject matter of the present disclosure.

Claims

1. A method for controlling engagement of a dog clutch in an electrified transmission system, comprising: Lock the transmission shaft; positioning an actuator of the transmission in a specified position; Command the motor to rotate at a selected speed; as well as When the motor is stalled, the engagement threshold position is updated based on the specified position of the actuator.

2. The method according to claim 1, wherein the actuator is actuated axially to close a functional gap in the same direction as another functional gap, wherein the other functional gap is closed by an axial force generated by a helix angle of a gear, wherein the gear can be engaged by the actuator.

3. The method of claim 2, wherein the transmission shaft is a driven shaft of the transmission, the method further comprising actuating an actuator according to the updated engagement threshold position during a subsequent engagement and / or disengagement process.

4. The method of claim 1 , wherein the engagement threshold position, the prescribed position, and the starting position are points on an axis along which the actuator and components of the dog clutch move in a direction parallel to the axis, wherein the starting position is the point at which the actuator positions the shift lever and components of the dog clutch prior to engaging or moving to the prescribed position to test the engagement threshold position.

5. The method according to claim 4, when the actuator is positioned at a specified position, a first event or a second event occurs, wherein in the first event, the engaging component connected to the actuator through the shift lever enters a repulsive zone, in which the actuator is subjected to a repulsive force and is pushed toward the starting position, and in the second event, the shift lever and the engaging component enter an attractive zone, in which the actuator is not pushed toward the starting position and causes the motor to stall when it is required to rotate.

6. The method of claim 5, wherein the repulsive force zone includes a first distance of the axis, the first distance including points from the starting position to a distance between a neutral threshold position and the engaged threshold position.

7. The method of claim 6, wherein the attraction zone includes a second distance of the axis, the second distance including a point where the distance from the starting position to the engagement threshold position is greater than the engagement threshold position.

8. The method of claim 7, wherein the dog clutch comprises the engagement member being complementary to a coupling member, wherein the engagement member comprises at least one first tooth and the coupling member comprises at least one second tooth.

9. The method of claim 8, wherein the engagement member is a sleeve and the coupling member is a coupling ring.

10. The method of claim 9, wherein the sleeve is an engagement ring.

11. A system for estimating a neutral threshold position, comprising: the transmission’s dog clutch; as well as processor and memory whose instructions are used to Lock the drive shaft; positioning the actuator at a specified position; Command the motor to rotate at a selected speed; as well as When the actuator is pushed in a direction opposite to the axis shift direction in the second test position, the neutral threshold position is updated to the first test position, wherein the shift direction is the direction in which the actuator shifts to engage the dog clutch, and the first test position is the last test position before the second test position.

12. The system of claim 11 wherein the neutral threshold position, the prescribed position, and the starting position are points on an axis that the actuator and components of the dog clutch move parallel to, wherein the starting position is the point at which the actuator positions the shift lever and components of the dog clutch before moving to the prescribed position to test the neutral threshold position.

13. The system of claim 14, wherein when the actuator is positioned in a specified position, a first event, a second event, or a third event occurs, during which a clutch shift engaging member coupled to the actuator enters a neutral zone through a shift lever, and no force from a motor driving a gear set is applied to the actuator, the gear set including a gear selectively coupled to the dog clutch; during the second event, the shift lever and the engaging member enter a repulsion zone, and a repulsion force is applied to the actuator, pushing the actuator toward the starting position.

14. The system of claim 13, wherein in each iteration of the method, the prescribed position is incremented by a step size multiplied by a first counter.

15. The system of claim 14, wherein in the first event, the speed and torque of the motor decrease, and the increase coefficient of the first counter is 1, in the second event, the method ends, and in the third event, the step size decreases and the first counter is reset to zero.

Images