An intelligent control method for an electronic hydraulic clutch of a motorcycle

Abstract

The present application relates to the technical field of motorcycle clutch intelligent control, in particular to an electronic hydraulic clutch intelligent control method for a motorcycle, comprising: an electronic hydraulic driver with integrated sensors is arranged in the oil circuit between the clutch master cylinder and the slave cylinder. When the master cylinder is operated, the system monitors the oil pressure at the input end of the driver, and when the first pressure threshold is reached, the internal motor is activated to assist in separating the clutch. The change in the input oil pressure is continuously monitored, and when the change reaches the preset increment threshold, the motor is activated again to further increase the separation stroke. This process naturally attenuates the input oil pressure change to zero as the driver volume changes. This method realizes dynamic and segmented intelligent assistance during the clutch separation process, reduces the operating force, and ensures the linearity of the control process and the natural continuity of the feel.

Description

Technical Field

[0001] This invention relates to the field of intelligent control technology for motorcycle clutches, and more particularly to an intelligent control method for an electro-hydraulic clutch used in motorcycles. Background Technology

[0002] Traditional motorcycle hydraulic clutch systems rely entirely on the hydraulic pressure generated by the rider operating the master cylinder via a lever, which is then transmitted directly to the slave cylinders through pipelines. To address the issue of arduous operation, existing technology proposes an improved solution by integrating an electronic power assist device into the hydraulic lines. These solutions typically activate a motor to provide auxiliary thrust when a fixed preset value of oil pressure is detected at the input end.

[0003] Existing technical solutions have limitations in their control logic. Their power assist triggering relies on a single absolute pressure threshold; once activated, the subsequent assist output mode is often fixed, failing to respond to the continuously changing details of the driver's hand movements during operation. This results in a lack of subtle synchronization between the actual clutch disengagement process and the driver's operational intentions, affecting the smoothness of gear shifting and the precision of operation. Furthermore, conventional systems do not fully consider the direct impact of the power assist unit's own operation on the input-side hydraulic state. When the internal plunger moves, it inevitably causes a change in the effective volume of the input pipeline, but existing designs do not incorporate this physical feedback into the control closed loop. This neglect may cause the system to interfere with the original pressure transmission characteristics of the hydraulic circuit, leading to distorted or inconsistent force feedback perceived by the driver's hands. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and propose an intelligent control method for an electro-hydraulic clutch in motorcycles.

[0005] The technical problems to be solved by this invention include: how to make the electronic power-assist process more precisely match the driver's continuous and dynamic hand operations, and how to make the power-assist system work without disrupting the direct and natural operating feel feedback of the original hydraulic system.

[0006] The present invention adopts the following technical solution.

[0007] A smart control method for an electro-hydraulic clutch in a motorcycle, comprising: An electro-hydraulic actuator is installed in the oil circuit between the main pump and the slave pump of the hydraulic clutch operated by the motorcyclist. The electro-hydraulic actuator integrates a displacement sensor, a pressure sensor and an actuator motor. When the motorcycle driver operates the main pump of the hand-operated hydraulic clutch, the oil pressure information at the input end of the electro-hydraulic actuator is obtained. When the oil pressure information at the input end reaches the preset first pressure threshold, the actuator motor in the electro-hydraulic actuator is activated. The actuator motor drives the plunger in the electro-hydraulic actuator to push hydraulic oil, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, and driving the piston of the hydraulic clutch slave pump to push the clutch to achieve disengagement; During the operation of the manual hydraulic clutch master pump, the oil pressure change information at the input end of the electro-hydraulic actuator is continuously monitored. When the oil pressure change at the input end reaches the preset first pressure increment threshold, the actuator motor is activated again to continue increasing the pipeline oil pressure at the output end of the electro-hydraulic actuator, so that the piston of the hydraulic clutch slave pump continues to push the clutch to increase the separation stroke. As the internal volume of the input end of the electro-hydraulic actuator changes, the oil pressure change at the input end gradually decreases until it returns to zero.

[0008] As a further aspect of the present invention, the method further includes: When the change in the input oil pressure returns to zero, and the input oil pressure information returns to the first pressure threshold, the actuator motor is controlled to stop working. During the operation of the manual hydraulic clutch master pump, the process of the input oil pressure information changing between the first pressure threshold and the sum of the first pressure threshold and the first pressure increment threshold is repeatedly executed, and the pipeline oil pressure at the output end of the electro-hydraulic actuator is continuously increased to meet the requirement of increasing the clutch disengagement stroke.

[0009] As a further aspect of the present invention, the provision of an electro-hydraulic actuator in the oil circuit between the master pump and slave pump of the motorcycle driver's hydraulic clutch specifically involves: The electro-hydraulic actuator has a first oil passage connected to the output pipeline of the main pump of the motorcycle hydraulic clutch, a second oil passage connected to the input pipeline of the slave pump of the motorcycle hydraulic clutch, and a third oil passage located between the first oil passage and the second oil passage. The actuator motor is connected to the plunger located in the third oil passage through a transmission mechanism. The reciprocating motion of the plunger is used to change the volume of the third oil passage, thereby driving the hydraulic oil. The pressure sensor is disposed inside the housing of the electro-hydraulic actuator and is used to monitor the input oil pressure information in the first oil passage; The displacement sensor is installed inside the housing of the electro-hydraulic actuator and is used to monitor the real-time displacement information of the plunger.

[0010] As a further aspect of the present invention, when the motorcycle driver operates the main pump of the manual hydraulic clutch, the oil pressure information at the input end of the electro-hydraulic actuator is obtained; when the oil pressure information at the input end reaches a preset first pressure threshold, the actuator motor in the electro-hydraulic actuator is activated, specifically as follows: The motorcycle driver squeezes the hydraulic clutch lever, which in turn operates the hydraulic clutch master pump to establish initial oil pressure in the hydraulic lines. The pressure sensor inside the electro-hydraulic actuator collects the oil pressure information at the input end of the electro-hydraulic actuator in real time; The real-time collected input oil pressure information is compared with the preset first pressure threshold stored in the electronic control unit memory. When the real-time collected oil pressure information at the input terminal is greater than or equal to the first pressure threshold, the electronic control unit sends an activation signal to the drive circuit of the actuator motor, and the activation signal controls the actuator motor to start rotating in the forward direction.

[0011] As a further aspect of the present invention, the step of controlling the actuator motor to drive the plunger in the electro-hydraulic actuator to push hydraulic oil, thereby increasing the pipeline oil pressure at the output end of the electro-hydraulic actuator, specifically involves: The actuator motor begins to rotate in the forward direction after receiving the activation signal from the electronic control unit; The output shaft of the actuator motor drives the plunger to move towards the output end along the third oil passage of the electro-hydraulic actuator through a worm gear transmission mechanism; The movement of the plunger compresses the hydraulic oil in the third oil passage and the second oil passage connected to it, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator.

[0012] As a further aspect of the present invention, during the operation of the manually operated hydraulic clutch main pump, the oil pressure change information at the input end of the electro-hydraulic actuator is continuously monitored. When the oil pressure change at the input end reaches a preset first pressure increment threshold, the actuator motor is reactivated. Specifically: After the actuator motor is activated for the first time and drives the plunger to move, the oil pressure information at the input end continues to be collected through the pressure sensor; The difference between the continuously collected input oil pressure information and the baseline oil pressure information at the last time the actuator was activated or stopped is calculated to obtain the change in input oil pressure. The calculated change in input oil pressure is compared with the preset first pressure increment threshold stored in the electronic control unit memory. When the change in oil pressure at the input terminal is greater than or equal to the first pressure increment threshold, the electronic control unit sends an activation signal to the drive circuit of the actuator motor again.

[0013] As a further aspect of the present invention, the change in oil pressure at the input terminal gradually decreases until it reaches zero as the internal volume of the input terminal of the electro-hydraulic actuator changes, specifically as follows: The actuator motor drives the plunger to continue moving towards the output end according to the reactivation signal of the electronic control unit; The movement of the plunger transmits force through hydraulic oil, causing a change in the volume of the connecting cavity between the input end of the electro-hydraulic actuator and the main pump of the manual hydraulic clutch. Because the change in the volume of the connecting cavity compensates for the increase in oil pressure caused by the driver operating the main pump of the hand-operated hydraulic clutch, the oil pressure information at the input end collected by the pressure sensor drops back. The electronic control unit continuously calculates the change in oil pressure at the input terminal until the change is less than the first pressure increment threshold and eventually returns to zero.

[0014] As a further aspect of the present invention, the method further includes a clutch engagement control step: When the motorcycle driver releases the hydraulic clutch lever, the system monitors the oil pressure drop at the input of the electro-hydraulic actuator. When the drop in oil pressure at the input end reaches the first pressure increment threshold, the actuator motor is controlled to rotate in the reverse direction. The reverse rotation of the actuator motor drives the plunger to move towards the input end, thereby reducing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, causing the piston of the hydraulic clutch slave pump to retract, and the clutch to engage. During this process, the internal volume of the input end of the electro-hydraulic actuator changes due to the movement of the plunger, and the oil pressure information at the input end changes between the first pressure threshold and the difference between the first pressure threshold and the first pressure increment threshold. By repeatedly executing the process of the input oil pressure information changing between the first pressure threshold and the difference between the first pressure threshold and the first pressure increment threshold, the pipeline oil pressure at the output end of the electro-hydraulic actuator is continuously reduced to meet the clutch engagement requirements.

[0015] As a further aspect of the present invention, the method further includes an automatic mode control step: The operating mode of the electro-hydraulic actuator is set to automatic mode; Receive shift request signals from the motorcycle's overall control system; Upon receiving a gear shift disengagement request signal, the actuator motor is directly activated to rotate forward without the driver needing to operate the manual hydraulic clutch master pump. This drives the plunger to move, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator and achieving automatic clutch disengagement. Based on the oil pressure information of the pipeline at the output end of the electro-hydraulic actuator monitored by the pressure sensor, and combined with the preset correspondence between the clutch separation stroke and the pipeline oil pressure, the operation of the actuator motor is controlled to achieve the target separation stroke. Upon receiving a gear shift engagement request signal, the actuator motor is controlled to rotate in the reverse direction, driving the plunger to move in the reverse direction to reduce the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, thereby achieving automatic clutch engagement.

[0016] As a further aspect of the present invention, the method further includes a failure protection step: When the motorcycle stalls, the system power supply fails, or the electronic control unit malfunctions, the power supply to the actuator motor is cut off. At this time, the plunger in the electro-hydraulic actuator is in a free state or is held in a preset position by a return spring, and the hydraulic oil pressure generated by the main pump of the manual hydraulic clutch is directly transmitted to the hydraulic clutch slave pump through the oil circuit in the electro-hydraulic actuator. The electro-hydraulic actuator does not affect the hydraulic circuit connectivity and operating force transmission between the main pump and the slave pump of the manually operated hydraulic clutch when the power is off.

[0017] Technical Effects: By monitoring the oil pressure changes at the input of the electro-hydraulic actuator and using the preset incremental threshold as a condition for multiple triggering of the actuator motor, dynamic and segmented assistance is achieved in the clutch disengagement process. Unlike methods that only trigger assistance once at the initial threshold point, this method dynamically converts the driver's continuous, variable-speed lever operation into a matching, phased auxiliary power output in real time. This makes the establishment of clutch disengagement force more gradual and linear, effectively eliminating the abruptness or interruption that may occur with traditional simple assistance. It ensures that the auxiliary force closely follows the driver's operational intentions, improving the delicacy, responsiveness, and smoothness of clutch control.

[0018] This invention, by sensing the gradual decrease in input hydraulic pressure until it reaches zero due to the execution of the motor-driven plunger during the assistance process, allows the system to naturally recognize the completion of a phased assistance action. This mechanism endows the electronic power steering system with internal feedback sensing capabilities for changes in hydraulic state caused by its own actions. Using this feedback, the system can adaptively determine when to stop the current stage of assistance output, thereby avoiding excessive disengagement or operational intervention that might occur due to continuous assistance without changing the driver's operating intention. This ensures that while the hydraulic system receives assistance to reduce operating force, it still maintains a clear, natural, and predictable clutch operating feel and feedback for the driver, preserving the coordination of human-machine interaction. Attached Figure Description

[0019] Figure 1 This is a flowchart of the intelligent control method for an electro-hydraulic clutch used in a motorcycle according to the present invention. Figure 2 The diagram shows the dynamic response curve of the electro-hydraulic clutch in a motorcycle. Figure 3 A flowchart for executing motor activation control; Figure 4 A dynamic line graph of the control hydraulic pressure during multiple cycles of clutch disengagement; Figure 5 A bar graph showing the relationship between the number of times the motor is activated and the increment of the input oil pressure in a motorcycle electro-hydraulic clutch. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] See Figure 1An intelligent control method for an electro-hydraulic clutch in a motorcycle is disclosed, the overall implementation of which is as follows: An electro-hydraulic actuator is installed in the oil circuit between the master pump and slave pump of the motorcycle's hand-operated hydraulic clutch. This electro-hydraulic actuator integrates a displacement sensor, a pressure sensor, and an actuator motor. When the motorcycle driver operates the master pump of the hand-operated hydraulic clutch, the oil pressure information at the input end of the electro-hydraulic actuator is acquired. When the oil pressure information at the input end reaches a preset first pressure threshold, the actuator motor within the electro-hydraulic actuator is activated. The actuator motor is controlled to drive the plunger within the electro-hydraulic actuator to push hydraulic oil, thereby lifting the... The oil pressure in the pipeline at the output end of the electro-hydraulic actuator drives the piston of the hydraulic clutch slave pump to push the clutch to disengage. During the operation of the manual hydraulic clutch master pump, the oil pressure change information at the input end of the electro-hydraulic actuator is continuously monitored. When the change in the input end oil pressure reaches the preset first pressure increment threshold, the actuator motor is activated again to continue to increase the pipeline oil pressure at the output end of the electro-hydraulic actuator, so that the piston of the hydraulic clutch slave pump continues to push the clutch to increase the disengagement stroke. As the internal volume of the input end of the electro-hydraulic actuator changes, the change in the input end oil pressure gradually decreases until it returns to zero.

[0022] In one embodiment of the present invention, in a specific implementation, the electronic control unit continuously monitors the oil pressure information at the input end of the electro-hydraulic actuator collected by the pressure sensor. During the operation of the hydraulic clutch master pump by the operator, when the change in oil pressure at the input end of the electro-hydraulic actuator returns to zero and the oil pressure information at the input end of the electro-hydraulic actuator returns to the first pressure threshold, the electronic control unit sends a stop signal to the drive circuit of the actuator motor to control the actuator motor to stop working. In some embodiments, the repeated execution of the above process constitutes the basis for increasing the clutch disengagement stroke. The electronic control unit monitors the periodic change of the oil pressure information at the input end of the electro-hydraulic actuator between the first pressure threshold and the sum of the first pressure threshold and the first pressure increment threshold, and accordingly activates and stops the actuator motor in each cycle, thereby gradually increasing the pipeline oil pressure at the output end of the electro-hydraulic actuator in each working cycle.

[0023] It is understandable that setting the specific value of the first pressure increment threshold will affect the relationship between the clutch lever operating force feedback and the rate of increase in the disengagement stroke. The value of the first pressure increment threshold is stored in the memory of the electronic control unit. In specific implementation, when the driver continuously squeezes the clutch lever, the manual hydraulic clutch master pump continuously outputs pressure, causing the oil pressure information at the input end of the electro-hydraulic actuator to rise from the initial value. Once the oil pressure information at the input end of the electro-hydraulic actuator reaches the first pressure threshold, the actuator motor is activated for the first time. As the actuator motor drives the plunger to move, the internal volume of the input end of the electro-hydraulic actuator changes, causing the oil pressure information at the input end of the electro-hydraulic actuator to fall back. During the fall back process, the electronic control unit calculates the real-time oil pressure change. The calculation of the oil pressure change follows the following relationship:

[0024] in: This represents the real-time oil pressure change during the current control cycle. This represents the instantaneous value of the oil pressure information at the input of the electro-hydraulic actuator, currently collected by the pressure sensor. This represents the baseline oil pressure value at the input of the electro-hydraulic actuator at the start of the nth control cycle or when the motor stopped during the previous cycle. When the preset first pressure increment threshold is reached, the actuator is reactivated to start a new pressurization cycle.

[0025] In practical implementation, the stepwise increase in pipeline oil pressure at the output end of the electro-hydraulic actuator directly corresponds to the gradual increase in the displacement of the hydraulic clutch slave pump piston, i.e., the gradual increase in clutch disengagement stroke. In some embodiments, the final output oil pressure required for complete clutch disengagement may be achieved through multiple cycles as described above. Each cycle causes the oil pressure information at the input end of the electro-hydraulic actuator to rise from a first pressure threshold. After reaching the sum of the first pressure threshold and the first pressure increment threshold, the actuator motor is triggered to operate. Subsequently, the oil pressure drops and stabilizes again at the first pressure threshold, and the actuator motor stops, completing one control cycle. It can be understood that by adjusting the size of the first pressure increment threshold, the increase in output oil pressure in each control cycle can be adjusted, thereby adjusting the granularity of the clutch disengagement stroke increase.

[0026] In one embodiment of the present invention, in a specific implementation, the housing of the electro-hydraulic actuator has a first oil passage connected to the output pipeline of the main pump of the motorcycle hydraulic clutch, a second oil passage connected to the input pipeline of the slave pump of the motorcycle hydraulic clutch, and a third oil passage located between the first oil passage and the second oil passage. In some embodiments, the first oil passage, the second oil passage, and the third oil passage are interconnected within the housing of the electro-hydraulic actuator through precision-machined channels, allowing hydraulic oil to flow between these oil passages. The actuator motor is connected to a plunger located in the third oil passage via a transmission mechanism. The reciprocating motion of the plunger changes the volume of the third oil passage, thereby driving the hydraulic oil. The transmission mechanism includes a worm gear assembly that converts the rotational motion of the actuator motor into the linear motion of the plunger. The plunger's seal ensures that the hydraulic oil in the third oil passage does not leak.

[0027] In specific implementations, a pressure sensor is installed inside the electro-hydraulic actuator housing to monitor the input oil pressure information in the first oil passage; a displacement sensor is installed inside the electro-hydraulic actuator housing to monitor the real-time displacement information of the plunger; in some embodiments, the sensing end of the pressure sensor is in direct contact with the hydraulic oil in the first oil passage to measure the oil pressure, and the probe of the displacement sensor is connected to the end or side of the plunger to obtain the position data of the plunger; optionally, the design of the electro-hydraulic actuator housing takes into account the sealing of the sensor installation, and the signal lines of the pressure sensor and the displacement sensor are led out through waterproof connectors and connected to the electronic control unit.

[0028] It is understandable that the change in the volume of the third oil passage is directly related to the displacement of the plunger, which is monitored by a displacement sensor. The relationship is described by the following formula:

[0029] in: The real-time volume representing the contents of the third oil passage. This represents the initial volume of the third oil passage when the plunger is in its initial position. Represents the cross-sectional area of ​​the plunger. This represents the real-time displacement information of the plunger monitored by the displacement sensor; in specific implementations, the plunger cross-sectional area... It is a fixed value determined by the diameter of the plunger. Therefore, the real-time volume of the third oil passage changes linearly with the plunger displacement. When the actuator drives the plunger to move, the volume of the third oil passage decreases, squeezing the hydraulic oil to flow to the second oil passage, thereby increasing the pipeline oil pressure at the output end of the electro-hydraulic actuator. Optionally, the electronic control unit can calculate the real-time volume change of the third oil passage based on the real-time displacement information of the plunger fed back by the displacement sensor and the known cross-sectional area of ​​the plunger, thereby assisting in controlling the operation of the actuator motor.

[0030] In practical implementation, the connection between the first oil passage and the output pipeline of the motorcycle hydraulic clutch main pump adopts a standard hydraulic connector, and the connection between the second oil passage and the input pipeline of the motorcycle hydraulic clutch slave pump also adopts a standard hydraulic connector to ensure reliable sealing and oil circuit connectivity. It can be understood that the third oil passage is located in the central area of ​​the electro-hydraulic actuator housing, the plunger slides in the third oil passage, and the two ends of the third oil passage are connected to the first oil passage and the second oil passage through internal channels respectively, forming a complete hydraulic passage. Optionally, the electro-hydraulic actuator housing is made of high-strength aluminum alloy, and the internal oil passages are polished to reduce hydraulic oil flow resistance.

[0031] The method for monitoring real-time piston displacement within the housing of an electro-hydraulic actuator relies on a non-contact linear displacement sensor. The sensor body is fixed within a specially machined mounting hole on the electro-hydraulic actuator housing. Inside the sensor body is an induction coil and a movable ferromagnetic core. The end of the ferromagnetic core is rigidly connected to the tail end of the piston via a non-magnetic connecting rod. When the piston reciprocates linearly within the third oil passage, it drives the ferromagnetic core to move synchronously within the induction coil. This change in the ferromagnetic core's position causes a linear change in the inductance of the induction coil. The sensor's built-in circuit converts this inductance change into a voltage or digital pulse signal output proportional to the displacement. This signal is transmitted via a shielded cable to the dedicated analog input channel or digital interface of the electronic control unit. The microcontroller inside the electronic control unit reads the signal at a fixed sampling frequency and maps the voltage or pulse value to a precise millimeter-level displacement value by looking up the sensor calibration data table stored in the memory. The calibration data table is measured and written to each sensor individually during the assembly process using a precision displacement platform, ensuring a definite and repeatable correspondence between the displacement measurement value and the actual position of the plunger. This method avoids the wear and jamming problems that may exist with mechanical contact sensors, and its response speed is sufficient to keep up with the dynamic process of the actuator motor driving the plunger to move.

[0032] The method for monitoring the input oil pressure information in the first oil passage employs an integrated silicon piezoresistive pressure sensor. The sensor's pressure-sensitive diaphragm forms part of the wall of the first oil passage, directly contacting the hydraulic oil to sense pressure changes. The minute deformation caused by the hydraulic oil acting on the diaphragm results in a change in the resistance value of the integrated Wheatstone bridge. The amplification and temperature compensation circuitry on the sensor chip amplifies the millivolt-level differential signal output from the bridge and converts it into a standard analog voltage signal. The range of this voltage signal strictly corresponds to the sensor's pressure measurement range. The analog voltage signal is output to the electronic control unit via an electrical interface on the electro-hydraulic actuator housing. The high-resolution analog-to-digital converter inside the electronic control unit samples this voltage signal at a rate of no less than one thousand times per second. The converter transforms continuous analog voltage into discrete digital codes. The microcontroller reads these digital codes and uses a linear conversion formula to calculate the corresponding oil pressure value. The parameters of this linear conversion formula, including zero offset and sensitivity coefficient, are measured and embedded in the electronic control unit's program at the time the sensor leaves the factory. To ensure long-term stability, the electronic control unit executes a self-test sequence every time the system is powered on. This sequence reads the output value of the pressure sensor under a known zero pressure state and compares it with the stored zero parameters. If there is a slight deviation, dynamic compensation is performed. This direct contact oil pressure monitoring method eliminates the errors that may be caused by indirect conversion and can reflect the hydraulic pressure established in the first oil passage when the driver operates the hydraulic clutch master pump in a true and real-time manner.

[0033] See Figure 2 This is a dynamic response curve of the electro-hydraulic clutch oil pressure in a motorcycle. This graph fully illustrates the oil pressure variation during two complete engagement-disengagement cycles. The green dashed line (first pressure threshold of 8 bar) is the core trigger point. Whenever the input oil pressure exceeds this threshold, the output oil pressure rises rapidly, which is completely consistent with the patent's description of "activating the actuator motor when the input oil pressure reaches the first pressure threshold." The output oil pressure is consistently significantly higher than the input oil pressure, demonstrating the amplification effect of the electro-hydraulic actuator, which aligns with the patent's design goal of "increasing the output pipeline oil pressure to increase the clutch disengagement stroke." During the motor activation phase, the input oil pressure experiences a slight drop (e.g., in the 0–2.5s range), which is a direct manifestation of the "compensation of oil pressure increment by changes in the connected cavity volume" mentioned in the patent.

[0034] In one embodiment of the present invention, see [reference] Figure 3In specific implementation, the motorcycle driver squeezes the hydraulic clutch lever, manually operating the hydraulic clutch master pump to establish initial oil pressure in the hydraulic lines; the pressure sensor in the electro-hydraulic actuator collects the oil pressure information at the input end of the electro-hydraulic actuator in real time, and the sampling signal of the pressure sensor is input to the electronic control unit through an analog-to-digital converter; the electronic control unit compares the real-time collected oil pressure information at the input end of the electro-hydraulic actuator with a preset first pressure threshold stored in the electronic control unit's memory, and the comparison operation is performed in each control cycle; in some embodiments, the judgment logic followed by the above comparison process can be expressed by the following relation:

[0035] in: This represents the instantaneous value of the oil pressure information at the input of the electro-hydraulic actuator, which is collected in real time by the pressure sensor. This represents a preset first pressure threshold stored in the electronic control unit's memory. When the real-time collected oil pressure information at the input end of the electro-hydraulic actuator is greater than or equal to the first pressure threshold, the electronic control unit sends an activation signal to the drive circuit of the actuator motor, and the activation signal controls the actuator motor to start rotating in the forward direction.

[0036] It is understandable that the continuous monitoring of the oil pressure information at the input end of the electro-hydraulic actuator by the electronic control unit is the basis for judging the driver's operating intention and initiating the power assist process. In specific implementation, the setting of the first pressure threshold needs to take into account the minimum working pressure of the hydraulic clutch system and avoid false triggering. This value is determined through calibration and stored in the memory of the electronic control unit. When the electronic control unit sends an activation signal to the drive circuit of the actuator motor, the actuator motor receives the activation signal from the electronic control unit and begins to rotate in the forward direction. In some embodiments, the output shaft of the actuator motor drives the plunger to move towards the output end along the third oil passage of the electro-hydraulic actuator through a worm gear transmission mechanism. The worm gear transmission mechanism has a self-locking characteristic and can maintain the position of the plunger when the actuator motor stops.

[0037] In practical implementation, the movement of the plunger compresses the hydraulic oil in the third oil passage and the connected second oil passage, causing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator to increase. The movement of the plunger causes the volume of the third oil passage to decrease, and according to hydraulic principles, this volume change is directly converted into an increase in pipeline oil pressure. Optionally, the electronic control unit can indirectly estimate or verify the change in pipeline oil pressure at the output end of the electro-hydraulic actuator by monitoring the displacement information of the plunger. It can be understood that the speed and torque of the actuator motor, after being reduced and amplified by the worm gear transmission mechanism, are converted into a linear force that pushes the plunger. This force is sufficient to overcome the back pressure of the hydraulic system and push the piston of the hydraulic clutch slave pump. Optionally, the drive circuit of the actuator motor receives a pulse width modulation signal from the electronic control unit to control the speed and direction of rotation of the actuator motor, thereby precisely adjusting the moving speed and displacement of the plunger.

[0038] In one embodiment of the present invention, after the actuator motor is activated for the first time and drives the plunger to move, the oil pressure information at the input end of the electro-hydraulic actuator continues to be collected by the pressure sensor. The electronic control unit calculates the difference between the continuously collected oil pressure information at the input end of the electro-hydraulic actuator and the baseline oil pressure information at the time when the actuator motor was last activated or stopped, and obtains the change in oil pressure at the input end of the electro-hydraulic actuator. In some embodiments, the baseline oil pressure information is determined based on the start time of a control cycle, that is, the value of the oil pressure information at the input end of the electro-hydraulic actuator tending to stabilize after the actuator motor stopped working, or the value of the oil pressure information at the input end of the electro-hydraulic actuator recorded at the moment when the actuator motor was last activated. The electronic control unit compares the calculated change in oil pressure at the input end of the electro-hydraulic actuator with a preset first pressure increment threshold stored in the memory of the electronic control unit. When the change in oil pressure at the input end of the electro-hydraulic actuator is greater than or equal to the first pressure increment threshold, the electronic control unit sends an activation signal to the drive circuit of the actuator motor again.

[0039] It is understood that the above calculation and comparison process is performed cyclically to achieve the tracking of the force of the driver's hand operating the hydraulic clutch master pump; in specific implementation, an exemplary oil pressure change and actuator response sequence can be illustrated by the following table, which shows the evolution relationship of key parameters in several consecutive control cycles starting from the initial state, see Table 1.

[0040] Table 1: Oil Pressure Changes and Motor Response During Clutch Disengagement

[0041] In practice, the actuator motor drives the plunger to continue moving towards the output end based on the reactivation signal from the electronic control unit. The movement of the plunger transmits force through hydraulic oil, causing a change in the volume of the connecting chamber between the input end of the electro-hydraulic actuator and the main pump of the manually operated hydraulic clutch. In some embodiments, the change in the volume of the connecting chamber compensates for the oil pressure increase caused by the driver operating the main pump of the manually operated hydraulic clutch, resulting in a drop in the oil pressure information at the input end of the electro-hydraulic actuator collected by the pressure sensor. The electronic control unit continuously calculates the change in oil pressure at the input end of the electro-hydraulic actuator until the change is less than the first pressure increment threshold and eventually returns to zero. This process is quantified using the following formula:

[0042] in: Represents at discrete time points The calculated real-time oil pressure change. Represents a point in time The instantaneous value of the oil pressure information at the input end of the electro-hydraulic actuator is acquired by the pressure sensor. This represents the constant baseline oil pressure value used during the current control cycle. When the value decreases from a positive value to below the first pressure increment threshold, the actuator enters a stop or standby state; this can be understood as... At the start of each new control cycle, the oil pressure is updated to the stable oil pressure value at the end of the previous cycle or the oil pressure value at the start of the cycle, thus ensuring that the reference for calculating the oil pressure change at the input of the electro-hydraulic actuator is accurate.

[0043] Optionally, the electronic control unit is equipped with a timer or displacement counter to monitor the longest running time or maximum displacement after a single activation of the actuator motor, as a safety protection to prevent system overload or jamming. In specific implementation, the movement of the plunger changes the volume of the third oil passage inside the electro-hydraulic actuator. The reduction in volume is equal to the volume of hydraulic oil pushed into the second oil passage and ultimately acting on the hydraulic clutch slave pump. Optionally, the rate and magnitude of the drop in oil pressure information at the input end of the electro-hydraulic actuator are related to the drive speed of the actuator motor, the cross-sectional area of ​​the plunger, and the stiffness of the hydraulic pipeline. The matching of these parameters needs to be considered during system design.

[0044] See Figure 4This is a dynamic line graph of the hydraulic pressure during multi-cycle clutch disengagement control. This graph fully presents the hydraulic pressure variation of a motorcycle's electro-hydraulic clutch over four consecutive control cycles. The blue curve (baseline hydraulic pressure) increases with each cycle, reflecting the patent's design of "updating the baseline to the stable hydraulic pressure value at the end of the previous cycle in each new cycle," ensuring accurate calculation of hydraulic pressure changes. The orange curve (first pressure increment threshold, constant at 0.5 bar) is the core trigger line. When the yellow curve (hydraulic pressure change) is ≥0.5 bar, the actuator motor is activated; when the hydraulic pressure change is <0.5 bar, the motor remains in standby mode. The yellow curve (hydraulic pressure change) decreases cycle by cycle, directly reflecting the patent's design of "compensating for hydraulic pressure increments by changes in the volume of the connecting chamber, causing the hydraulic pressure change to gradually decrease until it reaches zero," verifying the system's dynamic tracking capability. This graph clearly shows the hydraulic pressure evolution process under multi-cycle control and can be used to analyze the correspondence between piston displacement and hydraulic pressure change, providing a basis for system parameter matching.

[0045] In one embodiment of the present invention, when the motorcycle driver releases the hydraulic clutch lever, the electronic control unit monitors the oil pressure drop information at the input end of the electro-hydraulic actuator. This oil pressure drop information is continuously collected by a pressure sensor and transmitted to the electronic control unit. The electronic control unit calculates the amount of oil pressure drop at the input end of the electro-hydraulic actuator. When the amount of oil pressure drop reaches a first pressure increment threshold, the electronic control unit controls the actuator motor to rotate in the reverse direction. In some embodiments, the process of calculating the oil pressure drop follows the following relationship:

[0046] in: This represents the real-time calculated drop in oil pressure at the input of the electro-hydraulic actuator. This represents the baseline value of the electro-hydraulic actuator input oil pressure determined at the start of the clutch engagement control cycle. This represents the instantaneous value of the oil pressure at the input of the electro-hydraulic actuator, acquired by the pressure sensor at time point t; when When the pressure increment is greater than or equal to the preset first pressure increment threshold, the motor is triggered to rotate in the reverse direction.

[0047] The actuator motor rotates in the reverse direction, driving the plunger to move towards the input end, thereby reducing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator. This causes the piston of the hydraulic clutch slave pump to retract, and the clutch begins to engage. During this process, the internal volume of the electro-hydraulic actuator input end changes due to the plunger movement, and the oil pressure information at the input end of the electro-hydraulic actuator changes between a first pressure threshold and the difference between the first pressure threshold and the first pressure increment threshold. It can be understood that the engagement process is the reverse process of the disengagement process. By repeatedly executing the process of the oil pressure information at the input end of the electro-hydraulic actuator changing between the first pressure threshold and the difference between the first pressure threshold and the first pressure increment threshold, the electronic control unit periodically activates the actuator motor to rotate in the reverse direction, thereby continuously reducing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator to meet the requirement of smooth clutch engagement. Optionally, the first pressure increment threshold during clutch engagement can be the same value set during disengagement, or it can be set independently to a different value to adapt to different requirements for smoothness during engagement.

[0048] In specific implementation, the electro-hydraulic actuator is set to automatic mode. When the motorcycle's overall control system needs to shift gears, it sends a shift request signal to the electronic control unit of the electro-hydraulic actuator. The electronic control unit receives the shift request signal from the motorcycle's overall control system. Upon receiving the shift disengagement request signal, without the driver's manual operation of the hydraulic clutch master pump, the electronic control unit directly activates the actuator motor to rotate forward, driving the plunger to move and increase the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, thereby achieving automatic clutch disengagement. In some embodiments, based on the oil pressure information in the pipeline at the output end of the electro-hydraulic actuator monitored by the pressure sensor, combined with the pre-set correspondence between the clutch disengagement stroke and the pipeline oil pressure stored in the electronic control unit, the electronic control unit controls the operating time, speed, or target displacement of the actuator motor to achieve the target disengagement stroke. Upon receiving the shift engagement request signal, the electronic control unit controls the actuator motor to rotate in reverse, driving the plunger to move in reverse to reduce the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, thereby achieving automatic clutch engagement.

[0049] It is understood that the automatic mode control steps enable the motorcycle to achieve rapid gear shifting or automatic clutch operation in autonomous driving scenarios. When the motorcycle stalls, the system power fails, or the electronic control unit malfunctions, the electro-hydraulic actuator enters the fail-safe step. In specific implementations, the fail-safe circuit or the electronic control unit cuts off the power supply to the actuator motor. At this time, the plunger in the electro-hydraulic actuator is in a free state or is held in a preset position by a return spring. The hydraulic oil pressure generated by the master pump of the manual hydraulic clutch is directly transmitted to the slave pump of the hydraulic clutch through the oil circuit in the electro-hydraulic actuator. In some embodiments, the return spring is installed in the third oil passage, which pushes the plunger back to a position that minimizes the resistance between the first and second oil passages when there is no power supply. The electro-hydraulic actuator does not affect the hydraulic oil circuit connectivity and operating force transmission between the master pump and slave pump of the manual hydraulic clutch when there is no power, thereby ensuring the basic control functions of the motorcycle.

[0050] See Figure 5 This is a bar chart showing the relationship between the number of times the motor is activated and the increase in input hydraulic pressure in a motorcycle's electro-hydraulic clutch. As the number of activations increases from 1 to 6, the corresponding increase in hydraulic pressure shows a continuous decreasing trend. The increase is approximately 0.8 MPa at the first activation and drops to approximately 0.55 MPa at the sixth. This trend perfectly matches the description in the technical documentation that "after each motor activation, the change in input hydraulic pressure gradually decreases until it reaches zero." Each motor activation pushes the plunger to move, compensating for the increase in hydraulic pressure caused by the driver's operation, causing the input hydraulic pressure to drop. As the disengagement stroke gradually increases, the hydraulic pressure increase required by the system continuously decreases, ultimately achieving complete clutch disengagement.

Claims

1. A method for intelligent control of an electro-hydraulic clutch for a motorcycle, characterized in that, Includes the following steps: An electro-hydraulic actuator is installed in the oil circuit between the main pump and the slave pump of the hydraulic clutch operated by the motorcyclist. The electro-hydraulic actuator integrates a displacement sensor, a pressure sensor and an actuator motor. When the motorcycle driver operates the main pump of the hand-operated hydraulic clutch, the oil pressure information at the input end of the electro-hydraulic actuator is obtained. When the oil pressure information at the input end reaches the preset first pressure threshold, the actuator motor in the electro-hydraulic actuator is activated. The actuator motor drives the plunger in the electro-hydraulic actuator to push hydraulic oil, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, and driving the piston of the hydraulic clutch slave pump to push the clutch to achieve disengagement; During the operation of the manual hydraulic clutch master pump, the oil pressure change information at the input end of the electro-hydraulic actuator is continuously monitored. When the oil pressure change at the input end reaches the preset first pressure increment threshold, the actuator motor is activated again to continue increasing the pipeline oil pressure at the output end of the electro-hydraulic actuator, so that the piston of the hydraulic clutch slave pump continues to push the clutch to increase the separation stroke. As the internal volume of the input end of the electro-hydraulic actuator changes, the oil pressure change at the input end gradually decreases until it returns to zero.

2. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, The method further includes: When the change in the input oil pressure returns to zero and the input oil pressure information returns to the first pressure threshold, the actuator motor is controlled to stop working. During the operation of the manual hydraulic clutch master pump, the process of the input oil pressure information changing between the first pressure threshold and the sum of the first pressure threshold and the first pressure increment threshold is repeatedly executed, and the pipeline oil pressure at the output end of the electro-hydraulic actuator is continuously increased to meet the requirement of increasing the clutch disengagement stroke.

3. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, The provision of an electro-hydraulic actuator in the oil circuit between the master pump and slave pump of the motorcycle driver's hydraulic clutch specifically involves: The electro-hydraulic actuator has a first oil passage connected to the output pipeline of the main pump of the motorcycle hydraulic clutch, a second oil passage connected to the input pipeline of the slave pump of the motorcycle hydraulic clutch, and a third oil passage located between the first oil passage and the second oil passage. The actuator motor is connected to the plunger located in the third oil passage through a transmission mechanism. The reciprocating motion of the plunger is used to change the volume of the third oil passage, thereby driving the hydraulic oil. The pressure sensor is disposed inside the housing of the electro-hydraulic actuator and is used to monitor the input oil pressure information in the first oil passage; The displacement sensor is installed inside the housing of the electro-hydraulic actuator and is used to monitor the real-time displacement information of the plunger.

4. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, When the motorcycle driver operates the manual hydraulic clutch master pump, the oil pressure information at the input terminal of the electro-hydraulic actuator is obtained. When the oil pressure information at the input terminal reaches a preset first pressure threshold, the actuator motor in the electro-hydraulic actuator is activated. Specifically: The motorcycle driver squeezes the hydraulic clutch lever, which in turn operates the hydraulic clutch master pump to establish initial oil pressure in the hydraulic lines. The pressure sensor inside the electro-hydraulic actuator collects the oil pressure information at the input end of the electro-hydraulic actuator in real time; The real-time collected input oil pressure information is compared with the preset first pressure threshold stored in the electronic control unit memory. When the real-time collected oil pressure information at the input terminal is greater than or equal to the first pressure threshold, the electronic control unit sends an activation signal to the drive circuit of the actuator motor, and the activation signal controls the actuator motor to start rotating in the forward direction.

5. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, The control of the actuator motor to drive the plunger in the electro-hydraulic actuator to push hydraulic oil, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, specifically involves: The actuator motor begins to rotate in the forward direction after receiving the activation signal from the electronic control unit; The output shaft of the actuator motor drives the plunger to move towards the output end along the third oil passage of the electro-hydraulic actuator through a worm gear transmission mechanism; The movement of the plunger compresses the hydraulic oil in the third oil passage and the second oil passage connected to it, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator.

6. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, During the operation of the manual hydraulic clutch main pump, the oil pressure change information at the input end of the electro-hydraulic actuator is continuously monitored. When the oil pressure change at the input end reaches a preset first pressure increment threshold, the actuator motor is reactivated. Specifically: After the actuator motor is activated for the first time and drives the plunger to move, the input oil pressure information continues to be collected through the pressure sensor; The difference between the continuously collected input oil pressure information and the baseline oil pressure information at the last time the actuator was activated or stopped is calculated to obtain the change in input oil pressure. The calculated change in input oil pressure is compared with the preset first pressure increment threshold stored in the electronic control unit memory. When the change in oil pressure at the input terminal is greater than or equal to the first pressure increment threshold, the electronic control unit sends an activation signal to the drive circuit of the actuator motor again.

7. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 6, characterized in that, As the internal volume of the input terminal of the electro-hydraulic actuator changes, the change in oil pressure at the input terminal gradually decreases until it reaches zero. Specifically: The actuator motor drives the plunger to continue moving towards the output end according to the reactivation signal of the electronic control unit; The movement of the plunger transmits force through hydraulic oil, causing a change in the volume of the connecting cavity between the input end of the electro-hydraulic actuator and the main pump of the manual hydraulic clutch. Because the change in the volume of the connecting cavity compensates for the increase in oil pressure caused by the driver operating the main pump of the hand-operated hydraulic clutch, the oil pressure information at the input end collected by the pressure sensor drops back. The electronic control unit continuously calculates the change in oil pressure at the input terminal until the change is less than the first pressure increment threshold and eventually returns to zero.

8. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, The method also includes a clutch engagement control step: When the motorcycle driver releases the hydraulic clutch lever, the system monitors the oil pressure drop at the input of the electro-hydraulic actuator. When the drop in oil pressure at the input end reaches the first pressure increment threshold, the actuator motor is controlled to rotate in the reverse direction. The reverse rotation of the actuator motor drives the plunger to move towards the input end, thereby reducing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, causing the piston of the hydraulic clutch slave pump to retract, and the clutch to engage. During this process, the internal volume of the input end of the electro-hydraulic actuator changes due to the movement of the plunger, and the oil pressure information at the input end changes between the first pressure threshold and the difference between the first pressure threshold and the first pressure increment threshold. By repeatedly executing the process of the input oil pressure information changing between the first pressure threshold and the difference between the first pressure threshold and the first pressure increment threshold, the pipeline oil pressure at the output end of the electro-hydraulic actuator is continuously reduced to meet the clutch engagement requirements.

9. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, The method also includes an automatic mode control step: The operating mode of the electro-hydraulic actuator is set to automatic mode; Receive shift request signals from the motorcycle's overall control system; Upon receiving a gear shift disengagement request signal, the actuator motor is directly activated to rotate forward without the driver needing to operate the manual hydraulic clutch master pump. This drives the plunger to move, thereby increasing the oil pressure in the pipeline at the output end of the electro-hydraulic actuator and achieving automatic clutch disengagement. Based on the oil pressure information of the pipeline at the output end of the electro-hydraulic actuator monitored by the pressure sensor, and combined with the preset correspondence between the clutch separation stroke and the pipeline oil pressure, the operation of the actuator motor is controlled to achieve the target separation stroke. Upon receiving a gear shift engagement request signal, the actuator motor is controlled to rotate in the reverse direction, driving the plunger to move in the reverse direction to reduce the oil pressure in the pipeline at the output end of the electro-hydraulic actuator, thereby achieving automatic clutch engagement.

10. The intelligent control method for an electro-hydraulic clutch in a motorcycle according to claim 1, characterized in that, The method also includes a fail-safe step: When the motorcycle stalls, the system power supply fails, or the electronic control unit malfunctions, the power supply to the actuator motor is cut off. At this time, the plunger in the electro-hydraulic actuator is in a free state or is held in a preset position by a return spring, and the hydraulic oil pressure generated by the main pump of the manual hydraulic clutch is directly transmitted to the hydraulic clutch slave pump through the oil circuit in the electro-hydraulic actuator. The electro-hydraulic actuator does not affect the hydraulic circuit connectivity and operating force transmission between the main pump and the slave pump of the manually operated hydraulic clutch when the power is off.

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