Adaptive Engine and Transmission Control for Off-Highway Machines
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Solution Overview
Problem
Existing engine and transmission control systems for machines, such as off-highway vehicles, face challenges in accurately controlling engine speed and transmission output torque due to variations in operating environments and component wear, leading to inefficiencies and increased CO2 emissions.
Innovation Solution
A control system that includes adaptive adjustment modules to determine current machine operating patterns based on multiple operating parameters, comparing them to predefined patterns, and adjusting engine speed and transmission output speed accordingly, using a combination of fuel control and variable speed member displacement to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque control mappings are used to control hydraulic variator, then torque control is achieved, but accuracy deteriorates due to operating environment variations, machine variations, and tolerance changes
Solution Approach 1:
The patent implements a closed-loop feedback control system that continuously monitors actual torque output and compares it with desired torque. The controller adjusts the hydraulic variator control pressure based on the torque error signal, enabling real-time compensation for mapping inaccuracies caused by environmental variations, machine differences, and component wear. This feedback mechanism maintains accurate torque control despite changes in operating conditions.
Solution Approach 2:
The system dynamically adjusts control parameters including hydraulic pressure, flow rate, and variator ratio based on real-time operating conditions. The controller modifies these parameters to optimize torque control accuracy across different operating environments, machine configurations, and component wear states, moving beyond fixed mappings to adaptive parameter control.
2Productivity
If gain factors are optimized for closed-loop control, then system performance improves, but effectiveness deteriorates when components wear or operating state changes
Solution Approach 1:
The patent employs dynamic gain scheduling where controller gains are adjusted based on real-time operating conditions such as engine speed, load, and hydraulic pressure. Rather than using fixed gain factors, the system adapts gain values to match current operating state, maintaining optimal response characteristics and control accuracy throughout the component lifecycle and across varying operating conditions.
Solution Approach 2:
The control system performs self-adjustment by continuously monitoring its own performance and automatically modifying control parameters to maintain optimal operation. The controller adapts to component wear and operating changes without external intervention, maintaining productivity and accuracy through autonomous parameter optimization.
3Productivity
If CVT is used to increase transmission efficiency, then engine can run at constant speed, but hydraulic elements apply load causing engine stalling or lugging
Solution Approach 1:
The system uses feedback control to monitor engine speed and torque output, adjusting hydraulic variator pressure to maintain engine operation within stable parameters. When hydraulic load threatens to cause stalling or lugging, the controller reduces variator pressure or adjusts the ratio to relieve excessive load, ensuring engine stability while maintaining high transmission efficiency.
Solution Approach 2:
The hydraulic variator acts as an intermediary between the engine and the mechanical load, providing smooth torque multiplication and speed variation. By continuously adjusting the variator ratio and control pressure, the system mediates the interaction between engine output and transmission demand, preventing direct load shocks that cause stalling while maintaining efficiency.
4Stability of the object's composition
If transmission ratio is controlled based on error signal, then engine speed variation is minimized, but system complexity increases due to precise control requirements
Solution Approach 1:
The patent combines multiple control functions into a single integrated controller that manages both engine parameters and hydraulic variator operations. By merging torque control, speed regulation, and ratio management into one control unit with unified feedback loops, the system achieves precise engine speed stability without proportionally increasing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the efficiency and productivity of machines by precisely managing load and power distribution, reducing the risk of engine stalling and lugging, and minimizing CO2 emissions by optimizing engine and transmission performance in response to changing operating conditions.
Implementation Method 1
receiving signals indicative of multiple operating parameters of the machine; determining a current machine operating pattern based on the multiple operating parameters
Implementation Method 2
a first controller in communication with an engine, the first controller being configured to control a speed of the engine based on supply of fuel
Implementation Method 3
a variable speed member drivably coupled to the engine of the machine; a second controller in communication with the variable speed member, the second controller being configured to control an output speed of the variable speed member
Data Source
AI summary
A method of controlling a machine is disclosed. The method includes receiving signals indicative of multiple operating parameters of the machine. The method further includes determining a current machine operating pattern based on the multiple operating parameters. The method further includes comparing the determined current machine operating pattern with reference to a plurality of predefined machine operating patterns and controlling at least one of a speed of an engine and an output speed of a variable speed member based on the comparison of the determined current machine operating pattern. The variable speed member is drivably coupled to the engine of the machine.