Autonomous Manual Clutch Control System Reducing ECU Complexity

Solution Overview

Problem

The increasing complexity and cost of electronic control systems in vehicles, particularly in manual transmissions, due to the proliferation of multiple electronic control units (ECUs) that often provide more power than necessary, necessitate a solution to reduce ECU numbers and costs while maintaining system functionality and providing additional control benefits.

Innovation Solution

The autonomous manual transmission clutch control (AMTC) system, which pairs with existing electronic systems like the electronic belt alternator system (BAS) to utilize underutilized micro controllers and gate drives for control, communication, and cooling, reducing the need for dedicated ECUs and minimizing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple dedicated ECUs are used to control various vehicle systems, then system control functionality is improved, but system cost and complexity increase

Engineering Contradiction:

Improvesystem control functionalityVSAvoidnumber of ECUs

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies multi-functionality by enabling a single ECU to control multiple vehicle systems including the clutch actuator, alternator, and other accessories simultaneously. The ECU contains multiple independent control modules that can independently manage different functions, allowing one control unit to replace what would traditionally require multiple separate ECUs, thereby reducing system complexity while maintaining comprehensive control capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges previously separate control functions into a unified ECU architecture. The clutch control module, alternator control module, and other accessory control functions are integrated within a single ECU unit, combining multiple control responsibilities into one centralized system that manages all functions through coordinated operation of its internal modules

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple dedicated ECUs are used to control various vehicle systems, then system control functionality is improved, but system cost increases

Engineering Contradiction:

Improvesystem control functionalityVSAvoidsystem cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies multi-functionality by enabling a single ECU to control multiple vehicle systems including the clutch actuator, alternator, and other accessories simultaneously. The ECU contains multiple independent control modules that can independently manage different functions, allowing one control unit to replace what would traditionally require multiple separate ECUs, thereby reducing system complexity while maintaining comprehensive control capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges previously separate control functions into a unified ECU architecture. The clutch control module, alternator control module, and other accessory control functions are integrated within a single ECU unit, combining multiple control responsibilities into one centralized system that manages all functions through coordinated operation of its internal modules

Inventive Principle:

Principle #5Merging (Combining)

3Power

If the clutch plate is kept partially engaged to improve torque transfer, then torque transfer performance is improved, but clutch wear increases

Engineering Contradiction:

Improvetorque transferVSAvoidclutch life

Core Design Contradiction:

PowerVSDuration of action of stationary object

Solution Approach 1:

The patent applies dynamics by implementing continuous, real-time adjustment of the clutch plate engagement state rather than maintaining a fixed position. The ECU continuously monitors vehicle operating conditions and dynamically modifies the actuator command signals to optimize the clutch plate slip amount, allowing the system to adaptively balance torque transfer performance with clutch wear prevention based on changing operational requirements

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent applies feedback by using sensors to continuously monitor clutch plate position, engagement state, and related parameters, then feeding this information back to the ECU which adjusts the actuator commands accordingly. This closed-loop control ensures the clutch operates optimally by preventing excessive wear while maintaining adequate torque transfer, with the system self-correcting based on actual operating conditions

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS10099674B2System for controlling manual clutch

Publication Date: 2018.10.16 BORGWARNER INC

AI summary

An electronically operated autonomous manual transmission clutch system and a second electronically operated vehicle system, such as a belted alternator starter system (BAS), in which the ECU and micro controller of the second electronic system are utilized for both systems.