Clutch Protection via Slip Energy Calculation
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Solution Overview
Problem
Manual transmission systems face challenges in protecting clutches from damage due to heat generation during clutch slip, especially during heavy vehicle launches, without relying on costly gear or clutch position sensors.
Innovation Solution
A clutch protection system that calculates clutch slip and energy based on input rotational velocity, limits torque requests using lookup tables, and controls the torque generating system to prevent clutch damage without requiring gear or clutch position sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gear position sensors or clutch position sensors are implemented to limit torque requests and protect the clutch, then clutch protection reliability is improved, but system cost increases
Solution Approach 1:
The system uses the torque generating system's own control capabilities to limit torque requests based on calculated clutch energy and slip conditions. The controller monitors rotational velocity, calculates clutch slip and energy accumulation, and automatically adjusts torque requests to prevent clutch damage without requiring external sensors.
Solution Approach 2:
The patent replaces mechanical sensor-based detection systems with a computational approach. Instead of using gear position sensors or clutch position sensors to detect slip conditions, the system calculates clutch slip and energy based on rotational velocity measurements and torque data, substituting physical sensing with mathematical modeling.
2Speed
If the clutch is allowed to slip during heavy launches to enable vehicle movement, then vehicle mobility is improved, but clutch temperature increases causing potential damage
Solution Approach 1:
The system calculates clutch energy accumulation in advance during slip conditions and predicts potential clutch damage before it occurs. By monitoring the rate of energy accumulation and comparing it against damage thresholds, the controller proactively limits torque requests to prevent excessive temperature rise and clutch damage before heavy launches complete.
Solution Approach 2:
The system continuously monitors rotational velocity, calculates clutch slip and energy accumulation, and uses this feedback to dynamically adjust torque requests. The controller modifies torque output based on real-time clutch conditions, creating a closed-loop control system that prevents overheating while allowing necessary slip during vehicle launches.
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
Effectively prevents clutch damage by predicting and limiting torque requests based on calculated clutch energy and slip, reducing the need for expensive sensors and ensuring safe operation.
Implementation Method 1
The friction between the clutch and the flywheel during clutch slip generates heat
Data Source
AI summary
Clutch protection systems and methods include calculating a slip of a clutch of a manual transmission based on an input rotational velocity of a flywheel coupled to a torque generating system. The calculated slip is used to calculate an energy into the clutch. In one implementation, an accumulated energy into the clutch is calculated based on a rate of the calculated energy and a torque request for the torque generating system is limited based on the accumulated energy. In one implementation, an energy capacity remaining in the clutch until a threshold indicative of damage occurring is calculated based on the calculated energy and a limited torque request for the torque generating system is generated. The limited torque request corresponds to an amount of allowable torque before full clutch engagement occurs, where this time is calculable based on a rate at which the clutch slip is decreasing.