DCT Gearbox Actuator Self-Calibration via Position Deviation
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Solution Overview
Problem
Dual-clutch gearbox actuators in vehicles experience wear and fatigue, leading to non-optimal positioning and malfunctions, requiring manual intervention for replacement and recalibration, which renders the vehicle unusable until after-sales service can update the actuator positions.
Innovation Solution
A method and device that automatically determine new actuator positions by calculating the difference between known and measured positions during a malfunction, allowing for automatic updating of the correspondence table, enabling precise repositioning without driver or technician intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If actuators are manually replaced and recalibrated at after-sales service, then positioning precision is restored, but vehicle downtime increases and driver convenience deteriorates
Solution Approach 1:
The system performs self-diagnosis and self-calibration by automatically detecting actuator positioning problems and updating the correspondence table without requiring external technician intervention. The control unit continuously monitors actuator positions and autonomously corrects deviations by updating stored position data.
Solution Approach 2:
The system performs preliminary calibration actions by pre-storing correspondence tables that map actuator positions to gear selection states. When deviations are detected, the system uses these pre-stored references to automatically recalibrate, avoiding the need for manual repositioning and reducing downtime.
2Reliability
If actuators are manually replaced at after-sales service, then gearbox reliability is restored, but ease of operation deteriorates due to immediate service requirement
Solution Approach 1:
The control unit automatically detects reliability issues by monitoring actuator positioning deviations and performs self-correction by updating the correspondence table. This eliminates the need for the vehicle to be taken to service centers, maintaining continuous usability while restoring reliability.
Solution Approach 2:
The system continuously monitors actuator positions during gear selection operations and provides feedback to the control unit. When positioning deviations are detected, the feedback loop triggers automatic recalibration, ensuring reliability is maintained without interrupting vehicle operation.
3Measurement precision
If actuator positions are updated manually, then positioning accuracy is restored, but device complexity increases due to service intervention requirements
Solution Approach 1:
The control unit automatically performs position calibration by detecting deviations and updating the correspondence table without requiring technician intervention or complex service procedures. The system simplifies the overall process by eliminating manual service steps while maintaining positioning accuracy.
Solution Approach 2:
The system restores positioning accuracy by changing the stored position parameters in the correspondence table based on detected deviations. Instead of physical actuator replacement or manual repositioning, the solution updates the digital parameter data, simplifying the correction process while restoring precision.
Data Source
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AI summary
A device (DD) is intended to determine, in a vehicle, new positions of actuators (AC1-AC2) of a DCT gearbox (BV) comprising two portions (PB1-PB2) having at least one actuator (AC1) able to act on an associated synchroniser (S1) when it is placed in known positions stored in a table, corresponding with known engine torques and transmitted to the other portion. This device (DD) is suitable, in the event of detecting a problem resulting from a movement of an actuator (AC1) of one portion (PB1), for determining, in the table, the known position of this actuator (AC1) which is associated with a known engine torque corresponding to the engine torque transmitted to the other portion (PB2) during the detected problem, then for determining a difference between this known position and a position of the actuator (AC1) measured during the detected problem, and for replacing, in the table, this known position by a new position according to the difference determined.