DCT Hydraulic Power Control System Pressure Management
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Solution Overview
Problem
Existing DCT hydraulic power control systems suffer from excessive power consumption due to poor control characteristics.
Innovation Solution
A method for operating a DCT hydraulic power control system that includes a high pressure section for activating clutches and synchronizers, a low pressure section for cooling and lubrication, and regulator means to direct excess oil to a lubrication and cooling system, with specific valve operations to manage pressure and reduce power consumption across different speed modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is maintained in the high pressure section for clutch and synchronizer activation, then control characteristics are improved, but power consumption increases
Solution Approach 1:
The system dynamically adjusts pressure levels based on operating conditions. In medium speed mode, the high pressure section is activated only when clutch engagement is required, while in low speed mode, both pump outlets operate in parallel to maintain high pressure continuously. This dynamic adaptation resolves the contradiction by maintaining reliable control only when necessary while reducing power consumption during normal operation.
Solution Approach 2:
The system changes pressure parameters according to speed modes. The high pressure section operates at elevated pressure levels during clutch activation, while the low pressure section maintains lower pressure levels for cooling and lubrication. This parameter differentiation allows the system to achieve reliable control characteristics when needed while minimizing overall power consumption through selective high pressure operation.
2Reliability
If oil flow is directed to the high pressure section for clutch activation, then control function is improved, but system losses increase
Solution Approach 1:
The hydraulic system is segmented into two distinct pressure sections: a high pressure section for clutch and synchronizer activation, and a low pressure section for cooling and lubrication. This segmentation allows oil to be directed to the high pressure section only when activation is required, minimizing system losses by avoiding continuous high pressure operation while maintaining reliable activation function when needed.
3Power
If both pump outlets operate in parallel at high pressure, then power supply capability is improved, but power consumption increases
Solution Approach 1:
The pump operation is dynamically controlled based on speed modes and activation requirements. In medium speed mode, only one pump outlet operates at high pressure when needed, while the other maintains lower pressure. In low speed mode, both outlets operate in parallel to ensure sufficient power supply. This dynamic control resolves the contradiction by providing adequate power supply capability only when necessary while minimizing power consumption during normal operation.
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
The solution effectively lowers power consumption, especially in medium speed mode, by optimizing oil flow and pressure management, widening the medium speed range and minimizing system losses, while maintaining flexibility and constant pressure in both sections.
Implementation Method 1
forcing oil to flow through a check valve disposed in a first branch line of the low pressure section leading to the high pressure section
Implementation Method 2
opening, in a medium speed mode, the directional valve of the low pressure section by activating an ON/OFF valve creating an ON/OFF pilot pressure for the directional valve
Implementation Method 3
pump means for providing desired oil flow under desired oil pressure conditions
Data Source
AI summary
A DCT hydraulic power control system has a pump, a high pressure section for providing oil to actuators of the DCT, a low pressure section for providing oil to a lubrication and cooling system of the DCT, and a regulator for directing excess oil from the high pressure section to the lubrication and cooling section. A hydraulic control includes a first directional valve disposed in a main line of the low pressure section between the pump and the lubrication and cooling system, wherein the directional valve is controlled by an ON/OFF valve disposed between a check valve and the directional valve, wherein the check valve is disposed in a branch line of the low pressure section leading to the high pressure section, and wherein a second directional valve connects the second pressure outlet associated to the low pressure section with a suction side of the pump.