Dual Clutch Gearbox Synchronization Sleeve Position Forecasting
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Solution Overview
Problem
Double-clutch gearboxes experience inaccuracies in synchronization sleeve control due to axial clearances and deformations caused by torque transmission, leading to degraded comfort and wear risks.
Innovation Solution
A method for calculating the positions of synchronization sleeves by applying a predetermined engine torque setpoint curve during preparation, measuring, and storing positions, then using these values to forecast positions during driving, accounting for clearances and flexibilities, thereby facilitating smooth gear engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional synchronization control methods are used, then gear engagement can be achieved, but inaccuracies occur due to axial clearances and deformations under torque, leading to degraded comfort and wear risks
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing the positions of particular points on synchronization sleeves under various torque conditions during a preparation phase. These pre-acquired position data are then used during actual gear engagement to compensate for axial clearances and deformations, eliminating the need for real-time measurement and correction while improving position accuracy and reducing wear.
2Measurement precision
If real-time measurement and correction of sleeve positions were implemented, then accuracy would improve, but system complexity and computational load would increase
Solution Approach 1:
The patent avoids real-time measurement and correction by performing all necessary calculations and measurements in advance during a preparation phase. The control computer stores pre-calculated position data for particular points on synchronization sleeves under various torque conditions. During actual gear engagement, the system simply retrieves and applies the appropriate pre-calculated positions based on current torque, significantly reducing computational load and system complexity while maintaining high accuracy.
3Ease of operation
If gear engagement is performed without compensation for torque-induced deformations, then the control process is simpler, but comfort is degraded and wear increases
Solution Approach 1:
The patent performs preliminary action by pre-calculating the positions of particular points on synchronization sleeves under various torque conditions during a preparation phase. The control computer stores these pre-acquired position data. During actual gear engagement, the system retrieves the appropriate pre-calculated positions based on current torque and uses them to control the synchronization sleeves, ensuring smooth engagement without noise or wear while keeping the control process relatively simple.
Data Source
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AI summary
Method for calculating the positions of specific points of sleeves for synchronising a gearbox, said gearbox comprising two half-boxes, each controlled by a clutch, wherein, in a preparation phase for each engaged gear ratio of a half-box, the method applies a predetermined engine torque set point curve and, over this set point curve, engages gear ratios of the other half-box, while measuring and storing positions of specific points (120, 122, 124) of the synchronisation sleeves when these engagement steps take place; subsequently, during running phases of the vehicle, the method calculates forecast positions for the specific points (120, 122, 124) by carrying out a comparison with the stored positions of the specific points (120, 122, 124).