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Development and Analysis of Synchronization Process Control Algorithms in a Dual Clutch Transmission

The Dual Clutch Transmission (DCT) is a relatively new kind of transmission which shows increased e\ufb03ciency and comfort compared to manual transmissions. Its construction is much like two parallell manual transmissions, where the gear- shifts are controlled automatically. The gear-shift of a manual transmission in- volves a synchronization process, which synchronizes and locks the input shaft to the output shaft via the desired gear ratio. This process, which means transporta- tion of a synchronizer sleeve, is performed by moving the gear shift lever which is connected to the sleeve. In a DCT, there is no mechanical connection between the gear-shift lever and the sleeve. Hence, an actuator system, controlled by a control system, must be used. This report includes modelling, control system design and simulation results of a DCT synchronization process. The thesis work is performed at GM Powertrain (GMPT) in Trollhättan. At the time of this thesis, there is no DCT produced by GM, and therefore the results and conclusions rely on simulations. Most of the used system parameters are reasonable values collected from employees at GMPT and manual transmission literature. The focus of the control design is to achieve a smooth, rather than fast, move- ment of the synchronizer sleeve. Simulations show that a synchronization process can be performed in less than 400 ms under normal conditions. The biggest prob- lems controlling the sleeve position occur if there is a large amount of drag torque a\ufb00ecting the input shaft. Delay problems also worsen the performance a lot. An attempt to predict the synchronizer sleeve position is made and simulations shows advantages of that. Some further work is needed before the developed control software can be used on a real DCT. Investigations of sensor noise robustness and the impact of dogging forces are the most important issues to be further investigated. Implementation of additional functionality for handling special conditions are also needed.

Andreas Gustavsson


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