Optimal design of an electro-hydraulic valve for heavy-duty vehicle clutch actuator with certain constraints

Abstract The main objective of this paper is to investigate the sensitivity analysis and optimal design of a proportional solenoid valve (PSV) operated pressure reducing valve (PRV) for heavy-duty automatic transmission clutch actuators. The nonlinear electro-hydraulic valve model is developed based on fluid dynamics. In order to implement the sensitivity analysis and optimization for the PRV, the PSV model is validated by comparing the results with data obtained from a real test-bench. The sensitivity of the PSV pressure response with regard to the structural parameters is investigated by using Sobol׳s method. Finally, simulations and experimental investigations are performed on the optimized prototype and the results reveal that the dynamical characteristics of the valve have been improved in comparison with the original valve.

[1]  Riccardo Amirante,et al.  Fluid-dynamic design optimization of hydraulic proportional directional valves , 2014 .

[2]  Guillermo Palau-Salvador,et al.  Three-Dimensional Modeling and Geometrical Influence on the Hydraulic Performance of a Control Valve , 2008 .

[3]  Jianqiu Li,et al.  Combined AFS and DYC Control of Four-Wheel-Independent-Drive Electric Vehicles over CAN Network with Time-Varying Delays , 2014, IEEE Transactions on Vehicular Technology.

[4]  Agusmian Partogi Ompusunggu.  On the derivation of the pre-lockup feature based condition monitoring method for automatic transmission clutches , 2014 .

[5]  Jinwu Gao,et al.  Antishudder Gearshift Controller Design for Automatic Transmission , 2011, IEEE Transactions on Vehicular Technology.

[6]  Zongxuan Sun,et al.  Pressure-Based Clutch Control for Automotive Transmissions Using a Sliding-Mode Controller , 2012, IEEE/ASME Transactions on Mechatronics.

[7]  W. Y. Li,et al.  Method for precise controlling of the at shift control system , 2014 .

[8]  Li Chen,et al.  Experimental study on improvement in the shift quality for an automatic transmission using a motor-driven wedge clutch , 2014 .

[9]  Hong Jiang,et al.  Shift control strategy and experimental validation for dry dual clutch transmissions , 2014 .

[10]  Harald Aschemann,et al.  Nonlinear model-predictive control with hysteresis compensation of an electro-pneumatic clutch for truck applications , 2014 .

[11]  Zongxuan Sun,et al.  Challenges and opportunities in automotive transmission control , 2005, Proceedings of the 2005, American Control Conference, 2005..

[12]  Hyunsoo Kim,et al.  Development of Brake System and Regenerative Braking Cooperative Control Algorithm for Automatic-Transmission-Based Hybrid Electric Vehicles , 2015, IEEE Transactions on Vehicular Technology.

[13]  Hui Zhang,et al.  Vehicle Lateral Dynamics Control Through AFS/DYC and Robust Gain-Scheduling Approach , 2016, IEEE Transactions on Vehicular Technology.

[14]  Maarten Steinbuch,et al.  Fast and Smooth Clutch Engagement Control for a Mechanical Hybrid Powertrain , 2014, IEEE Transactions on Control Systems Technology.

[15]  Perry Y. Li,et al.  Robust Optimal Design of Unstable Valves , 2007, IEEE Transactions on Control Systems Technology.

[16]  Rui Liu,et al.  A simplified approach to force control for electro-hydraulic systems☆ , 2000 .

[17]  Peyman Yadmellat,et al.  Adaptive Modeling of a Magnetorheological Clutch , 2014, IEEE/ASME Transactions on Mechatronics.

[18]  Ilya M. Sobol,et al.  Sensitivity Estimates for Nonlinear Mathematical Models , 1993 .

[19]  H. E. Merritt,et al.  Hydraulic Control Systems , 1991 .

[20]  Chen Huiyan,et al.  Research on Control Strategy of Shifting Progress , 2008 .

[21]  Dongpu Cao,et al.  System Modeling and Pressure Control of a Clutch Actuator for Heavy-Duty Automatic Transmission Systems , 2016, IEEE Transactions on Vehicular Technology.

[22]  F. Ronchi,et al.  Control and performance evaluation of a clutch servo system with hydraulic actuation , 2004 .

[23]  Paul D. Walker,et al.  Nonlinear Modeling and Analysis of Direct Acting Solenoid Valves for Clutch Control , 2014 .

[24]  Perry Y. Li,et al.  Using Steady Flow Force for Unstable Valve Design: Modeling and Experiments , 2005 .

[25]  Zhihong Man,et al.  Sliding Mode Control for Steer-by-Wire Systems With AC Motors in Road Vehicles , 2013, IEEE Transactions on Industrial Electronics.

[26]  Hamid Reza Karimi,et al.  Robust energy-to-peak sideslip angle estimation with applications to ground vehicles , 2015 .

[27]  A. Vacca,et al.  The Modeling of Electrohydraulic Proportional Valves , 2012 .

[28]  Chang Seop Koh,et al.  An Optimal Design of Large Scale Permanent Magnet Pole Shape Using Adaptive Response Surface Method With Latin Hypercube Sampling Strategy , 2009 .

[29]  Hyunsoo Kim,et al.  Development and Control of an Electric Oil Pump for Automatic Transmission-Based Hybrid Electric Vehicle , 2011, IEEE Transactions on Vehicular Technology.

[30]  Corneliu Lazar,et al.  Simulation and control of an electro-hydraulic actuated clutch , 2011 .

[31]  Hui Zhang,et al.  H∞ Step Tracking Control for Networked Discrete-Time Nonlinear Systems With Integral and Predictive Actions , 2013, IEEE Transactions on Industrial Informatics.

[32]  Abhishek Dutta,et al.  Robust and two-level (nonlinear) predictive control of switched dynamical systems with unknown references for optimal wet-clutch engagement , 2014, J. Syst. Control. Eng..

[33]  Perry Y. Li.  Dynamic redesign of a flow control servo-valve using a pressure control pilot , 2001 .

[34]  Ronald L. Iman.  Latin Hypercube Sampling , 2008 .

[35]  Qifang Liu,et al.  Position Control of Electric Clutch Actuator Using a Triple-Step Nonlinear Method , 2014, IEEE Transactions on Industrial Electronics.

[36]  Jürgen Branke,et al.  Evolutionary optimization in uncertain environments-a survey , 2005, IEEE Transactions on Evolutionary Computation.