Gear shift strategies for automotive transmissions

The development history of automotive engineering has shown the essential role of transmissions in road vehicles primarily powered by internal combustion engines. The engine with its physical constraints on the torque and speed requires a transmission to have its power converted to the drive power demand at the vehicle wheels. Under dynamic driving conditions, the transmission is required to shift in order to match the engine power with the changing drive power. Furthermore, a gear shift decision is expected to be consistent such that vehicle can remain in the next gear for a period of time without deteriorating the acceleration capability. Therefore, an optimal conversion of the engine power plays a key role in improving the fuel economy and driveability. Moreover, the consequences of the assumptions related to the discrete state variable-dependent losses, e.g. gear shifting, clutch slippage and engine starting, and their e¿ect on the gear shift control strategy are necessary to be analyzed to yield insights into the fuel usage. The ¿rst part of the thesis deals with the design of gear shift strategies for electronically controlled discrete ratio transmissions used in both conventional vehicles and Hybrid Electric Vehicles (HEVs). For conventional vehicles, together with the fuel economy, the driveability is systematically addressed in a Dynamic Programming (DP) based optimal gear shift strategy by three methods: i) the weighted inverse of the power re¬serve, ii) the constant power reserve, and iii) the variable power reserve. In addition, a Stochastic Dynamic Programming (SDP) algorithm is utilized to optimize the gear shift strategy, subject to a stochastic distribution of the power request, in order to minimize the expected fuel consumption over an in¿nite horizon. Hence, the SDP-based gear shift strategy intrinsically respects the driveability and is realtime implementable. By per¬forming a comparative analysis of all proposed gear shift methods, it is shown that the variable power reserve method achieves the highest fuel economy without deteriorating the driveability. Moreover, for HEVs, a novel fuel-optimal control algorithm, consist-ing of the continuous power split and discrete gear shift, engine on-o¿ problems, based on a combination of DP and Pontryagin’s Minimum Principle (PMP) is developed for the corresponding hybrid dynamical system. This so-called DP-PMP gear shift control approach benchmarks the development of an online implementable control strategy in terms of the optimal tradeo¿ between calculation accuracy and computational e¿ciency. Driven by an ultimate goal of realizing an online gear shift strategy, a gear shift map design methodology for discrete ratio transmissions is developed, which is applied for both conventional vehicles and HEVs. The design methodology uses an optimal gear shift algorithm as a basis to derive the optimal gear shift patterns. Accordingly, statis¬tical theory is applied to analyze the optimal gear shift pattern in order to extract the time-invariant shift rules. This alternative two-step design procedure makes the gear shift map: i) respect the fuel economy and driveability, ii) be consistent and robust with respect to shift busyness, and iii) be realtime implementation. The design process is ¿exible and time e¿cient such that an applicability to various powertrain systems con¿gured with discrete ratio transmissions is possible. Furthermore, the study in this thesis addresses the trend of utilizing the route information in the powertrain control system by proposing an integrated predictive gear shift strategy concept, consisting of a velocity algorithm and a predictive algorithm. The velocity algorithm improves the fuel economy in simulation considerably by proposing a fuel-optimal velocity trajectory over a certain driving horizon for the vehicle to follow. The predictive algorithm suc¬cessfully utilizes a prede¿ned velocity pro¿le over a certain horizon in order to realize a fuel economy improvement very close to that of the globally optimal algorithm (DP). In the second part of the thesis, the energetic losses, involved with the gear shift and engine start events in an automated manual transmission-based HEV, are modeled. The e¿ect of these losses on the control strategies and fuel consumption for (non-)powershift transmission technologies is investigated. Regarding the gear shift loss, the study ¿rstly ever discloses a perception of a fuel-e¿cient advantage of the powershift transmissions over the non-powershift ones applied for commercial vehicles. It is also shown that the engine start loss can not be ignored in seeking for a fair evaluation of the fuel economy. Moreover, the sensitivity study of the fuel consumption with respect to the prediction horizon reveals that a predictive energy management strategy can realize the highest achievable fuel economy with a horizon of a few seconds ahead. The last part of the thesis focuses on investigating the sensitivity of an optimal gear shift strategy to the relevant control design objectives, i.e. fuel economy, driveability and comfort. A singu¬lar value decomposition based method is introduced to analyze the possible correlations and interdependencies among the design objectives. This allows that some of the pos¬sible dependent design objective(s) can be removed from the objective function of the corresponding optimal control problem, hence thereby reducing the design complexity

Actuators for Intelligent Electric Vehicles

This book details the advanced actuators for IEVs and the control algorithm design. In the actuator design, the configuration four-wheel independent drive/steering electric vehicles is reviewed. An in-wheel two-speed AMT with selectable one-way clutch is designed for IEV. Considering uncertainties, the optimization design for the planetary gear train of IEV is conducted. An electric power steering system is designed for IEV. In addition, advanced control algorithms are proposed in favour of active safety improvement. A supervision mechanism is applied to the segment drift control of autonomous driving. Double super-resolution network is used to design the intelligent driving algorithm. Torque distribution control technology and four-wheel steering technology are utilized for path tracking and adaptive cruise control. To advance the control accuracy, advanced estimation algorithms are studied in this book. The tyre-road peak friction coefficient under full slip rate range is identified based on the normalized tyre model. The pressure of the electro-hydraulic brake system is estimated based on signal fusion. Besides, a multi-semantic driver behaviour recognition model of autonomous vehicles is designed using confidence fusion mechanism. Moreover, a mono-vision based lateral localization system of low-cost autonomous vehicles is proposed with deep learning curb detection. To sum up, the discussed advanced actuators, control and estimation algorithms are beneficial to the active safety improvement of IEVs

Optimization-Driven Powertrain-Oriented Adaptive Cruise Control to Improve Energy Saving and Passenger Comfort

Assessing the potential of advanced driver assistance systems requires developing dedicated control algorithms for controlling the longitudinal speed of automated vehicles over time. In this paper, a multiobjective off-line optimal control approach for planning the speed of the following vehicle in adaptive cruise control (ACC) driving is proposed. The implemented method relies on the principle of global optimality fostered by dynamic programming (DP) and aims to minimize propelling energy consumption and enhance passenger comfort. The powertrain model and onboard control system are integrated within the proposed car-following optimization framework. The retained ACC approach ensures that the distance between the following vehicle and the preceding vehicle is always maintained within allowed limits. The flexibility of the proposed method is demonstrated here through ease of implementation on a wide range of powertrain categories, including a conventional vehicle propelled by an internal combustion engine solely, a pure electric vehicle, a parallel P2 hybrid electric vehicle (HEV) and a power-split HEV. Moreover, different driving conditions are considered to prove the effectiveness of the proposed optimization-driven ACC approach. Obtained simulation results suggest that up to 22% energy-saving and 48% passenger comfort improvement might be achieved for the ACC-enabled vehicle compared with the preceding vehicle by implementing the proposed optimization-driven ACC approach. Engineers may adopt the proposed workflow to evaluate corresponding real-time ACC approaches and assess optimal powertrain design solutions for ACC driving

Advanced Control and Estimation Concepts, and New Hardware Topologies for Future Mobility

According to the National Research Council, the use of embedded systems throughout society could well overtake previous milestones in the information revolution. Mechatronics is the synergistic combination of electronic, mechanical engineering, controls, software and systems engineering in the design of processes and products. Mechatronic systems put “intelligence” into physical systems. Embedded sensors/actuators/processors are integral parts of mechatronic systems. The implementation of mechatronic systems is consistently on the rise. However, manufacturers are working hard to reduce the implementation cost of these systems while trying avoid compromising product quality. One way of addressing these conflicting objectives is through new automatic control methods, virtual sensing/estimation, and new innovative hardware topologies

A low-cost and novel approach in gearshift control for a mild-hybrid powertrain

© 2017 IEEE. A novel, the low-cost mild hybrid powertrain is described. It relies on a manual, or robotized manual transmission together with a BLDC motor coupled at the output for filling the torque hole between gear changes. In order to keep manufacturing cost low and improve commercial attractiveness, it incorporates gearshift strategies that deliver high-quality gear shifts. A deliberate downsizing of componentry is implemented as far as possible to reduce cost, and control strategies are employed to exploit the maximum potential of the architecture using methods including torque-fill, ICE-assist, and ICE start-stop. The architecture is developed in simulation using an existing conventional platform to investigate system properties and their effect on performance. In particular, we discuss the gear-shift control algorithm design. Until the cost of full hybrids and fuel cell vehicles is significantly reduced, such a mild hybrid may have the potential to provide the right cost-benefit balance to achieve strong market penetration

Control of a hybrid electric vehicle with predictive journey estimation

Battery energy management plays a crucial role in fuel economy improvement of charge-sustaining parallel hybrid electric vehicles. Currently available control strategies consider battery state of charge (SOC) and driver’s request through the pedal input in decision-making. This method does not achieve an optimal performance for saving fuel or maintaining appropriate SOC level, especially during the operation in extreme driving conditions or hilly terrain. The objective of this thesis is to develop a control algorithm using forthcoming traffic condition and road elevation, which could be fed from navigation systems. This would enable the controller to predict potential of regenerative charging to capture cost-free energy and intentionally depleting battery energy to assist an engine at high power demand. The starting point for this research is the modelling of a small sport-utility vehicle by the analysis of the vehicles currently available in the market. The result of the analysis is used in order to establish a generic mild hybrid powertrain model, which is subsequently examined to compare the performance of controllers. A baseline is established with a conventional powertrain equipped with a spark ignition direct injection engine and a continuously variable transmission. Hybridisation of this vehicle with an integrated starter alternator and a traditional rule-based control strategy is presented. Parameter optimisation in four standard driving cycles is explained, followed by a detailed energy flow analysis. An additional potential improvement is presented by dynamic programming (DP), which shows a benefit of a predictive control. Based on these results, a predictive control algorithm using fuzzy logic is introduced. The main tools of the controller design are the DP, adaptive-network-based fuzzy inference system with subtractive clustering and design of experiment. Using a quasi-static backward simulation model, the performance of the controller is compared with the result from the instantaneous control and the DP. The focus is fuel saving and SOC control at the end of journeys, especially in aggressive driving conditions and a hilly road. The controller shows a good potential to improve fuel economy and tight SOC control in long journey and hilly terrain. Fuel economy improvement and SOC correction are close to the optimal solution by the DP, especially in long trips on steep road where there is a large gap between the baseline controller and the DP. However, there is little benefit in short trips and flat road. It is caused by the low improvement margin of the mild hybrid powertrain and the limited future journey information. To provide a further step to implementation, a software-in-the-loop simulation model is developed. A fully dynamic model of the powertrain and the control algorithm are implemented in AMESim-Simulink co-simulation environment. This shows small deterioration of the control performance by driver’s pedal action, powertrain dynamics and limited computational precision on the controller performance

Saving Fuel for Heavy-Duty Vehicles Using Connectivity and Automation

The booming of e-commerce is placing an increasing burden on freight transport system by demanding faster and larger amount of delivery. Despite the variety in freight transport means, the dominant freight transport method is still ground transport, or specifically, transport by heavy-duty vehicles. Roughly one-third of the annual ground freight transport expense goes to fuel expenses. If fuel costs could be reduced, the finance of freight transport would be improved and may increase the transport volume without additional charge to average consumers. A further benefit of reducing fuel consumption would be the related environmental impact. The fuel consumption of the heavy-duty vehicles, despite being the minority of road vehicles, has a major influence on the whole transportation sector, which is a major contributor to greenhouse gas emissions. Thus, saving fuel for heavy-duty trucks would also reduce greenhouse gas emission, leading to environmental benefits. For decades, researchers and engineers have been seeking to improve the fuel economy of heavy-duty vehicles by focusing on vehicles themselves, working on advancing the vehicle design in many aspects. More recently, attention has turned to improve fuel efficiency while driving in the dynamic traffic environment. Fuel savings effort may be realized due to advancements in connected and automated vehicle technologies, which provide more information for vehicle design and control. This dissertation presents state-of-the-art techniques that utilize connectivity and automation to improve the fuel economy of heavy-duty vehicles, while allowing them to stay safe in real-world traffic environments. These techniques focus on three different levels of vehicle control, and can result in significant fuel improvements at each level. Starting at the powertrain level, a gear shift schedule design approach is proposed based on hybrid system theory. The resulting design improves fuel economy without comprising driveability. This new approach also unifies the gear shift logic design of human-driven and automated vehicles, and shows a large potential in fuel saving when enhanced with higher level connectivity and automation. With this potential in mind, at the vehicle level, a fuel-efficient predictive cruise control algorithm is presented. This mechanism takes into account road elevation, wind, and aggregated traffic information acquired via connectivity. Moreover, a systematic tool to tune the optimization parameters to prioritize different objectives is developed. While the algorithm and the tool are shown to be beneficial for heavy-duty vehicles when they are in mild traffic, such benefits may not be attainable when the traffic is dense. Thus, at the traffic level, when a heavy-duty vehicle needs to interact with surrounding vehicles in dense traffic, a connected cruise control algorithm is proposed. This algorithm utilizes beyond-line-of-sight information, acquired through vehicle-to-vehicle communication, to gain a better understanding of the surrounding traffic so that the vehicle can response to traffic in a fuel efficient way. These techniques can bring substantial fuel economy improvements when applied individually. In practice, it is important to integrate these three techniques at different levels in a safe manner, so as to acquire the overall benefits. To achieve this, a safety verification method is developed for the connected cruise control, to coordinate the algorithms at the vehicle level and the traffic level, maximizing the fuel benefits while staying safe.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/147523/1/hchaozhe_1.pd

Comparative fuel economy, cost and emissions analysis of a novel mild hybrid and conventional vehicles

© IMechE 2017. Mild hybrid vehicles have been explored as a potential pathway to reduce vehicle emissions cost-effectively. The use of manual transmissions to develop novel hybrid vehicles provides an alternate route to producing low cost electrified powertrains. In this paper, a comparative analysis examining a conventional vehicle and a mild hybrid electric vehicle is presented. The analysis considers fuel economy, capital and ongoing costs and environmental emissions, and includes developmental analysis and simulation using mathematical models. Vehicle emissions (nitrogen oxides, carbon monoxide and hydrocarbons) and fuel economy are computed, analysed and compared using a number of alternative driving cycles and their weighted combination. Different driver styles are also evaluated. Studying the relationship between the fuel economy and driveability, where driveability is addressed using fuel-economical gear shift strategies. Our simulation suggests the hybrid concept presented can deliver fuel economy gains of between 5 and 10%, as compared to the conventional powertrain