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

Adaptive Equivalent Consumption Minimization Strategy with Rule-based Gear Selection for the Energy Management of Hybrid Electric Vehicles Equipped with Dual Clutch Transmissions

Based on observations of the behaviour of the optimal solution to the problem of energy management for plug-in hybrid electric vehicles, a novel real-time Energy Management Strategy (EMS) is proposed. In particular, dynamic programming results are used to derive a set of rules aiming at reproducing the optimal gearshift schedule in electric mode while the Adaptive Equivalent Consumption Minimization Strategy (A-ECMS) is employed to decide the powertrain operating mode and the current gear when power from the internal combustion engine is needed. In terms of total fuel consumption, simulations show that the proposed approach yields results that are close to the optimal solution and also outperforms those of the A-ECMS, a well-known EMS. One of the main aspects that differentiates the strategy here proposed from previous works is the introduction of a model to use physical considerations to estimate the energy consumption during gearshifts in dual-clutch transmissions. This, together with a series of properly tuned fuel penalties allows the controller to yield results in which there is no gear hunting behaviour

Integration of dual-clutch transmissions in hybrid electric vehicle powertrains

This dissertation presents a study focused on exploring the integration of Dual-Clutch Transmissions (DCTs) in Hybrid Electric Vehicles (HEVs). Among the many aspects that could be investigated regarding the electrification of DCTs, research efforts are undertaken here to the development of control strategies for improving vehicle dynamic performance during gearshifts and the energy management of HEVs. In the first part of the dissertation, control algorithms for upshift and downshift maneuvers are developed for a Plug-in Hybrid Electric Vehicle (PHEV) architecture in which an electric machine is connected to the output of the transmission, thus obtaining torque filling capabilities during gearshifts. Promising results, in terms of the vehicle dynamic performance, are obtained for the two transmission systems analyzed: Hybrid Automated Manual Transmission (H-AMT) and Hybrid Dual-Clutch Transmission (H-DCT). On the other hand, the global optimal solution to the energy management problem for a PHEV equipped with a DCT is found by developing a detailed Dynamic Programing (DP) formulation. The main control objective is to reduce the fuel consumption during a driving mission. Based on the DP results, a novel real-time implementable Energy Management Strategy (EMS) is proposed. The performance of such controller, in terms of the overall fuel usage, is close to that of the optimal solution. Furthermore, the developed approach is shown to outperform a well-known causal strategy: Adaptive Equivalent Consumption Minimization Strategy (A-ECMS). One of the main aspects that differentiates the EMSs proposed here to those presented in previous works is the introduction of a model to estimate the energy consumption during gearshifts in DCTs. Thus, this dissertation illustrates how through the electrification of powertrains equipped with DCTs both the vehicle dynamic performance and the energy consumption can be improved

Electric Vehicle Efficient Power and Propulsion Systems

Vehicle electrification has been identified as one of the main technology trends in this second decade of the 21st century. Nearly 10% of global car sales in 2021 were electric, and this figure would be 50% by 2030 to reduce the oil import dependency and transport emissions in line with countries’ climate goals. This book addresses the efficient power and propulsion systems which cover essential topics for research and development on EVs, HEVs and fuel cell electric vehicles (FCEV), including: Energy storage systems (battery, fuel cell, supercapacitors, and their hybrid systems); Power electronics devices and converters; Electric machine drive control, optimization, and design; Energy system advanced management methods Primarily intended for professionals and advanced students who are working on EV/HEV/FCEV power and propulsion systems, this edited book surveys state of the art novel control/optimization techniques for different components, as well as for vehicle as a whole system. New readers may also find valuable information on the structure and methodologies in such an interdisciplinary field. Contributed by experienced authors from different research laboratory around the world, these 11 chapters provide balanced materials from theorical background to methodologies and practical implementation to deal with various issues of this challenging technology. This reprint encourages researchers working in this field to stay actualized on the latest developments on electric vehicle efficient power and propulsion systems, for road and rail, both manned and unmanned vehicles

Optimized design of multi-speed transmissions for parallel hybrid electric vehicles

In this paper, the optimal design of a multi-speed transmission system in terms of gear ratio, number of gears and gear shifting strategy is investigated for a parallel hybrid electric vehicle. The design procedure starts with the optimization of the transmission configuration to identify the optimal gear ratios for a specified number of gears. In order to avoid solving a complex co-optimization problem that involves numerous control variables for hybrid powertrain energy management (EM), gear ratios and gear shifting, the gear ratio optimization is properly decoupled from the co-optimization problem, while the optimal gear shifting strategy for the optimized gear ratios is determined jointly with the powertrain EM. The separation of the co-optimization makes it possible to solve individual problems by dynamic programming (DP), which guarantees global optimality. To show the impact of optimally designed and controlled transmission on fuel savings, the fuel economy solution of the proposed scheme is compared with the traditional EM and gear shifting optimization method that applies non-optimized gear ratios. Simulation examples verify the effectiveness of the proposed methodology and show the fuel savings incurred by the configuration optimization of the multi-speed transmission system

Time-optimal Control Strategies for Electric Race Cars with Different Transmission Technologies

This paper presents models and optimization methods to rapidly compute the achievable lap time of a race car equipped with a battery electric powertrain. Specifically, we first derive a quasi-convex model of the electric powertrain, including the battery, the electric machine, and two transmission technologies: a single-speed fixed gear and a continuously variable transmission (CVT). Second, assuming an expert driver, we formulate the time-optimal control problem for a given driving path and solve it using an iterative convex optimization algorithm. Finally, we showcase our framework by comparing the performance achievable with a single-speed transmission and a CVT on the Le Mans track. Our results show that a CVT can balance its lower efficiency and higher weight with a higher-efficiency and more aggressive motor operation, and significantly outperform a fixed single-gear transmission.Comment: 5 pages, 4 figures, submitted to the 2020 IEEE Vehicle Power and Propulsion Conferenc