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Design Analysis and Experimental Validation of A N
Design Analysis and Experimental Validation of A N
Jie Yu1,2, Ligang Yao1, Chengcheng Ren1, Xiaolei Yan2 and Li Lin3
Abstract
The transmission system has an important influence on the dynamic performance, endurance mileage, and energy saving
in an all-electric vehicle. This article proposes an innovative two-speed seamless dry-friction automatic transmission sys-
tem to improve the dynamic performance and endurance mileage of an all-electric vehicle with the existing battery tech-
nology. The proposed system consists of two-stage epicyclical gear sets without outer ring gears, a dry-friction clutch,
and a brake band, realizes a seamless shifting between any two speeds in an electric vehicle. Based on the working princi-
ple and dynamic modeling of the proposed seamless dry-friction automatic transmission system, the ratio optimization
was carried out to improve the dynamic performance and the power consumption at the same time, and the combina-
tion of the weight ratio method and the multi-island genetic algorithm method was introduced to solve the optimization
problem. It is shown both theoretically and experimentally that the proposed seamless dry-friction automatic transmis-
sion method demonstrates a better dynamic performance and shifting comfort when compared to the automated man-
ual transmission with same transmission ratio.
Keywords
Seamless auto transmission, electric vehicle, experiment, simulation
Creative Commons CC BY: This article is distributed under the terms of the Creative Commons Attribution 4.0 License
(http://www.creativecommons.org/licenses/by/4.0/) which permits any use, reproduction and distribution of the work without
further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/
open-access-at-sage).
2 Advances in Mechanical Engineering
Figure 3. Power transmission path: (a) power transmission in the first gear and (b) power transmission in the second gear.
and the brake band. When the clutch C is disengaged 1. If the front sun gear is completely grounded by
and the brake band B is engaged, the SDAT works in engaging the brake band (i:e: vs1 = 0), the first
the first gear; when the clutch C is engaged and the gear ratio can be obtained as
brake band B is disengaged, the SDAT works in the
second gear; when the clutch C and the brake band B vin Z1
=1+ = i1 ð3Þ
are both disengaged, the SDAT works in the neutral vout Z2
gear.
2. If the front sun gear and the rear sun gear are
To understand the working principle of SDAT, the
fixed together by engaging the clutch
kinematic relation among the front sun gear, the rear
(i:e:vs1 = vs2 = vC ), the second gear ratio is
sun gear, and the carrier need to be examined in detail.
obtained
The ratio between the front sun gear S1 and the rear
sun gear S2 is proposed by the perspective of standing vin
on the carrier (planetary gear train is simplified to fixed = 1 = i2 ð4Þ
vout
axis gear train) and is given as
3. If neither the clutch nor the brake band is
vs1 vC Z2 engaged (vs1 6¼ 0, vs1 6¼ vs2 ), the neutral gear
iC12 = = ð1Þ
vs2 vC Z1 ratio can be obtained and is given as
where vs1 denotes the front sun gear speed, vc is the vin Z1 Z1 vs1
carrier speed, vs2 is the rear sun gear speed, Z1 is the =1+ = ig ð5Þ
vout Z2 Z2 vC
teeth number of the front sun gear, and Z2 is the teeth
number of the rear sun gear.
According to equation (1), the gear set of SDAT has where i1 and i2 represent the first and the second gear
2 degrees of freedom, and two steps of gear ratios are ratios, respectively, and ig is the transient gear ratio
possible by controlling the working state of clutch and during the gear shifting process.
brake band. Since the rear sun gear S2 is connected to
the input shaft and the carrier to the output shaft, the
gear ratio of the transmission (the ratio between the Dynamic modeling of the power train system with
input speed and the output speed) can be expressed as SDAT
vin vs2 To carry out the ratio optimization task, it is necessary
= ð2Þ
vout vC to build a simulation model which includes a driving
cycle, energy storage, a vehicle control, and the power
where vin denotes the input speed of transmission and train system (as shown in Figure 4). The power train
vout is the output speed of transmission. system consists of an electric motor, input shaft,
By examining equations (1) and (2), three different SDAT, output shaft, final drive, and longitudinal vehi-
gear ratios can be achievable: cle dynamics, as shown in Figure 5. Due to the page
4 Advances in Mechanical Engineering
brake band, and the output torque of SDAT, In equation (22), the positive rotational direction of
respectively. brake band is considered as the energizing mode of the
Moreover, the kinematic relationship between the band brake.
components of the two-stage planetary gear set is According to equations (16) and (17), the gear shift-
ing process can be divided into torque phase and inertia
RC1 vc = Rs1 vs1 + Rp1 vp1 ð14Þ phase for analysis.15 During the shift process, a coordi-
nated control of the clutch, brake band, and the motor
RC2 vc = Rs2 vs2 + Rp2 vp2 ð15Þ
is the key to realize seamless shift and change the
According to equations (1) and (8)–(15), the overall SDAT output torque smoothly.
dynamic equations of SDAT system can be obtained as
Dynamic modeling for final drive and longitudinal vehicle
Tm + TBR TT =Js1 v_ s1 + Js2 v_ s2 + Jc0 v_ c = J1 v_ s2 + J2 v_ c
dynamics. Since the output shaft is modeled as a spring–
ð16Þ damp system, the output torque of SDAT is expressed
Rs2 as
Tm TCL + ðTBR + TCL Þ = J3 v_ s2 + J4 v_ c ð17Þ
Rs1
TT = kos ðuT uos Þ + cos ðvT vos Þ ð24Þ
where
where angle uT uos is the torsion angle of the flexible
Rs2 output shaft, kos is the elastic coefficient of output shaft,
J1 = Js1 + Js2 ð18Þ cos is the damping factor of output shaft, and vos is the
Rs1
speed at the end of output shaft next to the final drive,
Rs2 and the relationship between vos and the wheel speed
J2 = Js1 1 + + Jc0 ð19Þ
Rs1 vw is
2 2 2
Rs2 Rs2 Rs2 vos = ifd vw ð25Þ
J3 = Js1 + Js2 + Jp1 Jp2
Rs1 Rp1 Rp2
Then, using the torque balance equation and lumped
ð20Þ
mass method,16 the longitudinal vehicle dynamics can
Rs2 Rs2 Rs2 Rc1 be expressed as follows
J4 = Js1 1 + + Jp1 1
Rs1 Rs1 Rp1 Rp1
ð21Þ ifd 1
Rs2 Rc2 v_ w = TT Tv ð26Þ
+ Jp2 1 Jv Jv
Rp2 Rp2
where Jv is the combined inertia of the vehicle and
For the SDAT system proposed in this article, the wheels, ifd is the final drive ratio, and Tv is the resisting
clutch connecting the front sun gear and the rear sun torque on the vehicle that can be calculated as follows
gear is same as the conventional single-plate dry clutch
type. Thus, the relation between the normal applied Tv = Twind + Troll + Tslope ð27Þ
force on the plate FCL and the resulting torque is14
where Twind , Troll , and Tslope are the resisting torques
2 R3o R3i from wind, rolling, and slope, respectively, and can be
TCL = mp FCL signðvS2 Þ, FCL 0 ð22Þ calculated as follows
3 R2o R2i
By combining equations (6), (7), (17), (25), and (26) Table 1. The main parameters of the electric vehicle for ratio
together, the full-state dynamics of the system are given optimization.
as follows
Components Parameters Values
8
> Tm = kis ðum us Þ + cis ðvm vs2 Þ
>
> v_ = J4
Vehicle body Curb mass (kg) 9800
>
> s2 ðT + TBR TT Þ + J1 J4JJ 2
Gross mass (kg) 13,500
>
> h J1 J4 J2 J3 m i 2 J3
>
> Rs2 Frontal area (m2) 7.0
>
> T m T CL + ð TBR + T CL Þ
< Rs1 Drag coefficient 0.6
v_ c = J2 J3JJ
3
ð T m + TBR TT Þ + J2 J3JJ
1
ð32Þ Rolling radius (m) 0.436
>
> h 1 J4 i 1 J4
Final drive gear ratio i0
>
> T T + Rs2
ð T + T Þ
>
> m CL Rs1 BR CL Battery pack Rated capacity (AH) 258
>
>
> TT = kos ðuT uos Þ + cos ðvT vos Þ
> Rated voltage (V) 537
>
: i Motor Rated/peak power (kW) 80/160
v_ w = Jfdv TT J1v Tv Peak speed (r/min) 4000
Peak torque (N m) 900
The full-state dynamics of the system was applied in
the EV simulation in the next section.
process of biological evolution, the GA encodes optimi- Table 3. The parameters of multi-island genetic algorithm.
zation problem solution space of the individual and
takes the encoded individual populations into genetic Name Value
operations (such as selection, crossover, and mutation). Value range: i0 2.1 \ i0 \ 6.2
Finally, the optimal solution or the combination of the Value range: i1 2.0 \ x \ 2.2
optimal solution can be found through iterations. Default variable bound (absolute value) 1000.0
MIGA divides a large population into a number of Migration interval 5
Number of generations 10
subpopulations, called ‘‘island,’’ and uses conventional
Number of islands 10
GA algorithms on each island to carry out subpopula- Random seed value 21
tion evolution. The parameters of MIGA are shown in Rate of crossover 1.0
Table 3. Rate of migration 0.01
The calculation results for dynamic and power con- Rate of mutation 0.01
Rel tournament size 0.5
sumption factors are shown in Figure 7. Then, the opti- Subpopulation size 10
mal ratios for i1 and i0 are selected from the Pareto
solution set. The calculated results of the state point
i1 = 2:16 and i0 = 2:8 are 0.126 for dynamic factor and
0.522 for power consumption factor. The calculated feature in Figure 10 shows that the current velocity can
results of the optimal point i1 = 2:18 and i0 = 6:19 are follow the desired velocity from driving cycle, which
0.139 for dynamic factor and 0.514 for power consump- means that the dynamic performance satisfies the driv-
tion factor (Figure 8). ing cycle demand.
Using the obtained optimal design point, the charac-
teristics of acceleration and peak slope are shown in Experimental verification on the vehicle
Figure 9. As shown in Figure 9(a), the peak slope
changes with the speed of EV. For example, the peak
with novel SDAT
slope is 21.8% when the EV is operating at 10 km/h. It After understanding the design and analysis of the pro-
can also be observed from this figure that the current posed SDAT in the previous sections, the seamless shift
velocity changes as the acceleration time increases. For process was verified by real EV test. As shown in
example, the 0–50 km/h acceleration time of the EV is Figure 11, the results from a real driving cycle were
about 17.5 s. The maximum velocity of EV in the simu- obtained from the experiment on the EV with SDAT.
lation is about 103 km/h. Under the NEDC.aut driving Data collection for the motor speed and velocity from
cycle, the power consumption is about 0.52 kW h/km the test carried out on EV is presented in Figure 12.
at the optimal design point. The velocity tracking The gear shifting characteristics of a upshift process
8 Advances in Mechanical Engineering
Figure 8. The iterative results of optimization target: (a) calculated history of dynamic factor and (b) history of power
consumption factor.
for the EV with AMT is shown in Figure 13, whereas characteristics. It is worth mentioning that the
the proposed SDAT method is shown in Figure 14. power consumption per kilometer is about 0.53 kW
Based on the test results shown in Figures 12–14, it h/km, and the upshift time is about 0.5 s for SDAT,
can be concluded that the vehicle with SDAT has a as shown in Figure 15. As stated earlier, the power
seamless upshift since the velocity increases steadily consumption obtained in simulations is about 0.52
during the shifting process, but the vehicle with kW h/km, the simulation accuracy is verified by the
AMT does not have such smooth shift experiment result.
Yu et al. 9
Figure 9. Dynamic characteristic for EV at the optimal design point: (a) characteristics of peak slope and (b) characteristics of
acceleration.
Figure 11. The gearshift and power consumption test: (a) the novel SDAT, (b) the vehicle with SDAT for test, (c) data acquisition
software for test and (d) additional weight for test.
Yu et al. 11
Figure 13. Upshift process of the real velocity test with AMT.
Figure 14. Upshift process of the real velocity test with SDAT.