Search Results (13)

Model Predictive Control (MPC) has emerged as a promising approach for energy management in hybrid electric vehicles, enabling predictive optimization of powertrain operation. The energy management problem in parallel hybrid powertrains constitutes a Mixed-Integer Nonlinear Programming (MINLP) problem, combining continuous decision variables such as torque distribution with discrete decisions including engine on/off states and clutch engagement. This problem structure presents distinct challenges for different optimization approaches. Gradient-based methods such as Sequential Quadratic Programming (SQP) solve continuous, differentiable optimization problems and require auxiliary methods to handle integer variables, while metaheuristic approaches such as Genetic Algorithms (GA) can handle the mixed-integer structure directly at the cost of increased computational effort. This study presents a systematic comparison between GA and SQP as optimization solvers within an MPC framework for a P1P3 parallel hybrid powertrain. A multi-objective cost function is formulated to simultaneously optimize system efficiency, battery state of charge management, and noise emissions. Both approaches are evaluated across the WLTC as well as a real-world RDE scenario. On the WLTC, both MPC approaches reduce fuel consumption by 0.5–1.0% and improve system efficiency by 3.7–4.6% compared to a state-of-the-art deterministic reference strategy optimized for fuel consumption. At the same time, both approaches additionally achieve substantial reductions in noise emissions compared to the deterministic reference, which was not optimized for acoustic behavior. On both cycles, the GA-based MPC achieves favorable performance compared to SQP, with the performance gap widening from the WLTC to the RDE cycle. Both methods achieve real-time capability, yet SQP reduces computational time by a factor of four compared to GA. As long as computational resources in automotive ECUs remain constrained, this efficiency advantage positions gradient-based optimization for series production applications, whereas metaheuristic methods offer greater flexibility for concept development stages with relaxed real-time requirements. The findings contribute to the understanding of optimization algorithm selection for MINLP energy management problems in hybrid electric vehicles. Full article

This study addresses the thermal hazards that arise during the initial engagement stage of wet clutches, where rapid heat generation within the transient lubricating film may cause premature film rupture, torque instability, and accelerated wear. To overcome these challenges, a coupled thermo–fluid model was developed to capture oil film flow, heat transfer, and viscous torque behavior under varying groove structures. A novelty of this work is the first integration of computational fluid dynamics (CFD) with response surface methodology (RSM) to systematically reveal how groove geometry—cross-sectional shape, number, and inclination angle—collectively influences peak temperature and viscous torque during the lubricating film stage. Simulation results show that spiral semi-circular grooves provide superior thermal management, reducing the peak friction plate temperature to 75.5 °C, while the optimized design obtained via RSM (groove depth of 0.89 mm, 19 grooves, and a 5.28° inclination angle) further lowers the maximum temperature to 68.2 °C and sustains torque transmission above 18.5 N·m. These findings demonstrate that rational groove design, guided by multi-objective optimization, can mitigate thermal risks while maintaining torque stability, offering new insights for the high-performance design of wet clutches. Full article

The loader is one of the most widely used pieces of engineering machinery in the world for soil transportation, loading and unloading materials, and low-intensity shovel digging operations in harsh and complex operating conditions; it requires very frequent shifting and has other challenging characteristics. In order to realize automatic frequent shifting, we need to better design the shifting rules in the shifting process, improve the shifting quality and working efficiency, and solve the key engineering problems of energy saving and high efficiency in the shifting process of loaders. In this paper, a 7-ton wheel loader is taken as the research object, the loader shoveling process of the four operating modes is analyzed, and a multi-mode variable parameter shift law is designed. Aiming at the complicated and nonlinear characteristics of the power transmission system of the loader, an intelligent shift control method based on an RBF neural network is proposed. Finally, the simulation test and the clutch shift oil pressure test are carried out. From the test results, the clutch test oil pressure curve obviously shows a four-stage upward trend during shifting, and the buffering effect is obvious. The designed multi-mode variable-parameter intelligent shift law of the loader is reasonable and feasible, and the shift recognition rate reaches 97.92%, which provides theoretical support for the realization of intelligent automatic speed change control of the loader, and it certainly has engineering value. Full article

When a single-axis parallel hybrid electric vehicle (HEV) equipped with a multi-speed AMT gearbox is in its shifting process, the superposition of dynamic characteristics of multiple power sources and the intervention and withdrawal of AMT transmissions can easily cause significant vehicle longitudinal jerk. To achieve rapid and smooth output changes during the shifting process, this paper proposes an integrated multi-stage robust shifting control method for a single-axis parallel hybrid electric vehicles with a multi-speed AMT gearbox. First, models of key driveline components are constructed, and the shifting process is divided into five stages to provide a clear description of the control problem. Subsequently, we reproduce an integrated multistage robust control method to achieve favorable switching performance and control robustness under external disturbances. We propose a data-driven model predictive control strategy based on additional constraints in the torque unloading and recovery phases. Simultaneously, we present a joint control algorithm that integrates the optimal control and disturbance suppression in the speed synchronization phase. In addition, we develop a sliding mode auto-disturbance rejection control algorithm to achieve accurate position tracking of the shift actuator in the pickup and engage phases. Finally, simulations and bench tests are carried out to verify the effectiveness of the robust control method under different driving conditions. The results demonstrate that the proposed control method can not only coordinate the torque across different power sources and clutch while minimizing vehicle longitudinal jerk, shift time, and friction work, but also provides apparent robustness to model uncertainties and external disturbance. Therefore, the proposed method may offer a theoretical reference for the actual vehicle controller during shifting. Full article

To overcome the problems existing in the practical application of traditional in-wheel motors used for electric vehicles, an integrated double rotor in-wheel motor was proposed, which can realize three drive modes to meet variable operating condition requirements of the vehicle. The process of switching between different drive modes affects the ride comfort of a vehicle. Taking the mode switching from a single inner motor drive to a dual-motor coupling drive as a research object, a dynamic modeling method of drive mode switching based on the switching system was proposed. According to the critical conditions of each state transition, the switching rules expressed by the segmental constant function were designed. At the engagement stage of electromagnetic clutch II, the torque coordination control strategy based on model predictive control (MPC) and control allocation was proposed. The simulation results show that the proposed strategy can effectively reduce the impact degree of a vehicle and the slipping-friction work of the clutch on the premise of ensuring the fast response of mode switching and the steady increase in vehicle speed. The switching quality of the mode-switching process is effectively improved. In addition, the drive mode switching control of the double rotor in-wheel motor prototype was tested, which proves its ability to operate in multi-drive mode. Full article

The article provides a discussion on a methodology intended for testing of power transmission systems featuring an innovative highly torsionally flexible metal clutch patented by the co-authors of this paper. What this methodology takes into account is the amplitude and frequency analyses discussed in the article, as well as a sensing system based on diverse piezoelectric and magnetic phenomena, the Doppler effect, etc. Both contact and non-contact (laser measurement) methods were used during the tests. The purpose of the tests conducted at the stand, originally designed by the authors in accordance with the methodology proposed, was to evidence that using the innovative and patented, highly torsionally flexible metal clutch makes it possible to reduce the vibrations of multi-stage toothed gears, consequently reducing the forces affecting the gear bearings and those acting at the tooth space, which is to enable the service life of individual components of the power transmission systems intended for mining scraper conveyors to be significantly extended. Based on the studies and analyses performed by the authors, one can observe and conclude that the methodology proposed in the paper makes it possible to use an example of a relatively complex power transmission system in order to examine the relationships between the processes at work, i.e., the decline of the linear vibrations of the gear housing (which is undoubtedly positive in power transmission systems) at the expense of increasing torsional vibrations of the innovative clutch, the latter not to be considered unfavourable to users in the case analysed. Full article

Torsional vibration of the automotive driveline has significant influence on driving comfort. This study investigates the influence of clutch nonlinear behaviors on the torsional vibration of the driveline with numerical and experimental methods. A generic automobile powertrain model with 7 degrees of freedom is proposed considering the transient engine torque, the nonlinear characteristics of multi-stage clutch and tire slip. Taking a commercial vehicle as an example, the dynamic behaviors and inherent characteristics of the driveline system are calculated and analyzed. Based on the proposed model, the influences of the clutch parameters on driveline torsional vibration are investigated. In order to validate the proposed model and the analytical results, an optimized clutch is designed and the experiments of torsional vibration are conducted with the prototype and the optimized clutch. The analytical and experimental results demonstrate that an increase in the first end-stop angle and the main-stage hysteresis or a decrease in the second end-stop angle and the main-stage stiffness of the clutch can effectively suppress driveline torsional vibration during vehicle accelerating. Full article

A magnetorheological (MR) multi-plate clutch was proposed with both mechanical friction mode and magnetic field control modes. The magnetic field control mode was based on an MR fluid coupler that changed its viscous properties according to the density of an applied magnetic field. This mode was used in the early stage of clutch operation to reduce the impact of friction between the disc and plate, and eliminate to the extent possible the difference in their relative speeds when contacting each other in later stages. Once the rotational speed difference between the disc and plate was reduced, the clutch was operated in mechanical friction mode by compressing the friction surfaces together. A torque modeling equation was then derived for each mode based on the Bingham model of the MR fluid, and the transmission torque of the proposed multi-plate clutch was derived using these equations as well as magnetic field analysis results obtained using ANSYS Maxwell. A multi-plate MR clutch was then fabricated, and its torque transmission characteristics were evaluated in the magnetic field control and mechanical friction modes. The results confirmed that the model-based torque calculations were consistent with the observed transmission torque. Finally, control algorithms for mechanical friction only and mixed mechanical friction/magnetic field control torque tracking of the proposed MR multi-plate clutch were designed, and their performances were evaluated when applying unit step command, half-sine-wave command, and rotational speed changes. The results indicated that the torque tracking control was performed smoothly, demonstrating the advantages of the proposed clutch. Full article

Piecewise-type nonlinearities, such as clutch dampers in a torsional system, induce complex nonlinear dynamic behaviors that resemble super- and sub-harmonic responses. This study focuses on investigating the sub-harmonic responses induced by piecewise-type nonlinearities in the middle of various dynamic behaviors in a torsional vibratory system. To examine the dynamic characteristics in a sub-harmonic regime, the harmonic balance method (HBM) was implemented. Its results were compared with the numerical simulation (NS). To reveal the sub-harmonic responses, the input conditions of the HBM were modified with a small number of input values. In addition, bifurcation diagrams were numerically determined and projected onto stable and unstable solutions of the HBM to examine the effective dynamic behaviors within the unstable regimes. The results of the HBM with the modified input conditions reveal the sub-harmonic effects well, and the comparisons of bifurcation diagrams under unstable conditions lead to an understanding of the complex dynamic behaviors. Overall, this study suggests the first analytical technique to determine the sub-harmonic responses with the HBM, and second investigates the complex dynamic behaviors in a practical vibratory system by considering the bifurcations in the unstable regimes. Full article

The multi-stage roll die forming (RDF) process is a plastic forming process that can manufacture a transmission part with a complex shape, such as a drum clutch, by using a die set with rotational rolls. However, it is difficult to satisfy dimensional accuracy because of spring-back and unfilling. The purpose of this study is to design a multi-stage RDF process for the manufacturing of a drum clutch to improve dimensional accuracy using an artificial neural network (ANN). Finite element (FE) simulation of the multi-stage RDF process is performed to predict the dimensional accuracy according to various clearances for each stage. Moreover, the ANN is used to determine the relationship between the clearance and dimensional accuracy of the drum clutch to reduce the number of FE simulation. The results of the FE simulation and ANN are used to determine the optimal clearance for each stage of the RDF process. Finally, the drum clutch is fabricated using the determined conditions. The experimental results are in good agreement with the results of FE simulation from the aspect of outer diameter, inner diameter, thickness of outer tooth, thickness of inner tooth, and face thickness of tooth. Full article

Wet-running multi-plate clutches should be prevented from failing due to the often safety-relevant functions they fulfill in the drive train. In addition to long-term damage, spontaneous damage is of particular relevance for failures. This paper focuses on the influence of spontaneous damage on frictional behavior in the later life cycle. The aim of the experimental investigations is to initially cause spontaneous damage in wet-running multi-plate clutches with sintered friction linings. For this purpose, three clutches are first pre-damaged in stage tests with different intensities, so that the first spontaneous damage (local discoloration, sinter transfer) occurs. In the second step, an endurance test is carried out with the pre-damaged clutch packs and a non-pre-damaged reference clutch. The friction behavior of the clutches during the endurance test is compared and evaluated. It shows that local discoloration and sinter transfer are no longer visible after the endurance tests. At the beginning of the endurance test, the values of coefficient of friction are higher over the entire speed range of the heavily pre-damaged clutches than with the slightly pre-damaged clutch and the non-pre-damaged reference clutch. At the end of the endurance test, it can be observed that the greater the pre-damage to the clutches is, the greater the coefficient of friction increases with decreasing sliding speed. Full article

Dynamic behaviors in practical driveline systems for wind turbines or vehicles are inherently affected by multiple nonlinearities such as piecewise-type torsional springs. However, various excitation conditions with different levels of magnitudes also show strong relationships to the dynamic behaviors when system responses are examined in both frequency and time domains. This study investigated the nonlinear responses of torsional systems under various excitations by using the harmonic balance method and numerical analysis. In order to understand the effect of piecewise-type nonlinearities on vibrational energy with different excitations, the nonlinear responses were investigated with various comparisons. First, two different jumping phenomena with frequency up- and down-sweeping conditions were determined under severe excitation levels. Second, practical system analysis using the phase plane and Poincaré map was conducted in various ways. When the system responses were composed of quasi-periodic components, Poincaré map analysis clearly revealed the nonlinear dynamic characteristics and thus it is suggested to investigate complicated nonlinear dynamic responses in practical driveline systems. Full article

Torsional systems with gear pairs such as the gearbox of wind turbines or vehicle driveline systems inherently show impact phenomena due to clearance-type nonlinearities when the system experiences sinusoidal excitation. This research investigates the vibro-impact energy of unloaded gears in geared systems using the harmonic balance method (HBM) in both the frequency and time domains. To achieve accurate simulations, nonlinear models with piecewise and clearance-type nonlinearities and drag torques are defined and implemented in the HBM. Next, the nonlinear frequency responses are examined by focusing on the resonance areas where the impact phenomena occur, along with variations in key parameters such as clutch stiffness, drag torque, and inertias of the flywheel and the unloaded gear. Finally, the effects of the parameters on the vibro-impacts at a specific excitation frequency are explained using bifurcation diagrams. The results are correlated with prior research by defining the gear rattle criteria with key parameters. This article suggests a method to simulate the impact phenomena in torsional systems using the HBM and successfully assesses vibro-impact energy using bifurcation diagrams. Full article