Powertrain System Dynamic Model Development: HMMWV- High Mobility Multi-purpose Wheeled Vehicle

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Powertrain System Dynamic Model Development: HMMWV- High Mobility Multi-purpose Wheeled Vehicle University of Wisconsin-Madison Powertrain Control

1 Powertrain System Dynamic Model Development: HMMWV- High Mobility Multi-purpose Wheeled Vehicle University of Wisconsin-Madison Powertrain Control Research Lab - Engine Research Center John J. Moskwa, PI David E. Foster, co-pi Gordon Wright, co-pi Scott A. Munns Zachary J. Rubin Joseph W. Anthony Wenbo Wang

2 Presentation Topics Description of M998A HMMWV powertrain system hardware Modular HMMWV powertrain system models Engine, torque converter, transmission, gearbox, differentials, driveshafts Functionalities captured in the dynamic models Case study: Using the dynamic powertrain models for system optimization Focus on transmission models Description of tests conducted and results Summary and Conclusions

3 M998A HMMWV Powertrain System Hardware Overall vehicle Many variations on basic chassis (curb weight varies with application and armor, M996-M097) Gross vehicle weight (GVW): 0,00 lbs (4,67 kg) Engine DDC 6.5L IDI V-8 naturally aspirated diesel Bore x stroke: 4.06 x.8 in (0 x 97 mm) Compression ratio:.: 60 hp (0 rpm 90 ft-lbf (9 Nm) rpm

4 M998A HMMWV Powertrain System Hardware Transmission Hydra-Matic Matic,, 4L80-E, 4-speed automatic Torque converter ratio:.: Ratios:.48:,.48:, :, 0.75: (Rev.:.08:) Transfer case Gear ratios:.7: (low),.0: (high) Differentials Zexel-Gleason torque-biasing worm-gear Hypoid with a overall ratio of.7: Geared wheel hubs Speed reduction ratio:.9:

5 M998A HMMWV Modular Powertrain System Models Mean value modular engine model (DDC 6.5L) Full Dynamic drivetrain model Hydra-matic 4L80-E automatic transmission Torque converter with lock-up clutch Zexel-Gleason worm differentials -speed transfer case Flexible drive and axleshafts Quasi steady drivetrain model Inertia reflected at engine and wheels Driveline modeled as variable gear ratio Significantly speeds up system simulation Lower overall fidelity

6 The University of Wisconsin-Madison HMMWV The Powertrain University System of Wisconsin-Madison Dynamic Model HMMWV The Powertrain University of System Wisconsin-Madison Dynamic Model HMMWV The Powertrain Copyright University System 997 of Wisconsin-Madison Dynamic Model HMMWV Powertrain Copyright System 997 Copyright 997Dynamic Model Copyright 997 t orq_tc_pump t orq_tc_pump t orq_tc_pump t orq_tc_pump pedal_pos pedal_pos pedal_pos pedal_pos LINKAGE LINKAGE LINKAGE LINKAGE ENGINE ENGINE ENGINE ENGINE Load Vehicle Specific Load Vehicle Data time Specific Load Vehicle Data time Specific time Load Vehicle Data Clock double-click Specific beforedata Clock time Clock starting double-click simulation before Clock starting double-click simulation before starting double-click simulation before starting simulation Top Level Drivetrain Drivetrain Drivetrain Drivetrain torq_tc_pump torq_tc_pump T.C. and Transmission T.C. and Transmission Transfer Case Transfer Case torq_fds torq_fds Part of the HMMWV powertrain system modular structure (torque converter to wheels Driveline shown) omega_front omega_front omega_rear omega_rear Rear Driveline Rear Driveline torq_rds torq_rds omega_tire_lr omega_tire_lr omega_tire_rr omega_tire_rr omega_tire_fr omega_tire_fr F_tractive_rf F_tractive_rf torq_tc_pump torq_tc_pump torq_tc_turb torq_tc_turb 0. -Kveh.speed 0. -Kveh.speed ft/s->mph ft/s->mph torq_clutches torq_clutches Clutch Capacity Clutch Control Capacity Control omega_trans_out omega_trans_out Front Driveline Front Driveline omega_tire_fl xdot_veh 0. omega_tire_fl xdot_veh ft/s -> mph 0. Vehicle ft/s -> mph Dynamics Vehicle Dynamics omega_tire_rf omega_tire_rf RF Tire RF Tire /FDSR /FDSR FDTR FDTR Right front axle Right front axle torq_fds_out torq_fds_out Front Driveline Torque Converter Torque Converter torq_trans_in torq_trans_in 4L80E 4L80E TORSEN TORSEN Front driveshaft Front driveshaft omega_trcase_out omega_trcase_out omega_diff_pinion omega_diff_pinion Torque Converter and and Transmission omega_tire_lf omega_tire_lf /FDSR /FDSR Left front axle Left front axle ogear ogear LF Tire LF Tire FDTR FDTR fuel_com fuel_com 0 0 offset offset tps tps tps tps gear gear c_p_ c_p_ F_tractive_lf F_tractive_lf omega _ww omega _ww alp ha_ww alp ha_ww Calc. mu Calc. mu speed speed /TCGR /TCGR speed speed up_s hift up_s hift upshift upshift d_shift d_shift d_shift d_shift shifts shifts shift_way Demux shift_way Demux shift_logic shift_logic 0-> c_p_ 0-> c_p_ 0-> 0-> c_p_ c_p_ 0-> 0-> c_p_4 c_p_4 0-> 0-> c_p_5 c_p_5 0-> 0-> c_p_6 c_p_6 0-> 0-> Safety Factor Safety Factor clutc h_c om clutc h_c om Clutch Commands Clutch Commands Clutch Control T_frontright T_frontright T_frontleft T_frontleft T_f pc T_f pc f(u) /s Calc. f(u) omega_wws /s alpha_wws Calc. omega_wws alpha_wws Worm Wheel Torques Worm Wheel Torques alp ha_fpc alp ha_fpc f(u) /s Calc. f(u) omega_fpc /s alpha_fpc Calc. omega_fpc alpha_fpc omega _fpc omega _fpc Front Axle Front Axle Torsen Differential T_fds T_fpc T_fds T_fpc FinalDr omega_fpin Ratio FinalDr omega_fpin Ratio LF axle LF axle RF axle RF axle

7 M ode 4 4th Gear C Locked C Locked C4 Locked Mode rd Gear C Locked C Locked C5 Locked M ode nd Gear C Locked C Locked C5 Locked M ode st Gear C Locked C5 Locked C6 Locked C4 Locks C5 Locks C Locks C4 Unlocks C (-way) Locks C (Plate) Locks C Unlocks C6 Locks C Locks C5 Unlocks C Unlocks C (-way) Unlocks C6 Unlocks M ode 7 Reverse C Locked C5 Locked C6 Locked Mode5 -> 4, 4-> Shifts C Locked C Locked Sp eed Phase Mode8 ->, -> Shifts C Locked C5 Locked Sp eed Phase C (Plate) Unlocks Mode6 ->, -> Shifts C Locked C5 Locked Speed Phase Hydra-Matic 4L80-E Model: State Transition Diagram (shift logic) - 4 Forward gears - Reverse gear - Intermediate states (speed phases)

8 M998A HMMWV System Optimization Examples Case study: Examine the dynamic interactions between transmission hardware and transmission control strategy. How does clutch capacity (hardware configuration) and shift time (control strategy) combine to affect the overall system? Shift maximum dissipated power? (affects vehicle performance) Shift total dissipated energy? (affects clutch life) Torque hole magnitude? (affects shift quality) Cost functions to optimize hardware & strategy!

9 M998A HMMWV Definition of Optimization Tests Shift from first to second gear rd clutch on-coming (control pressure increase) Overriding sprag clutch off-going Vary clutch capacity = maximum possible torque transmitted through that clutch Size of clutch plates Clutch piston size Maximum working hydraulic pressure Maximum friction coefficient Vary engaged time: length of time for on- coming clutch pressure to reach maximum Control Strategy

10 The University of Wisconsin-Madison HMMWV The Powertrain University System of Wisconsin-Madison Dynamic Model HMMWV The Powertrain University of System Wisconsin-Madison Dynamic Model HMMWV The Powertrain Copyright University System 997 of Wisconsin-Madison Dynamic Model HMMWV Powertrain Copyright System 997 Copyright 997Dynamic Model Copyright 997 t orq_tc_pump t orq_tc_pump t orq_tc_pump t orq_tc_pump pedal_pos pedal_pos pedal_pos pedal_pos LINKAGE LINKAGE LINKAGE LINKAGE ENGINE ENGINE ENGINE ENGINE Load Vehicle Specific Load Vehicle Data time Specific Load Vehicle Data time Specific time Load Vehicle Data Clock double-click Specific beforedata Clock time Clock starting double-click simulation before Clock starting double-click simulation before starting double-click simulation before starting simulation Top Level Drivetrain Drivetrain Drivetrain Drivetrain torq_tc_pump torq_tc_pump T.C. and Transmission T.C. and Transmission Transfer Case Transfer Case torq_fds torq_fds omega_front omega_front omega_rear omega_rear Modify: rd clutch capacity rd clutch control Analyze: Affects on overall Driveline system Rear Driveline Rear Driveline torq_rds torq_rds omega_tire_lr omega_tire_lr omega_tire_rr omega_tire_rr omega_tire_fr omega_tire_fr F_tractive_rf F_tractive_rf torq_tc_pump torq_tc_pump torq_tc_turb torq_tc_turb 0. -Kveh.speed 0. -Kveh.speed ft/s->mph ft/s->mph torq_clutches torq_clutches Clutch Capacity Clutch Control Capacity Control omega_trans_out omega_trans_out Front Driveline Front Driveline omega_tire_fl xdot_veh 0. omega_tire_fl xdot_veh ft/s -> mph 0. Vehicle ft/s -> mph Dynamics Vehicle Dynamics omega_tire_rf omega_tire_rf RF Tire RF Tire /FDSR /FDSR FDTR FDTR Right front axle Right front axle torq_fds_out torq_fds_out Front Driveline Torque Converter Torque Converter torq_trans_in torq_trans_in 4L80E 4L80E TORSEN TORSEN Front driveshaft Front driveshaft omega_trcase_out omega_trcase_out omega_diff_pinion omega_diff_pinion Torque Converter and and Transmission omega_tire_lf omega_tire_lf /FDSR /FDSR Left front axle Left front axle ogear ogear LF Tire LF Tire FDTR FDTR fuel_com fuel_com 0 0 offset offset tps tps tps tps gear gear c_p_ c_p_ F_tractive_lf F_tractive_lf omega_ ww omega_ ww alp ha_ww alp ha_ww Calc. mu Calc. mu speed speed /TCGR /TCGR speed speed up_s hift up_s hift upshift upshift d_shift d_shift d_shift d_shift shifts shifts shift_way Demux shift_way Demux shift_logic shift_logic 0-> c_p_ 0-> c_p_ 0-> 0-> c_p_ c_p_ 0-> 0-> c_p_4 c_p_4 0-> 0-> c_p_5 c_p_5 0-> 0-> c_p_6 c_p_6 0-> 0-> Safety Factor Safety Factor clutc h_c om clutc h_c om Clutch Commands Clutch Commands Clutch Control T_frontright T_frontright T_frontleft T_frontleft T_f pc T_f pc f(u) /s Calc. f(u) omega_wws /s alpha_wws Calc. omega_wws alpha_wws Worm Wheel Torques Worm Wheel Torques alp ha_fpc alp ha_fpc f(u) /s Calc. f(u) omega_fpc /s alpha_fpc Calc. omega_fpc alpha_fpc omega_ fpc omega_ fpc Front Axle Front Axle Torsen Differential T_fds T_fpc T_fds T_fpc FinalDr omega_fpin Ratio FinalDr omega_fpin Ratio LF axle LF axle RF axle RF axle

11 Hydra-Matic 4L80-E Transmission Upshift (clutch capacity & shift strategy) Link C-4 C-5 Link C- Planetary Gearset C- C- Link 5 Link 4 C-6 Link 6 Planetary Gearset Planetary Gearset Input Shaft (Link ) Output Shaft (Link 7)

12 Maximum Dissipated Power Normalized Maximum Dissipated Power Engaged time[s] Clutch Capacity[ft lb] 0 00

13 Total Dissipated Energy Normalized Total Dissipated Energy Clutch Capacity[ft lb] Engaged time[s]

14 Magnitude of Shift Torque Hole Normalized Torque Hole Clutch Capacity[ft lb] Engaged time[s]

15 Weighted Dissipated Energy & Power Weighted Distribution Clutch Capacity[ft lb] Engaged time[s]

16 Weighted Energy, Power & Torque Hole 5 Optimization of Objective Function Clutch Capacity[ft lb] Engaged time[s]

17 Summary and Conclusions: Case Studies n Maximum Dissipated Power n Power losses minimized with a short and high torque shift (very little slipping) n Total Dissipated Energy n Larger clutch capacity and shorter shifts mean more energy absorbed by the clutch n Torque Hole n Minimum torque hole with slow, low torque shift n Weighted Optimization n Find desired regions of operation (optimize hardware & strategy)

18 Summary and Conclusions: Overall Models n Dynamic models of the complete HMMWV powertrain system have been developed by the University of Wisconsin-Madison Quad - see erc.wisc.edu/powertrain/ n Powertrain system models can be used for optimization of individual components, subsystems, or overall system performance. n Examples were presented showing the combined optimization of both hardware (clutch capacity) and control (shift strategy), for performance, shift quality, and clutch life.

Powertrain Simulation of the M1A1 Abrams using Modular Model Components

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