dynamic shift coordinated control based on motor active...
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Research ArticleDynamic Shift Coordinated Control Based on Motor ActiveSpeed Synchronization with the New Hybrid System
Ting Yan,1 Lin Yang,1 Bin Yan,1 Wei Zhou,1 Liang Chen,2 andWei Zhou1
1 Institute of Automotive Electronic Technology, School of Mechanical Engineering, Shanghai Jiao Tong University,Shanghai 200240, China2Shanghai 01 Power Technology Co., Ltd., Shanghai 200240, China
Correspondence should be addressed to Lin Yang; [email protected]
Received 1 November 2016; Accepted 10 April 2017; Published 11 July 2017
Academic Editor: Mario Terzo
Copyright ยฉ 2017 Ting Yan et al.This is an open access article distributed under the Creative Commons Attribution License, whichpermits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Considering the inherent disadvantages that severely affect driving comfortability during the shift process in HEVs, a dynamicshift coordinated control based on motor active speed synchronization is proposed to improve shift quality by reduction of shiftvibration.The whole control scheme is comprised of three phases, preparatory phase, speed regulation phase, and synchronizationphase, which are implemented consecutively in order.The key to inhibiting impact and jerk depends on the speed regulation phase,wheremotor active speed synchronization is utilized to reach theminimum speed difference between the two ends of synchronizer.A newhybrid systemwith superior performances is applied to present the validity of the adopted control algorithmduring upshift ordownshift, which can represent planetary gear system and conventional AMT shift procedure, respectively. Bench test, simulation,and road test results show that, compared with other methods, the proposed dynamic coordinated control can achieve shiftingcontrol in real time to effectively improve gear-shift comfort and shorten power interruption transients, with robustness in bothconventional AMT and planetary gear train.
1. Introduction
Hybrid electric vehicle (HEV) is emerging as an importantsubstitution for traditional transportation due to its fuel econ-omy improvement and emission reduction. Its powertraincan be classified as conventional AMT type and planetarygear train type based on coupled manner. A new type ofhybrid system is proposed in this paper, whose structurecombines both of the two mainstream types together, withsuperiority in dynamic performance and fuel economy aswell [1โ3]. However, since they have complicated powertrainstructure and various operational modes, power interruptionand torque fluctuation during mode transformation, espe-cially in the shift synchronization period, can easily result indriving vibrations and jerks, which greatly influences drivingcomfortability. Alleviating and damping driving vibrationsduring gear-shift become one of the key issues in vehicledynamic switching control [4].
Many approaches have been proposed to find bettersolutions to overcome the shortcomings in gear-shifting
process of HEV. Glielmo et al. raised a hierarchical methodbased on cascaded and decoupled speed and torque con-trol loops [5]. Shin et al. developed a combined gear-shifting method assisted by motor speed feedback control[6]. Baraszu and Cikanek demonstrated that during the gear-shifting process a motor should provide torque directly toreduce the power interruption time [7]. A combination ofDynamic Programming (DP) and Pontryaginโs MinimumPrinciple (PMP) was utilized in a model predictive controllerframework to realize a predictive controller in a recedinghorizon mode for a PHEV equipped with an AMT [8]. Thecomputational burden and assumption that velocity profileis available ahead limit its application in real-time control.Control strategies used in clutchless gear-change drivelinesin hybrid electric vehicles are discussed in [9โ11]. This limitsthe usage of the proposed methods in these literatures to thegear-shifting process related to clutch engagement and thedrivability performances cannot be guaranteed. The strategyin electric vehicles equipped with hydraulic combined clutchtransmissions in [12] is presented to improve the shift quality.
HindawiShock and VibrationVolume 2017, Article ID 2716251, 16 pageshttps://doi.org/10.1155/2017/2716251
2 Shock and Vibration
ClutchEngine
MG1
S
k1k2
MG2
โ โก
Figure 1: Simplified structural diagram of new HEV system (S: shift synchronizer, MG1: generator, MG2: motor, and ๐พ1/๐พ2: gear ratio).
Nevertheless, the complexity of the shift hydraulic circuit andits nonlinear feature bring in challenges to predict the oilpressure acting on the brake piston. A synthesis algorithmto realize accurate engine speed control and shift motorposition control without disengaging the clutch using engineactive control was presented by Zhong et al. [13], which hasnot significantly improved the conditions on account of theslow response of engine. So motor active speed control wasproposed to achieve shifting synchronization during gear-shifting process on account of the rapid response of motorcharacteristics [14, 15]. However, their powertrain structuresare simple, which are both single motor in single axlewithout clutch, and the algorithms raised cannot be appliedto complex powertrains with clutch or dual motors, not tomentionwith planetary gear system. As a consequence, a newmotor active speed synchronization with clutch coordinatedcontrol is introduced to achieve a fast and smooth gear-shiftin the new hybrid system.
Due to the tremendous structural difference between thetwo gears of the new hybrid system, the speed differencebetween the two ends of synchronizer is large as it is ready toshift. Upshift or downshift directly will lead to strong vibra-tions and severe wear of the synchronizer. As a result, motorspeed adjustment is required before the synchronizationbegins in order tominimize shift time andpower interruptionperiod and decrease the impact force and improve shiftquality. Meanwhile, to acquire a fast and smooth gear-shift,the engine, motor, clutch, and actuator of the gearbox arecontrolled precisely and coordinately. Before switching toneural gear, the transmitted torque to the output shaft mustbe reduced to close to zero; otherwise attempting to disengageor engage the gears which are transmitting large torquescan bring about torsional vibration, teeth surface damage ofthe gears, and synchronization difficulty. So unloading thepower sources as well as disengaging the clutch completely isnecessary prior to switching to neutral gear. Clutch remainsdisengaged throughout andmotors are unloaded again beforethe synchronization begins due to the same reason. Thecoordinated control raised above can ensure the rapidity andsmoothness of the gear-shift process as validated by on-boardtests.
The dynamic shift coordinated control scheme based onmotor active speed regulation can be divided into three
phases: unload and switch to neural gear, speed regulation,and mechanical speed synchronization by the synchronizer.The second phase is the core part. The new type of HEVsystem is employed to assess the feasibility of the controlscheme. The reason to select this new hybrid system asthe research object depends on two points. Firstly, the newhybrid system has huge advantages in fuel economy anddynamic performances. The rate of fuel saving can reach17%โผ28% in different driving cycles in comparison withconventional parallel hybrid vehicles, which can attain up tonearly 40% when compared with traditional diesels [1, 3]. Onthe other hand, the maximum output torque before the finaldrive of the new system is over 3600Nm, which can meetpower demands in assorted situations. Secondly, it containstwo representative powertrains in two gears and the struc-tural difference between the two gears results in inevitablespeed regulation during shift process. By presenting upshiftand downshift control scheme, the regulation process inconventional AMT and planetary gear train can both berevealed in the new hybrid system, as shown in Section 3.2.In Section 2, the structure and operating principle of the newHEV system is presented. In Section 3, dynamic coordinatedcontrol and active speed synchronization are elaborated,respectively. Bench test and on-board test results showingthe effectiveness of the proposed approach are presented inSection 4. Conclusions that summarize the results of thepaper are obtained in Section 5.
2. The New HEV System
The simplified structural diagramof theHEV system adoptedin this paper is shown in Figure 1. It is mainly composedof a diesel engine, two permanent magnetic motors, anda planetary gear coupling system. MG2 is linked to thesun gear directly, while MG1 is connected to the ring gearand separated from engine by an electronic control clutch.Comparedwith the traditional hybrid system, the new systemcan adjust the speed range of engine operating point flexiblythrough the CVT coupling system, which ensures that engineis working in high-efficiency area and improves vehicle fueleconomy. Meanwhile engine can collaborate with generatorto drive the vehicle or charge the battery to meet vehicledynamic and duration requirements.
Shock and Vibration 3
While the shift synchronizer is placed at the right end,gear number is 1. And the motor output torque is amplifieda few times via a conventional gear train to the outputshaft to meet the working condition requirement as thedemanded torque is high, such as vehicle launching process.As mentioned previously, this relationship can be written asfollows:
๐๐ = ๐MG2 ร ๐พ1 ร ๐พ2, (1)
๐๐1 = ๐MG2(๐พ1 ร ๐พ2) , (2)
where ๐๐ and ๐MG2 denote the output shaft torque and MG2torque, respectively, ๐๐1 and ๐MG2 denote the output shaftspeed at the first gear andMG2 speed, and๐พ1 and๐พ2 denotethe gear ratios of the gear train.
While the shift synchronizer is placed at the left end, gearnumber is 2. The sun gear (MG2) and the ring gear (MG1and engine) are coupled and transfer torque to the planetarygear ultimately. With the known features of the planetarygear train, the relationship in the steady state is described asfollows:
๐๐ = ๐MG2 ร ๐ผ, (3)
๐๐ = ๐๐ + ๐MG2 = ๐MG2 ร (1 + ๐ผ) , (4)
๐๐ = ๐MG1 + ๐ ร ๐ICE, (5)
๐๐2 = ๐ผ ร ๐MG1 + ๐MG21 + ๐ผ , (6)
where
๐ ={{{{{{{{{
1, clutch is engaged
0, clutch is disengaged
0โผ1, clutch is slipping.
(7)
๐ผ denotes the coefficient of planetary gear, ๐๐, ๐MG1, and๐ICE denote the ring gear torque, MG1 torque, and enginetorque, respectively, and ๐MG1, ๐ICE, and ๐๐2 denote MG1speed, engine speed, and output shaft speed at the secondgear.
When the clutch is engaged,
๐MG1 = ๐ICE. (8)
Engine is linked to the powertrain completely in themeantime. From (6) and (8), we can conclude that by adjust-ing MG2 speed the engine can work in its high-efficiencyspeed range, leading to vehicle fuel economy improvement,as shown in Figure 2.
While the shift synchronizer is placed in the middle, thepowertrain is interrupted. No power can be transferred tothe output shaft due to the interruption. It is at the neutralposition at this moment.
The operating state of the newHEV system can be dividedinto four modes. The selection criteria depend on vehiclespeed, power requirement, and battery SOC.The four modesare tabulated in Table 1.
0
1000
2000
3000
4000
5000
6000
โ1000
Vehicle speed
Spee
d (r
pm)
โ2000๏ผ๏ผ๏ผ ๏ผ๏ผ2
1600 ๏ผฌ๏ผช๏ผง1400 ๏ผฌ๏ผช๏ผง1200 ๏ผฌ๏ผช๏ผง
5911 ๏ผฌ๏ผช๏ผง5457 ๏ผฌ๏ผช๏ผง5002 ๏ผฌ๏ผช๏ผง
2672 ๏ผฌ๏ผช๏ผง2218 ๏ผฌ๏ผช๏ผง1763 ๏ผฌ๏ผช๏ผง
โ566 ๏ผฌ๏ผช๏ผงโ1024 ๏ผฌ๏ผช๏ผงโ1475 ๏ผฌ๏ผช๏ผง
80 ๏ผฅ๏ผง/๏ผข
50 ๏ผฅ๏ผง/๏ผข
20 ๏ผฅ๏ผง/๏ผข
Figure 2: Adjusting MG2 speed to regulate engine operating point.
3. Dynamic Coordinated Control
Coordinated control with other components is indispensableduring shift process. It is needed to guarantee the smoothnessof synchronization after speed regulation.Thewhole dynamiccoordinated control scheme is composed of three phases,which are shown in Figure 3 and described in detail asfollows. Every step in each phase should be confirmed fromthe feedback of the controlled components before taking onto the next step, which ensures the reliability of the wholeprocedure.
3.1. Preparatory Phase (Unload and Switch to Neutral Gear).The aim of this phase is to make preparations for the motoractive speed regulation. The main task includes unloadingpower sources, disengaging clutch, and putting into neutralgear. Motors and engine are in no-load condition after beingunloaded, which makes it convenient to disengage the clutchlater. No torque transmitted to the powertrain helps to switchto neutral gear smoothly to avoid jerks and noise.
The preparatory phase period should not last too long.Otherwise, the driver would perceive the lack of power dueto no power output during the phase. On the other hand,the descending slope of the command torque sent to DMCMshould be considered not too large, which will induce thefeeling of abruption. The flow chart is shown in Figure 4.
3.2. Speed Regulation Phase. Speed regulation during shiftingprocess is indispensable, which is aimed at adjusting the inputshaft to a desired speed without overshoot and oscillation. Itis found by experiments that only when the speed differenceis less than an acceptable reference value ๐ can the synchro-nization start. Moreover, it is easier to put into the target gearwhen the speed of the active speed-adjusting end is slightlyhigher than the passive end of the synchronizer, which is inconsistence with the principle in conventional buses. So (9)must be satisfied before the synchronization begins:
๐ฟ โค ๐๐๐ โ ๐๐ โค ๐, (9)
4 Shock and Vibration
Table 1: The four operation modes of new HEV system.
Mode Gear number Clutch status DescriptionSingle-motor pureelectric mode 1 Engaged Only MG2 drives the
vehicle
Series mode 1 EngagedMG2 drives vehicle; MG1and engine collaborate to
generate electricityDual-motor pureelectric mode 2 Disengaged MG1 and MG2 drive the
vehicle together
Series-parallel mode 2 Engaged MG1, MG2, and enginedrive the vehicle together
Switch clutch pump solenoid valves on/off to engage or disengage the clutch
Synchronization phase(mechanical speedsynchronization)
DMCM1/DMCM2/ECU speed control
DMCM1/DMCM2/ECU unload control
Control shift motor to put into the target gear
Preparatory phase(unload and switch toneural gear)
Speed regulation phase(adjust MG1/MG2/engine speed)
Figure 3: The control scheme of the dynamic coordinated control.
where ๐๐๐ is the target speed of output shaft linked to thesynchronizer in the speed regulation phase, ๐๐ is actual speedof output shaft, and ๐ฟ and ๐ are speed calibrations determinedby the speed difference calibration experiment in the benchtest.
The output shaft speed is closely associated with thevehicle speed, as shown in the following equation:
๐๐ = ๐๐ ๐ ร ๐๐๐ ร 602๐ , (10)
where ๐๐ ๐ denotes vehicle speed, ๐๐ denotes final gear ratio,and ๐ denotes the wheelโs radius.
Due to short speed-adjusting time, large vehicle rota-tional inertia, and no power output during the neutralposition period, vehicle speed can be assumed to be approxi-mately constant.Then๐๐ can be presumed as nearly invariant
as well from (10). Equation (11) can be obtained from (2) and(6):
๐๐๐ ={{{{{{{{{
๐๐MG2(๐พ1 ร ๐พ2) downshift
๐๐MG2 + ๐ผ ร ๐๐MG11 + ๐ผ upshift,(11)
where ๐๐MG1 and ๐๐MG2 denote MG1 target speed and MG2target speed.
The speed regulation processes of upshift and downshiftare discussed, respectively, due to the complicated structureof the new HEV system.
3.2.1. The First Upshift Speed Regulation (Single-Motor Modeto Dual-Motor Mode). In single-motor mode, Only MG2
Shock and Vibration 5
Gearshift?
Start
Yes
No
Yes
Disengage the clutch
Clutch disengaged?No
Yes
Put into neutral gear
At neutral gear?No
Yes
End
No
|Ti| < 10
Unload control(MG1/MG2/engine)
Figure 4: The preparatory phaseโs flow chart.
propels the vehicle, while engine and MG1 are in idle stateand do not output power at all:
๐MG1 = ๐ICE = 0. (12)
In dual-motor mode, MG1 and MG2 propel the vehicletogether. One motor must be in speed control mode andthe other in torque control mode to keep the system stabledue to the features of planetary gear system. MG2 is chosenas the speed controlled motor because of its excellent speedadjustment performance. Then MG1 is in torque controlmode as its torque regulation performance is good. Theoptimal combination of MG2 and MG1 speed of highestsystem efficiency (๐โMG2, ๐โMG1) can be acquired based ontwo motorsโ efficiency characteristic curves under differentvehicle speed and vehicle demanded torque conditions. Thecalculation procedure is as follows.
(1) Set a combination of vehicle speed and demandedtorque (๐๐ ๐ , ๐Dmnd) as known quantities; then
๐MG1 = ๐Dmnd ร ๐ผ1 + ๐ผ , (13)
๐MG2 = ๐Dmnd1 + ๐ผ . (14)
(2) Given a series of MG1 speed (๐1MG1, ๐2MG1, . . . , ๐๐MG1),the corresponding MG2 speed under ๐๐ ๐ can be con-ducted (๐1MG2, ๐2MG2, . . . , ๐๐MG2) from the relationshipin (6):
๐๐MG2 = 60๐๐ ๐ (1 + ๐ผ) ๐๐2๐๐ โ ๐ผ๐๐MG1 ๐ = 1, 2, 3, . . . , ๐. (15)
(3) MG1 efficiency ๐๐MG1 and MG2 efficiency ๐๐MG2 aregained by making use of the obtained combination(๐๐MG1, ๐MG1) and (๐๐MG2, ๐MG2) to look up to MG1and MG2 efficiency curves.
(4) If there is a combination (๐๐MG1, ๐MG1, ๐๐MG1) or(๐๐MG2, ๐MG2, ๐๐MG2), which meets the equation
(๐๐MG1 ร ๐MG1)๐๐MG1+ (๐๐MG2 ร ๐MG2)๐๐MG2
= min[(๐๐MG1 ร ๐MG1)๐๐MG1+ (๐๐MG2 ร ๐MG2)๐๐MG2
] ,(๐, ๐ = 1, 2, . . . , ๐) ,
(16)
then (๐๐MG1, ๐๐MG2) is the speed optimal combination(๐โMG1, ๐โMG2) under (๐๐ ๐ , ๐Dmnd) conditions.(5) Repeat the steps above to get all the optimal speed
combination (๐โMG1, ๐โMG2) under different vehiclespeed and vehicle demanded torque conditions.
After switching to neutral gear, set MG1 operating intorque controlled mode. Assume that MG1 command torqueis ๐๐MG1; the time from current speed to the target speed๐rawMG1 is ๐ก1. MG1 unloads torque and prepares to put into the
target gear when reaching the target speed. But MG1 speedwill keep on rising up during the unload process becauseof its response delay until achieving the peak speed. Then itbegins to drop slowly. Set the peak speed as ๐๐MG1 and theperiod from ๐raw
MG1 to ๐๐MG1 as ๐ก2. Since MG1 has outstandingtorque regulation performance, MG1 actual torque can beconsidered as achieving the command torque quickly byfollowing a constant slope, as shown in Figure 5.
As MG1 reaches the peak speed, MG1 actual torque isclose to zero and the speed change is gentle, which makes itthe ideal optimal point.
Set
๐๐MG1 = ๐โMG1. (17)
6 Shock and Vibration
0
๏ผ๏ผ1_p
๏ผ๏ผ1_๏ผฌ๏ผ๏ผฑ
T๏ผ๏ผ1
๏ผ๏ผ2
t
t1 t๏ผ๏ผ1
๏ผ๏ผ1
T๏ผ๏ผ1_T
T๏ผ๏ผ1_๏ผฆ๏ผฉ๏ผญ๏ผญ
T
Figure 5: Variables changing curves in upshift speed regulation 1.
And the total MG1 speed regulation time is ๐กMG1:
๐กMG1 = ๐ก1 + ๐ก2. (18)
The speed regulation can be divided into two stages: 0โผ๐ก1and ๐ก1โผ๐กMG1. Equation (19) can be obtained in each stage:
(๐ โ ๐loss)22๐ + ๐(๐ก1 โ ๐๐ ) โ ๐loss๐ก1 = ๐ฝ๐rawMG1,
๐2 โ ๐2loss2๐ โ ๐loss๐ โ ๐loss๐ = ๐ฝ (๐๐MG1 โ ๐raw
MG1) ,๐ก2 = ๐ โ ๐loss๐ .
(19)
Then ๐กMG1 is attained by solving the above equations:
๐กMG1 = (๐ โ ๐loss)๐ + (๐2loss โ 2๐๐loss โ 2๐ฝ๐๐๐MG1)2๐ (๐loss โ ๐) , (20)
where ๐ and ๐loss denote MG1 command torque and frictiontorque; ๐ is MG1 torque response slope. ๐ฝ is MG1 equivalentrotational inertia.
The assignment of ๐ should consider that if ๐ is toolarge, even though ๐ก1 is short, the unloading process is longand speed increment is large. If ๐ is too small, even thoughunloading time ๐ก2 is short, ๐ก1 will be long due to the smallangular acceleration. ๐กMG1will be relatively long in either case.๐โ is presumed to be the optimal value of ๐, which meets thefollowing equation:
๐ (๐โ, ๐๐MG1) = min (๐กMG1) . (21)
Take the partial derivative of ๐ in (20) and ๐โ is obtainedas follows:
๐๐กMG1๐๐ = (๐2loss โ 2๐๐loss โ 2๐ฝ๐๐๐MG1)2๐ (๐loss โ ๐)2
โ ๐๐ (๐loss โ ๐) = 0,(22)
๐โ = ๐loss + โ๐2loss2 + ๐ฝ๐๐๐MG1. (23)
MG2 is set to operate in speed control mode on accountof its fast response and regulation precision. By adjustingMG2 target speed ๐๐MG2 quickly, the output shaft speed canbe coupled to ๐๐๐ exactly at the end of speed regulation.
MG2 target speed ๐๐MG2 is
๐๐MG1 = {{{๐โMG2 ๐ก โค ๐กMG1
(1 + ๐ผ) ๐๐๐ โ ๐ผ๐MG1 ๐ก > ๐กMG1; (24)
namely,MG2 speed is regulated to optimumvalue๐โMG2 priorto MG1 finishing torque regulation, which meets (9) as MG1rises to the peak speed ๐โMG1. If (9) cannot be met duringthe whole MG1 speed regulation process, then MG2 targetspeed is modified to satisfy the coupling relationship as MG1is free falling.The process is close to the shift speed regulationprocess in planetary gear systems with dual motors.
3.2.2. The Second Upshift Speed Regulation (Single-MotorMode/Series Mode to Series-Parallel Mode). In series-parallelmode, engine participates in propelling the vehicle. Takingthe output shaft speed ๐๐ , vehicle demanded torque ๐Dmnd,and engine power ๐ICE as the known quantity, a three-dimensional function table is made. The object of the func-tion is to acquire the highest combined efficiency of theengine and electrical system and meet the vehicle powerrequirement and reach SOC control target.The optimal com-bination (๐โMG2, ๐โMG1) is gained by following the procedurebelow.
(1) Set the combination (๐๐ , ๐Dmnd, ๐ICE) as the knownquantity. Vehicle demanded power ๐Dmnd = ๐Dmnd ร ๐๐ .
(2) Given a series of MG1 speed (๐1MG1, ๐2MG1, . . . , ๐๐MG1),the corresponding MG2 speed can be obtained as (๐1MG2,๐2MG2, . . . , ๐๐MG2) under vehicle speed ๐๐ ๐ condition by thefollowing relationship:
๐๐MG2 = ๐๐ ร (1 + ๐ผ) โ ๐ผ ร ๐๐MG1 ๐ = 1, 2, 3, . . . , ๐. (25)
Engine speed is equal to MG1 speed.(3) Engine torque is given as follows:
(๐1ICE, ๐2ICE, ๐3ICE, . . . , ๐๐ICE)= ( ๐ICE๐1MG1
, ๐ICE๐2MG1, ๐ICE๐3MG1
, . . . , ๐ICE๐๐MG1) . (26)
MG1 command torque is given as follows:
(๐1MG1, ๐2MG1, . . . , ๐๐MG1) = (๐Dmnd ร ๐ผ1 + ๐ผโ ๐1ICE, ๐Dmnd ร ๐ผ1 + ๐ผ โ ๐2ICE, . . . , ๐Dmnd ร ๐ผ1 + ๐ผ โ ๐๐ICE) .
(27)
MG2 torque is given as follows: ๐MG2 = ๐Dmnd/(1 + ๐ผ).(4)MG1 efficiency ๐๐MG1,MG2 efficiency ๐๐MG2, and engine
efficiency ๐๐ICE are gained by making use of the obtained
Shock and Vibration 7
combinations (๐๐MG1, ๐MG1), (๐๐MG2, ๐MG2), and (๐๐ICE, ๐ICE)to look up to MG1, MG2, and engine efficiency curves.
(5) If there are combinations (๐๐MG1, ๐MG1, ๐๐MG1), (๐๐MG2,๐MG2, ๐๐MG1), and (๐๐ICE, ๐ICE, ๐๐ICE) which meet the equation
(๐๐MG1 ร ๐MG1)๐๐MG1+ (๐๐MG2 ร ๐MG2)๐๐MG2
+ ๐พ ร ๐ICE๐๐ICE= min[(๐๐MG1 ร ๐MG1)๐๐MG1
+ (๐๐MG2 ร ๐MG2)๐๐MG2+ ๐พ
ร ๐ICE๐๐ICE ] (๐, ๐ = 1, 2, . . . , ๐) ,
(28)
where ๐พ is the equivalent conversion factor from enginepower to electric power, then (๐๐MG1, ๐๐MG2) is the speedoptimal combination (๐โMG1, ๐โMG2) under (๐๐ ๐ , ๐Dmnd) con-ditions.
(6) Repeat the steps above to get all the optimal speedcombination (๐โMG1, ๐โMG2) under different vehicle speed,vehicle demanded torque, and engine power conditions.
When entering series-parallel mode, clutch has to beengaged as soon as possible. Hence the speed differencebetween MG1 and engine should not be too big; otherwiseengaging directly will result in severe abrasion and jerk.Moreover, readjusting MG1 speed will delay MG1 torquerecovery time. To avoid the problems appearing after upshiftprocess, engine speed is always commanded to the optimumspeed ๐โMG1 during the shift process, which is also the targetspeed of MG1:
๐โICE = ๐๐MG1 = ๐โMG1. (29)
MG2 speed regulation target is the same as (24). MG1command torque in single-motor mode to series-parallelmode is identical to (23). The derivation of ๐โin series modeto series-parallel mode is similar to (19) and (22):
๐โ
={{{{{{{{{{{
๐loss + โ๐2loss2 + ๐ฝ๐ (๐๐MG1 โ ๐๐ MG1) ๐๐MG1 > ๐๐ MG1
๐loss โ โ๐2loss2 + ๐ฝ๐ (๐๐ MG1 โ ๐๐MG1) ๐๐MG1 < ๐๐ MG1,(30)
where ๐๐ MG1 is MG1 speed in series mode. Unlike the single-motor mode to series-parallel mode, ๐โ in series mode toseries-parallel mode may be positive or negative dependingon whether๐๐ MG1 is less than๐๐MG1 or not.The situation when๐โ > 0 is similar to Figure 4, while ๐โ < 0 is shown inFigure 6.
3.2.3. Downshift SpeedRegulation. OnlyMG2 connects to thepowertrain after downshift no matter in single-motor modeor in series mode. MG2 target speed can be obtained in (31),which is similar to conventional AMT:
๐๐MG1 = ๐๐๐ ร ๐พ1 ร ๐พ2. (31)
0
๏ฟฝํ ๏ฟฝํMG1_p
๏ฟฝํMG1_s
๏ฟฝํMG1_raw
TMG1
๏ฟฝํMG2
t
t1 tMG1
๏ฟฝํMG1
TMG1_T
TMG1_loss
T
Figure 6: Variables changing curves in upshift speed regulation 2.
MG1 speed does not need to be regulated during down-shift process.MG1 only needs tomake preparations to unloadand put into target gear. In summary, the flow chart of shiftspeed regulation process is as shown in Figure 7.
3.3. Synchronization Phase. Mechanical speed synchroniza-tion is executed by the synchronizer to put into the targetgear fromneutral gear in this phase, duringwhich shiftmotordrives the synchronizer to reach the stroke range of the targetgear. Hybrid control unit (HCU) adjusts the pulse duty ratioof 24V voltage to control the power of shift motor in orderto overcome the different situations. Moreover, PID controlof position and velocity closed loop is utilized to solve thenonlinear and parameter uncertainty situation inmechanicalsynchronization. If the synchronization time exceeds normaldefault value, it means that motor stalling appears due tospeed regulation failure or shift motor faults. Shift motor hasto be stopped immediately at this moment. The shift processinterrupts and enters fault mode, where the target gear isrevised to neutral gear due to the fact that the resistance toneural gear is relatively small and no contact exists betweensynchronizer and powertrain in neural gear so as to protectthe shiftmechanism and check fault reason in park condition.After returning to neutral gear, the shift synchronizer can tryto put into the target gear again up to three times. If threeattempts all end in failure, then fault lamp is lightened andthe gear fixes in neural gear.Theflow chart of synchronizationphase is shown in Figure 8.
4. Experiments Validation
In order to prepare for the on-board road test, a hybridelectric system bench test-bed was built to debug and validatethe basic characteristics of motors and vehicle functionimplementation, as shown in Figure 9. It consists of couplingsystem (including two motors and transmission), DMCMs,dynamometer, battery, engine, and accessories.
4.1. Motor Dynamic Characteristic Test on Bench Test-Beds. Itcan be concluded from (23) and (30) that parameters ๐ฝ, ๐,and ๐loss must be confirmed to attain the optimal command
8 Shock and Vibration
End ofpreparatoryphase
Need upshift?
MG2 in speed control modeMG1 in torque control mode
speed regulation
Reach the speed regulation target
End
MG2 speed regulation
Series mode toseries-parallel mode?
Engine speed regulation
Engine in idle state
Achieve target speed?
Achieve target speed?
Yes
Upshift start
No
Downshift start
NoNo
Yes
End
No
Engine controlMotor control
Yes
Yes
No
Yes
Figure 7: The speed regulation phaseโs flow chart.
torque ๐โ. As a series of MG1 free-fall curves under differentinitial speed conditions shown in Figure 10, in the initialperiod of time, all the MG1 speed curves are approximatedto a straight line of the same slope in the shift speed range.The kinetic equation is shown as follows:
๐loss = ๐ฝฮ๐ฮ๐ก . (32)
๐loss can be obtained by MG1 torque in its stable speedcontrol mode state. As verified by experiment, in MG1 speedrange during shift process, ๐loss is about 15Nm. The slope ofMG1 free-fall curves is around 19.4 rad/s2 from Figure 10.๐ฝ is 0.77 kgโm2 from (32). It is far more than the normalrotational inertia of rotors in permanent magnet motors.That is because MG1 transmission shaft is always linkedto the ring gear in planetary gear system. Besides, planetgear and carrier are also rotating when MG1 rotates alone.Hence ๐ฝ is actually the sum of MG1 rotational inertia andplanetary gear system equivalent rotational inertia. ๐ is 2500as motor torque response rate is 100Nm/40ms according
to the motor control requirement. By calculating on thebasis of the optimization algorithmmentioned above, ๐โMG1is1200 rpm. ๐๐ MG1 is 1300 rpm during series mode to series-parallel mode.๐โ is 509Nm obtained from (23) in the first upshiftspeed regulation. To verify the validity of the torque value๐โ, the relationships of total regulation time ๐กMG1 and speeddifference ฮ๐MG1 with unload speed ๐raw
MG1 under differentcommand torque conditions are recorded by experiments.The results are displayed in Figures 11 and 12.
It can be concluded that ๐กMG1 and ฮ๐MG1 are inter-restricted with each other from Figures 11 and 12. Short ๐กMG1requires ๐๐MG1 to be large enough, which will result in largeฮ๐MG1. On the contrary, small ๐๐MG1 signifies small ฮ๐MG1,but speed regulation process will be prolonged and the wholeshift process will be postponed accordingly. By comparingthe results of several sets of data, ๐โ around 500Nm can beregarded as the selected command torque comprehensivelyconsidering its fast speed regulation and acceptable increaseof speed, which is also consistent with the calculation results
Shock and Vibration 9
Unload control
End of speedregulation
Shift motor control starts
Reach the target stroke range?
End
Synchronizer moves towardsthe target gear
Exceed normal shift time?
Enter shift fault mode
No
Yes
No
No
Yes Yes
||Ti < 10๏ผ๏ผง
Figure 8: The synchronization phaseโs flow chart.
Figure 9: Bench test-bed for new hybrid electric system.
from (23). As ๐โ goes on increasing, the time contractioneffect is not obvious, whereas ฮ๐MG1 increases significantly.
In the second upshift speed regulation, ๐โ is 158Nm ascalculated from (30). Reducing ฮ๐MG1 is considered as the
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
200
400
600
800
1000
1200
1400
Time (s)
MG
1 sp
eed
(rpm
)
Figure 10: MG1 free-fall speed curves.
10 Shock and Vibration
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
0.500.550.600.650.700.750.800.850.900.951.001.051.101.151.201.25
The t
otal
regu
latio
n tim
e (s)
MG1 speed as it begins to unload (rpm)
200 ๏ผ๏ผง
300๏ผ๏ผง
400๏ผ๏ผง
500๏ผ๏ผง
600๏ผ๏ผง
Figure 11: The curves of ๐rawMG1 and ๐กMG1 under different ๐๐MG1.
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
50
100
150
200
250
300
350
400
450
Spee
d di
ffere
nce (
rpm
)
MG1 speed as it begins to unload (rpm)
200 ๏ผ๏ผง
300๏ผ๏ผง
400๏ผ๏ผง
500๏ผ๏ผง
600๏ผ๏ผง
Figure 12: The curves of ๐rawMG1 and ฮ๐MG1 under different ๐๐MG1.
main target at the moment due to the fact that the speedregulation time is relatively small.๐raw
MG1 can be obtained from (33) after ๐MG1_๐ and ๐๐MG1are confirmed:
๐rawMG1 = ๐๐MG1 โ (๐loss โ ๐๐MG1)22๐ฝMG1๐ . (33)
In practical engineering application, ๐rawMG1 can be deter-
mined by calibration tests directly. Given ๐๐MG1 = ๐โ as thecondition, ๐๐MG1 can be recorded by unloading from a set of
1100 1200 1300 1400 1500 1600 1700 1800 1900800
900
1000
1100
1200
1300
1400
1500
1600
1700
MG1 peak speed ๏ผ๏ผ1_p (rpm)
MG1
unlo
ad sp
eed๏ผ
๏ผ1
_๏ผฌ๏ผ๏ผฑ
(rpm
)
Figure 13: The peak speed ๐๐MG1 with unload speed ๐rawMG1.
different ๐rawMG1. A one-dimensional map was made on basis
of the data. ๐rawMG1 can be gained by the known ๐๐MG1 looking
up the map backwards. Taking the first upshift mode as anexample, ๐โ = 509Nm; the map is shown in Figure 13.
Meanwhile, speed control test forMG2 speed characteris-tics was carried out to make sure that MG2 speed response isfast and accurate. A series ofMG2 speed regulation tests wereimplemented throughout the speed range of shift process.Thetest results suggest that most of MG2 speed regulation endsin 0.5 s with high accuracy and regulating requirements aresatisfied.
The shift success rate was highest when ๐ฟ and ๐ weredetermined to be 10 rpm and 40 rpm by carrying on the testsabout output shaft speed difference in (9). The vibration andnoise are also in acceptable level.
4.2. Simulation Test. To prove the effectiveness of the pro-posed method, a simulation test was operated based onAMESim (Advanced Modeling Environment for performingSimulations of engineering systems). Since the maximumimpact degree during the shift process mainly relies onthe speed regulation phase and synchronization phase, theupshift procedure from single-motor mode to dual-motormode was chosen as the simulation object. The simulationarchitecture diagram of the proposedmethod was built basedon the powertrain transmission solution demo of AMESim,as shown in Figure 14.
The normal force applied on the sleeve of the synchro-nizer was obtained by the PID method to track an optimalsleeve displacement curve. Meanwhile a normal methodwithout speed regulation phase was simulated to compare theeffects, whose structure is shown in Figure 15.
The simulation results of both methods are listed in Fig-ures 16โ18.The 0.3 s ahead in proposedmethod was occupiedby speed regulation and the synchronization times in bothmethods are 0.3 s. Due to the fact that the synchronizationtime is constant (based on the displacement curve), theimpact degree can reflect the drivability performance. Itdenotes the variation rate of vehicle longitudinal acceleration
Shock and Vibration 11
From single-motor mode to dual-motor modeThe proposed method
โoptimal sleeve displacement curveโ
Sleeve
Load spring
Preload mechanism
Ring
Ring Idle gear
Power axle
Road slope
Vehicle
Figure 14: The simulation architecture diagram of the proposed method.
The normal methodโoptimal sleeve displacement curveโ
Sleeve
Load spring
Preload mechanism
Ring
Ring
Idle gear
Power axle
Road slope
Vehicle
From single-motor mode to dual-motor mode
Figure 15: The simulation architecture diagram of the normal method without speed regulation.
12 Shock and Vibration
Table 2: Definitions of clutch and gear states.
Clutch states Definitions Gear states Definitions1 Clutch is disengaged 1 At gear 12 Clutch is slipping 2 At gear 23 Clutch is engaged 0 At gear 0
3 In shift process
0.00 0.05 0.10 0.15 0.20 0.25 0.30500600700800900
0.00 0.05 0.10 0.15 0.20 0.25 0.30
0.0000.002
0.006
0.010
0.004
0.008
0.00 0.05 0.10 0.15 0.20 0.25 0.305.535
5.545
5.555
5.565
0.00 0.05 0.10 0.15 0.20 0.25 0.30โ3000
โ1000
1000
3000
Spee
d (r
pm)
Planetary gear speedOutput shaft speed
Actual sleeve displacementOptimal sleeve displacement
(m)
Disp
lace
men
t(m
/s)
Vehi
cle sp
eed
torq
ue (N
m)
Oup
ut sh
aft
X: time (s)
X: time (s)
X: time (s)
X: time (s)
Figure 16: The simulation results of the normal method withoutspeed regulation.
and embodies driverโs feeling about the impact load directlyand quantitatively, as shown in the following equation:
๐ฝ = ๐๐๐๐ก = ๐2V๐๐ก2 . (34)
On the other hand, another simulation based on a con-stant force exerted on the sleeve of the synchronizer was oper-ated.The results are shown in Figure 19.The synchronizationtimes of the proposedmethod and normalmethod are 0.354 sand 0.544 s, respectively. And the maximum impact degreesare 4.08m/s3 and 20.7m/s3, respectively.
Spee
d (r
pm)
Planetary gear speedOutput shaft speed
Actual sleeve displacementOptimal sleeve displacement
(m/s
)Ve
hicle
spee
dto
rque
(Nm
)O
uput
shaft
X: time (s)
X: time (s)
X: time (s)
X: time (s)0.0 0.1 0.2 0.3 0.4 0.5 0.6
550650750850950
0.0 0.1 0.2 0.3 0.4 0.5 0.6
0.0 0.1 0.2 0.3 0.4 0.5 0.65.485.505.525.545.56
0.0 0.1 0.2 0.3 0.4 0.5 0.6โ1000โ600โ200
200600
0.0000.002
0.006
0.010
0.004
0.008
(m)
Disp
lace
men
t
Figure 17: The simulation architecture diagram of the proposedmethod.
The two simulation results can verify that the speedregulation phase influences the drivability performance sig-nificantly and the proposed method can restrain the impactdegree and accelerate the synchronization process remark-ably.
4.3. Road Test. The vehicle carrying the new hybrid electricsystem is shown in Figure 20.
4.3.1. Upshift Test. Clutch states and gear states definitions arelisted in Table 2.
Shock and Vibration 13Im
pact
deg
ree (
m/๏ผญ
3)
Time (s)
16
14
12
10
8
6
4
2
0
โ2
โ4
โ6
โ8
โ10
โ12
โ14
0.0 0.1 0.2 0.3 0.4 0.5 0.6
Proposed methodNormal method
Figure 18: The impact degree curves of the proposed method andnormal method with an optimal displacement curve.
Impa
ct d
egre
e (m
/๏ผญ3)
Time (s)
Time (s)
0.0 0.1 0.2 0.3 0.4 0.5 0.6
Proposed methodNormal method
Proposed methodNormal method
Disp
lace
men
t (m
)
0.012
0.010
0.008
0.006
0.004
0.002
0.000
5
0
โ5
โ10
โ15
โ20
โ25
โ0.05
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
0.60
Figure 19: The results of the proposed method and normal methodwith a constant force.
Considering the space limit, single-motor mode to dual-motor mode is chosen as the research object of upshiftprocess. Clutch state and gear state are displayed in Figure 21.The control commands are in strict accordance with theshifting process execution.The variation curves of speed andtorque of two motors are shown in Figure 22. Engine isignored, since it is in condition of rest.
Figure 20: The vehicle carrying the new hybrid electric system.
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.2
0
2
4
posit
ion
Actu
al g
ear
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.2
0
2
4
posit
ion
Com
man
d ge
ar
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20
2
4
Clut
ch st
ate
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20
2
4
Time (s)
Time (s)
Time (s)
Time (s)sta
teCl
utch
com
man
d
Figure 21: Clutch state and gear state in upshift process.
It can be obtained that, after clutch disengages actually,the command gear turns to neutral gear and the shiftmechanism begins to move towards the neutral gear. Thenmotor speed regulation begins in the neutral gear. MG1command torque is 500Nm, which is cleared to zero afterMG1 actual speed reaches 969 rpm. The actual torque ofMG1 decreases to zero when MG1 speed attains 1182 rpm.MG2 speed is 2952 rpm as the gear position just turns to theneutral gear. MG2 command speed is 0 rpm at the beginning.
14 Shock and Vibration
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.2โ10
0
10
Jerk
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20
100020003000
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.2โ500
0
500
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20123
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20
1000
2000
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20
200400600
818.6 818.8 819 819.2 819.4 819.6 819.8 820 820.20
200400600
torq
ueco
mm
and
MG
1
torq
ueM
G1
Time (s)
Time (s)
Time (s)
Time (s)
Time (s)
Time (s)
Time (s)
MG
1sp
eed
MG
2m
ode
torq
ueM
G2
spee
dM
G2
Figure 22: The variation curves of speed and torque of two motors.
Then MG2 command speed direction changes from 0 to1 when its speed is below 200 rpm. MG2 speed reversesas the speed direction is 1. The value of MG2 commandspeed is calculated by (24). It is first based on MG1 peakspeed and its command speed changes as MG1 speed startsto free fall. After MG1 and MG2 speed regulation finishes,the relationship in (9) is satisfied. Then motor torque iscleared and mechanical synchronization begins. The shiftmechanism starts to migrate into the target gear.
The total shift process costs 1.08 s in the road test results.MG1 speed is 1170 rpm and MG2 speed is โ321 rpm afterspeed regulation process finishes. The coupling speed ๐๐๐ is714 rpm and output shaft speed๐๐ is 690 rpm at this time.Thespeed difference is 24 rpm, which meets the requirement of(9).
The degree of jerk during the shift process is recorded aswell. The test results in Figure 22 indicate that the maximum
448.2 448.3 448.4 448.5 448.6 448.7 448.8 448.9 449 449.1 449.2โ20
0
20
Deg
ree o
f jer
k
448.2 448.3 448.4 448.5 448.6 448.7 448.8 448.9 449 449.1 449.2
0
2
4
448.2 448.3 448.4 448.5 448.6 448.7 448.8 448.9 449 449.1 449.2
0
2
4
Actu
al g
ear
posit
ion
posit
ion
Com
man
d ge
ar
448.4 448.5 448.6 448.7 448.8 448.9 449 449.1 449.2 449.3
010002000
MG
2 sp
eed
448.2 448.3 448.4 448.5 448.6 448.7 448.8 448.9 449 449.1 449.2โ500
0
500
MG
2 to
rque
448.2 448.3 448.4 448.5 448.6 448.7 448.8 448.9 449 449.1 449.20
1
2
3
MG
2 m
ode
Time (s)
Time (s)
Time (s)
Time (s)
Time (s)
Time (s)
Figure 23: The parameters curves during downshift process.
degree of jerk is 8.42m/s3, which is smaller than Chinesestandard (๐ฝ < 17.64m/s3). So the comfort requirements aremet during the upshift process.
4.3.2. Downshift Test. The downshift process mainly refers toMG2 speed regulation.MG1 and engine are at idle state. MG2speed regulation process is shown in Figure 23.
MG2 speed direction is changed from reverse to forwardin the neutral gear. The target speed is regulated according to(31).MG2 controlmode is tuned from speed control to torquecontrol after speed regulation. Then MG2 starts to unload byclearing MG2 torque to zero. When the actual torque reacheszero, mechanical synchronization starts.
The total downshift time is 0.919 s. At the end of speedregulation, MG2 speed ๐๐MG2 is 2107 rpm. ๐๐๐ is 469 rpm by
Shock and Vibration 15
Table 3: Upshift and downshift on-board experiments results.
Methods Powertrain Shift time (s) Max jerk (m/s3)Dynamic coordinatedcontrol
Conventional AMT &planetary gear train
Upshift 1.08 Upshift 8.42m/s3
Downshift 0.92 Downshift 11.96m/s3
Motor speed feedbackcontrol AMT with dual clutch Upshift 1.24 Upshift 13.2 rad/s3
Downshift0.72โ0.83 Downshift 82.5 rad/s3
Without disengaging clutch Conventional AMT 1.35โ1.41 9โ12.3m/s3
Combined algorithm Conventional AMT Upshift 1.20 โDownshift 1.10
calculation in (2). Output shaft actual speed ๐๐ is 457 rpm,which is 12 rpm less than ๐๐๐ . As a result, the speed regulationis effective and (9) can be met. Besides, the degree of jerkduring downshift process also meets the smooth standard.
Many methods are presented in other literatures aboutgear-shift process with different structures, such as the com-bined gear-shifting method assisted by motor speed feedbackcontrol [5], control strategy without disengaging clutch [16],and combined control algorithm based on feed-forward,bang-bang, and PID control [7]. The results are listed inTable 3. Compared with other approaches and structures,the new hybrid systemโs structural change during gear-shiftis more complex, but the jerk and power interruption timeare less than others, which can validate that the proposeddynamic shift coordinated control can inhibit vehicle jerksand vibrations during short shift time intervals.
5. Conclusion
A new type of hybrid electric system is utilized to conductthe experiments of shift control and verify the validity of theproposed dynamic shift coordinated control. Motor activespeed regulation is required to keep the speed differencebetween two ends of synchronizer under acceptable levelto meet the demand of vibrations and shift success rate.The simulation and road test results proved that, comparedwith other approaches, the degrees of jerks in both upshiftand downshift processes were restrained more effectively,with the shift time interval being shorter as well. Besides,the robustness in conventional AMT and planetary geartrain can be validated by tests results during downshift andupshift processes. So far, the situation where vehicle speeddramatically changes during shift process has not been takeninto consideration, especially shift in ramp ways. This is alsothe research direction and focus in the future.
Conflicts of Interest
The authors declare that there are no conflicts of interestregarding the publication of this paper.
References
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