Design, modeling, and analysis of wedge-based actuator with application to clutch-to-clutch shift

Abstract

Clutch-to-clutch shift technology is a key enabler for fast and smooth gear shift process for multi gear transmissions. However, conventional hydraulic actuation systems for clutches have drawbacks of low efficiency, oil leakage and inadequate robustness. Electromechanical devices offer potential alternative actuators. In this paper, a novel motor driven wedge-based clutch actuator, featuring self-reinforcement, is proposed. The design concept and physical structure are thoroughly described. Dynamic models for the actuation system and vehicle powertrain are validated by experiments. Upshift and downshift processes at different engine throttle openings, clutch clearances and friction coefficients are discussed. The results show that, the self-reinforcement ratio is tested as 9.6; at the same time, the shift quality is comparable to that of the conventional hydraulic actuated clutch in automatic transmissions in terms of the shift duration (about 1 s) and vehicle jerk (<10 m/s3). Taking advantage of fast response of the actuation DC motor, the wedge-based actuator is robust dealing with uncertain clutch clearance and friction coefficient. Therefore, the wedge-based clutch actuator has potential to provide acceptable performance for clutch-to-clutch shift.