Method and device for synchronising an idler pinion of a gearbox with the shaft thereof

Abstract

The invention relates to a method for synchronising the common speed (ω p) of two concentric primary shafts (1, 6) of a hybrid transmission in a hybrid operating mode wherein said two shafts are rotatably connected by a first coupling means (5), with the speed (ω s) of a secondary transmission shaft (10) comprising at least one idler pinion for allowing the coupling of one of said pinions (11, 12) to the shaft (10) thereof by closing a second coupling means (13) that does not have mechanical synchronisation bodies, the torque (Te) of the electric machine being temporarily reduced during the synchronisation phase in order to meet the conditions of a perfect coupling when the value thereof caps at an upper limit value (T.sub.e.sup.max) or a lower limit value (T.sub.e.sup.min).

Claims

1. A synchronizing method of synchronizing a speed (ωp) common to two concentric primary shafts of a hybrid transmission cumulatively receiving torque (T.sub.ice) from a combustion engine and torque (Te) from an electric machine in a hybrid mode of operation in which the two concentric primary shafts are rotationally connected by a first coupling, with the speed (ωs) of a secondary transmission shaft bearing at least one idler pinion, to allow one of the at least one pinion to be coupled to the secondary transmission shaft by closure of a second coupling with no mechanical synchronizing members, the method comprising: temporarily reducing, via processing circuitry, the torque (Te) of the electric machine during the synchronizing phase to meet the conditions for perfect coupling when the torque (Te) reaches a ceiling represented by an upper limit value (T.sub.e.sup.max) or a lower limit value (T.sub.e.sup.min).

2. The synchronizing method as claimed in claim 1, wherein the torque (Te) of the electric machine is reduced by adjusting the magnitude of the torque (T.sub.ice) supplied by the combustion engine.

3. The synchronizing method as claimed in claim 2, wherein when a demanded torque (T.sub.e) demanded of the electric machine is below a minimum torque (T.sub.e.sup.min), the primary shafts are slowed with the combustion engine.

4. The synchronizing method as claimed in claim 2, wherein when a demanded torque (T.sub.e) demanded of the electric machine is above a maximum torque (T.sub.e.sup.max) the primary shafts are accelerated with the combustion engine.

5. The synchronizing method as claimed in claim 3, wherein the processing circuitry is activated in order to slow or accelerate the combustion engine.

6. The synchronizing method as claimed in claim 1, wherein the first coupling or the second coupling is one of a dog clutch, synchromesh, or progressive or non-progressive coupling.

7. A device comprising: processing circuitry configured to adjust a magnitude of torque (T.sub.ice) supplied by a combustion engine thereby synchronizing a speed (ωp) common to two concentric primary shafts of a hybrid transmission cumulatively receiving the torque (T.sub.ice) from the combustion engine and torque (Fe) from an electric machine in a hybrid mode of operation in which the two concentric primary shafts are rotationally connected by a first coupling, with the speed (ωs) of a secondary transmission shaft bearing at least one idler pinion, to allow one of the at least one pinion to be coupled to the secondary transmission shaft by closure of a second coupling with no mechanical synchronizing members.

8. The synchronizing device as claimed in claim 7, wherein the processing circuitry is further configured to influence the magnitude of the torque (Te) of the electric machine by reducing the torque (Te) hen a demanded torque (T.sub.e) demanded of the electric machine is higher than a maximum torque (T.sub.e.sup.max) supplied by the combustion engine.

9. The synchronizing device as claimed in claim 8, wherein when the demanded torque (T.sub.e) demanded of the electric machine is below a minthium torque (T.sub.e.sup.max), the processing circuitry is configured to slow down the electric machine along with the combustion engine until the demanded torque T.sub.e becomes higher than the minimum torque (T.sub.e.sup.min).

10. The synchronizing device as claimed in claim 8, wherein when the demanded torque (T.sub.e) demanded of the electric machine is higher than a maximum torque (T.sub.e.sup.max) the processing circuitry is configured to accelerate the electric machine along with the combustion engine until the demanded torque (T.sub.e) of the electric machine becomes lower than the max torque (T.sub.e.sup.max).

11. The synchronizing device as claimed in claim 9, wherein the processing circuitry is further configured to deliver a combustion engine torque setpoint (T.sub.ice) allowing the primary speed to he synchronized with the secondary speed to meet the conditions of perfect coupling between a secondary pinion and the secondary transmission shaft.

12. The synchronizing device as claimed in claim 7, wherein the processing circuitry is further configured to keep an electric torque request (T.sub.e.sup.appli) between a minimum torque value (T.sub.e.sup.min) and a maximum (T.sub.e.sup.maxfor the electric machine.

13. The synchronizing device as claimed in claim 7, wherein the processing circuitry is further configured to deliver a torque setpoint applied to the combustion engine (T.sub.ice.sup.appli) that is between minimum and maximninr values (T.sub.ice.sup.min:T.sub.ice.sup.max).

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The present invention will be better understood from reading the following description of one non-limiting embodiment thereof, with reference to the attached drawings in which:

(2) FIGS. 1, 2 and 3 show the drivetrain of a hybrid transmission in neutral and in two of its hybrid gear ratios,

(3) FIG. 4 describes the synchronizing device,

(4) FIG. 5 is the regulator of FIG. 4,

(5) FIGS. 6 and 7 show the first and second desaturator of FIG. 4, respectively,

(6) FIG. 8 illustrates the results of the proposed method, and

(7) FIG. 9 is another desaturation system.

DETAILED DESCRIPTION OF THE INVENTION

(8) In FIG. 2, the first coupling means 5 is closed in position 3, so as to secure the solid shaft 1 to the hollow shaft 6. The second coupling system 13 is closed, so as to secure the short-ratio idler pinion 12 and the secondary shaft 10. The transmission is in hybrid mode on the short ratio. The contributions from the combustion engine and from the electric machine to the drivetrain combine. They are transmitted from the hollow primary shaft 6 to the secondary shaft by the descent of the pinions 8, 12.

(9) In FIG. 3, the first coupling means 5 is still closed, in position 3, as in FIG. 5. The solid primary shaft 1 is therefore secured to the hollow primary shaft 6. The second coupling system 13 is also closed: the idler pinion 11 of the intermediate gear ratio is secured to the secondary shaft 10. The transmission is in hybrid mode on the intermediate gear ratio. The contributions of the combustion engine and of the electric machine to the drivetrain combine.

(10) The desired synchronization is that of the speed ω.sub.p, common to the two concentric primary shafts 1, 6 cumulatively receiving the torque T.sub.ice from the combustion engine and the torque T.sub.e from the electric machine 7 in a hybrid mode of operation in which these two shafts are rotationally connected by the first coupling means 5, with the speed ω.sub.s of the secondary transmission shaft 10 which bears the idler pinions 11, 12. It must allow one of these pinions to be coupled to its shaft 10 simply by closing the second coupling means 13, which has no synchronizing members.

(11) As indicated above, in the absence of mechanical synchronizing means, the synchronizing of the idler pinions 11 or 12 before they are coupled by dog clutches to the shaft 10 may be performed by adjusting the torque supplied by the electric machine. This is what is done during shifts between the two hybrid gear ratios, which are carried out with a break in torque by the dog-clutch coupling of the pinions 11 and 12 to the secondary shaft 10. The main difficulties to be overcome in effecting these gear shifts are: that of following paths of the “ramp” type corresponding to the unfavorable case of heavy braking on a steep downward slope, that of having sufficient static precision so that the speed discrepancy decreases very quickly down to around 30 revolutions per minute (a condition necessary for dog-clutch engagement to be carried out properly), that of desaturating the electric torque as quickly as possible because in this phase the system is likely to become uncontrollable, and that of eliminating the main sources of jerks in the flow of torque likely to be encountered during the coupling phase, thereby also avoiding bad wearing of the mechanical components of the coupling system.

(12) If ω.sub.e is the speed of the electric machine, T.sub.e is the torque of the electric power source and J.sub.e is the inertia of the electric machine, then the dynamics of the electric machine can be written as follows:
J.sub.e{dot over (ω)}.sub.e=T.sub.e+T.sub.de,
in which expression T.sub.de is the resistive torque of the electrical energy source, which is an unknown exogenic input.

(13) Similarly, the dynamics for the combustion engine can be written:
J.sub.ice{dot over (ω)}.sub.ice=T.sub.ice+T.sub.dice;  (2)
where J.sub.ice: is the inertia of the combustion engine; ω.sub.ice is the speed of the combustion engine; ω.sub.ice is the speed of the combustion engine; T.sub.ice is the torque of the combustion engine; and T.sub.dice is the resistive torque of the combustion energy source, which is an unknown exogenic input.

(14) Given that, during the relevant gear shifts in hybrid mode, ω.sub.e=ω.sub.ice=ω.sub.p (primary speed), it is possible to write:
(J.sub.ice+J.sub.e){dot over (ω)}.sub.p=T.sub.e+T.sub.ice+T.sub.dice+T.sub.de

(15) In FIG. 4, ω.sub.p is still the primary speed associated with the power sources, and ω.sub.s is the speed of the secondary shaft connected with the wheels of the vehicle. The regulator receives as input the current value ω.sub.p of the primary speed and the request for a synchronization speed equal to the secondary speed, disregarding the reduction ratio K, between the primary and secondary shaft in the hybrid operation. The regulator sends the electric torque setpoint T.sup.e to the first limiter unit or limiter, which keeps the requested electric torque T.sub.e.sup.appli between T.sub.e.sup.min, the minimum torque of the electric machine, and T.sub.e.sup.max, the maximum torque of the electric machine.

(16) The values T.sub.e.sup.min and T.sub.e.sup.max are sent respectively to the low desaturator (1) and to the high desaturator (2). In the event of low or high saturation of the electric torque signal T.sub.e, the desaturators send the combustion engine a torque setpoint T.sub.ice that is limited by the second limiter between minimum and maximum values (T.sub.ice.sup.min: the min torque of the combustion energy source and T.sub.ice.sup.max: the max torque of the combustion energy source). The second limiter delivers the torque setpoint applied to the combustion engine, T.sub.ice.sup.appli.

(17) The device of FIG. 4 comprises two desaturation units operating on the value of the torque T.sub.ice supplied by the combustion engine. It allows the torque of the electric machine to be desaturated by activating the desaturation units 1 and 2, so as to add a “desaturation” combustion torque to the electric machine when the torque T.sub.e reaches a ceiling at its minimum value T.sub.e.sup.min (desaturator 1) or its maximum value T.sub.e.sup.max (desaturator 2).

(18) This device reduces the electric torque, during the phase of synchronizing the speed of the primary shaft ω.sub.p and that of the secondary shaft ω.sub.s, disregarding the stepdown ratio K, in order to meet the conditions for perfect coupling of a pinion 11 or 12 to the shaft 10.

(19) The regulator unit of FIG. 5 compares the primary speed request with the primary speed ω.sub.p. An integral value of the difference is introduced into the calculation to eliminate static errors. In order to produce the reference signal T.sub.e, the signals generated by the integral action T.sub.e.sup.int and the proportional action T.sub.e.sup.prop are summed.

(20) The torque T.sub.e produced by the regulator unit of FIG. 5 is then compared against the minimum torque T.sub.e.sup.min and against the maximum torque T.sub.e.sup.max.

(21) If T.sub.e≦T.sub.e.sup.min, the desaturator block 1 of FIG. 6 (in which K.sub.p and K.sub.i are calibratable gains) is activated in such a way as to also provide retardation with the combustion engine until the torque T.sub.e becomes higher than the minimum torque T.sub.e.sup.min, producing a reference signal T.sub.ice. To produce this reference signal the signals generated by the integral action “T.sub.ice.sup.int” and the proportional action “T.sub.ice.sup.prop” (cf. FIG. 6) are summed.

(22) The torque of the electric machine 7 is thus reduced by influencing the value of the torque T.sub.ice supplied by the combustion engine.

(23) If T.sub.e≧T.sub.e.sup.min, the desaturation unit 2 of FIG. 7 (in which K.sub.P and K.sub.i are also calibratable gains) is activated so as to also accelerate with the combustion engine until the torque T.sub.e becomes lower than the max torque T.sub.e.sup.max, producing a reference signal T.sub.ice. In order to produce this reference signal, the signals generated by the integral action T.sub.ice.sup.int and by the proportional action T.sub.ice.sup.prop are summed (see FIG. 7).

(24) In other words, the torque T.sub.e of the electric machine is temporarily reduced during the synchronization phase in order to meet the conditions of perfect coupling when its value reaches a ceiling at an upper limit value T.sub.e.sup.max or a lower limit value T.sub.e.sup.min.

(25) FIG. 8 shows the time saving afforded by the invention in achieving synchronization. In this diagram it may be seen that the primary speed converges on the required value ω.sub.p.sup.rq at least one second earlier with the proposed strategy (curve 1) than in the absence thereof (curve 2).

(26) The advantages offered by the method of the invention are many. Among these it may be noted that it complies with the inherent constraints on the box concerned, which are: the ability to follow “ramp” paths in steep descents, corresponding to the unfavorable instances of heavy braking, having the required static precision so that the speed discrepancy very quickly falls into a range of 30 revolutions per minute, and that the electric torque is desaturated as soon as possible because in this phase the system is susceptible to becoming uncontrollable.

(27) Finally, it must be emphasized that the desaturation strategies generally applied in the control systems are of the “anti-windup” type, as may be that of FIG. 9, in which the discrepancy between the electric torque signal before and after limiting thereof is looped back into the regulator.

(28) The big difference between the proposed strategy and this type of regulation is that the desaturation is not strictly software but rather the electric machine is desaturated using another source of power such as the combustion engine.