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Research Papers

Design and Development of a Real-Time Simulation and Testing Platform for a Novel Seamless Two-Speed Transmission for Electric Vehicles1

[+] Author and Article Information
Truong Sinh Nguyen

The State Key Laboratory of
Automotive Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: ntsinhtb11@gmail.com

Jian Song

The State Key Laboratory of
Automotive Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: daesj@tsinghua.edu.cn

Liangyao Yu

The State Key Laboratory of
Automotive Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: yly@tsinghua.edu.cn

Shengnan Fang

The State Key Laboratory of
Automotive Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: fsn10@mails.tsinghua.edu.cn

Yuzhuo Tai

The State Key Laboratory of
Automotive Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: taiyuzhuo@126.com

Zhenghong Lu

The State Key Laboratory of
Automotive Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: thulzh@126.com

2Corresponding author.

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT,AND CONTROL. Manuscript received December 23, 2017; final manuscript received August 28, 2018; published online October 10, 2018. Assoc. Editor: Beshah Ayalew.

J. Dyn. Sys., Meas., Control 141(2), 021007 (Oct 10, 2018) (12 pages) Paper No: DS-17-1629; doi: 10.1115/1.4041358 History: Received December 23, 2017; Revised August 28, 2018

An approach for building a real-time simulation and testing platform for a novel seamless two-speed automated manual transmission (AMT) for electric vehicles (EVs) is proposed and experimentally evaluated. First, the structure of the AMT and the dynamic model of an EV powertrain system equipped with the AMT are presented. Then, according to the testing requirements, a prototype of the AMT, hardware components and software system of the platform are designed. Unlike a real-time transmission test bench, of which the real-time simulation and control system (RSCS) is built based on a dedicated simulator, the RSCS of the platform is built based on a standard desktop personal computer (PC) by using a useful and low-cost solution from matlab/simulink®. Additionally, a simulation model of EV, which is equipped with the AMT and is more suitable for hardware-in-the-loop (HIL) simulation, has been developed. In particular, for conducting various dynamic mechanical tests, the platform is combined with induction motors (IMs), which are adopted with direct torque control (DTC) technique to emulate the dynamic driving conditions of the transmission. The designed platform can be used for different test techniques, including rapid simulation, rapid control prototyping, HIL simulation as well as dynamic mechanical tests. The work expands the capability of the platform and makes the test conditions become closer to reality. Simulation and experimental results indicate that the platform responds well to the real-time dynamic requirements, and it is very useful for developing the proposed transmission.

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Figures

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Fig. 1

Schematic diagram of an EV powertrain system equipped with a novel seamless two-speed AMT (left) and principle of the transmission (right)

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Fig. 2

Block diagram of an EV powertrain system equipped with the seamless two-speed AMT (BR—brake; CL—clutch; C—carrier;P—planet gear; R—ring gear; S—sun gear)

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Fig. 3

Block diagram of the test platform

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Fig. 4

Real-time simulation model of EV equipped with the seamless two-speed AMT

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Fig. 5

Simulation model of the seamless two-speed AMT

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Fig. 6

Design of a real-time simulation and testing platform for a seamless two-speed AMT: (a) software configuration, (b) main hardware components, and (c) host PC and target PC

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Fig. 7

Simulation results of the EV model equipped with the seamless two-speed AMT using the UDDS drive cycle

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Fig. 8

Working points of the EV traction motor in the UDDS drive cycle

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Fig. 9

Shift actuator stroke control during upshift process

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Fig. 10

Input and output speeds of the AMT in upshift process

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Fig. 11

Input and output torques of the AMT in upshift process

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Fig. 12

Comparison of the experimental and simulation test results using drive cycle

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Fig. 13

Comparison of LM load torque results (zoomed-in view)

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