Electrohydraulic_Controls_BorgWarner

June,2010DualClutchTransmissionTechnologicalAdvantagesandImplementationStrategies2Electro-HydraulicControlsforDCTsMichaelRitschel3TerminologyElectro-hydrauliccontrolsforwetanddryDCTsElectro-hydrauliccontrolsw/steadystatepump(„Lowpressure“systems)Electro-hydrauliccontrolsw/ondemandpump(„Highpressure“systems)WetDCTWetDCTDryDCTLPSystemHPSystem4Electro-HydraulicPrincipleElectricHydraulicelectriccurrentOutputPowerInputSignalsolenoidarmaturespoolhydraulicflow/pressureFmagneticFhydraulic5OutlineElectro-HydraulicControlsLPSystems-SteadyStatePump-PowerSupplyDCTPowerFlowControlsModulesControlsFunctionsw/ExamplesElectro-HydraulicControlsHPSystems-OnDemandPump-PowerSupplyDCTPowerFlowControlsModulesControlsFunctionsw/Examples6LPSystem-MainCharacteristicsMechanicallyDrivenPumpPumpSizes~12-18cc/revMaximumLinePressure15-20barSystemLeakageCombinedOilCircuitwithGearSetOilContaminatedwithWearParticles7PowerSupply-LPSystemSteadyStatePump„LowPressure“-LPSystemEngineHydraulicControlModule(HCM)Pumpp_Linemax.linepressure(e.g.20bar)timep_Line(normaloperating)p_ClutchpressureEngineOn=PumpOnPumpDrive8DCTPowerFlow-LPSystemEngineLPSystemw/oIntegrationHydraulicControlModuleGearsWetClutchTransmissionControlUnitTCUEngineControlUnitECUActuationLubeGearActuationShiftForksOilCircuitGeneratorBatteryGearLubricationCooling9DCTPowerFlow-LPSystem(Options)EngineLPSystemHydraulicControlModuleGearsWetClutchTransmissionControlUnitTCUEngineControlUnitECUActuationLubeGearActuationShiftForksOilCircuitGeneratorBatteryGearLubricationCoolingw/IntegratedTCU,IntegratedGearActuation10DCTControlsExamples-LPSystemDCTControlsExamples„LowPressure“IntegratedTCUw/ointegratedgearactuationIntegratedTCUIntegratedgearactuationIntegratedgearactuationw/ointegratedTCU11DCTControlsFunctions-LPSystemFiltrationMainPressureControlClutchCoolingGearActuationClutchControl12LPSystem-FiltrationSumpSuctionFilterPumpPressureFilterOption2(ControlCircuit)OilCleanlinessRequirementaccISO4406xx/19/16OilVolume5-7litersPressureFilterOption1(Bypass)LineMainPressureRegulatorSecondPrioritySuctionPilotPressure13LPSystem-Filtersß15200(99,5%)Flow1.5l/minExchangableMeshsize~60-150µmFlow40l/minLifetimeSuctionFilterPressureFilterSourceFiltran14MainPressureRegulatorLPSystem-MainPressureControlp_LineSecondPrioritySuctionVariableBleedSolenoid(VBS)NormallyHigh(NH)15LPSystem-MainPressureControlcurrentVBSpressureVBS~9bar~1.2AVBSCharacteristicNHLinePressureCharacteristicLineSweep0,01,02,03,04,05,06,07,08,09,010,011,012,013,014,015,016,017,018,019,020,021,022,023,024,000,10,20,30,40,50,60,70,80,911,11,2CurrentVBS(A)LinePressure(bar)16LPSystem-ClutchCoolingp_LinePumpFlowLubeRegulatorVariableForceSolenoid(VFS)Low-FlowNormallyHigh(NH)ClutchLubeCooler/GearLubrication17LPSystem-ClutchCoolingcurrentVFSLF~1.2A~8barpressureVFSLFVFSLow-FlowCharacteristicNHLubeFlowCharacteristicLubeSweep0,0005,00010,00015,00020,00025,0000,0000,2000,4000,6000,8001,0001,200CurrentVFSLF[A]LubeFlow[l/min]18LPSystem-SolenoidsOpen-EndVBSLow-costoptionforLine,Lube,AxisFeedandCut-OffcontrolLow-FlowVFSExceptionalaccuracyacrosstemperatureandpressurerangesLowleakageLine,Lube,AxisFeedandCut-OffcontrolMiniDirect-ActingVFS(MDA)Low-FlowVFSOpen-EndVariableBleedSolenoids(OEVBS)19LPSystem-GearActuationp_LineMultiplexActuationMPx1On/OffSol5426R13NActuatorMultiplexValve#2MPx2On/OffSolActuatorMultiplexValve#1Act1VBSNormallyLowActuator1RegulatorActuator2RegulatorAct2VBSNormallyLowShiftForksOn/OffSolenoidsVBSNormallyLow(NL)20LPSystem-MultiplexcurrentVBSpressureVBS~9bar~1.2AVBSCharacteristicNLAxisFeedPressureCharacteristicAxisFeedPressure0,0002,0004,0006,0008,00010,00012,00014,00016,00018,00020,0000,0000,2000,4000,6000,8001,0001,200CurrentVBS[A]AxisFeedPressure[bar]21LPSystem-GearActuationDirectAccessActuationp_LineShiftForks64Act1VBSNormallyLowActuator1RegulatorActuator2RegulatorAct2VBSNormallyLow52R13NACS1ACS2ACS3ACS4AreaControlSolenoid(ACS)22LPSystem-DirectAccessACSCharacteristic01234567891000,20,40,60,811,2CurrentACS[A]FlowACS[l/min]ACSFlowCharacteristic23LPSystem-SolenoidsOn/OffSolenoidsLow-costoptionforgearactuationcontrolMultiplexingcontrolAreaControlSolenoids(ACS)AcuratecontrolofpistonvelocityLubeflowcontrolAreaControlSolenoids(ACS)On/OffSolenoids24LPSystem-ClutchControlDirectClutchControlVFSoddVFSevenClutchOddClutchEvenp_LineVariableForceSolenoid(VFS)-HighFlow25OddAFVFSSweep0,02,04,06,08,010,012,014,016,018,020,022,000,10,20,30,40,50,60,70,80,911,11,21,31,41,5CurrentVFS(A)PressureClutch(Bar)OddRegSweepLinePressureLPSystem-ClutchControlClutchPressureCharacteristicVFSHighFlow26LPSystemSolenoidsVFSHighFlowIdealfordirectclutchcontrolFastandstableclutchfillingperformanceExceptionalaccuracyacrosstemperatureandpressurerangesLowleakageHigh-FlowVFS27OutlineElectro-HydraulicControlsLPSystems-SteadyStatePump-PowerSupplyDCTPowerFlowControlsModulesControlsFunctionsw/ExamplesElectro-HydraulicControlsHPSystems-OnDemandPump-PowerSupplyDCTPowerFlowControlsModulesControlsFunctionsw/Examples28HPSystem-MainCharacter