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Simulating Automated Manual Transmission

Task

Automated manual transmission (AMT) operates similarly to manual transmission, except that it does not require clutch actuation or shifting by the driver. Automatic shifting is controlled electronically (shift-by-wire) and performed by electric motors or hydraulically.
In this application, an ECU for an AMT controls three electric direct current (DC) motors, one for the clutch and one each for the longitudinal and the lateral movement of the gear selector level. The ECU chooses the gear according to the motor rotation speed and accelerator pedal position it activates the clutch and engages the appropriate gear via the shift and the selector motor. It is also possible to shift up and down manually without engaging the clutch.

Challenge

To test the ECU with real motors as well, the test system allows switching between electric motors as real parts and simulated electric motors using simulation models. High currents up to 60 A are needed to simulate the inrush current of the DC motors.

Solution

A dSPACE hardware-in-the-loop simulator based on SCALEXIO is equipped with a DS2601 Signal Measurement Board, which provides various interfaces for connecting the ECU. New ECU variants can easily be adapted to the simulation just by changing the cable harness. Electronic load modules provide the hardware for simulating electric motors. To test the ECU's behavior during electric failures, high current failure simulation can be performed. dSPACE Automotive Simulation Models (ASM) such as ASM Drivetrain Dynamics are used for simulating the actual physical gearbox characteristics.

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