Optimizing Performance and Fuel Economy of a Dual-Clutch Transmission Powertrain with Model-Based Design

December 06, 2012 // By Pete Maloney, Wit Nursilo, MathWorks
Tight vehicle emission regulations and high fuel prices have intensified the demand for fuel-efficient cars. At the same time, customers continue to expect the same vehicle performance that they had when fuel prices were lower. These conflicting demands present an optimization challenge for automotive manufacturers: how to minimize fuel consumption and CO2 emissions without sacrificing performance?

In the distant past, automobile manufacturers tackled the problem by optimizing the power efficiency of each powertrain component separately. During the 1970s fuel crisis, large automakers began developing in-house computer simulation models to achieve optimal system-level performance. Despite this move toward system-level optimization, it is still common in some emerging markets to optimize individual components. This piecemeal approach misses a large opportunity to reduce vehicle-level fuel consumption by coordinating the operating points of the components.

Model-Based Design with MATLAB and Simulink enables all automakers and suppliers to achieve optimization results once reserved for a few large automakers with the resources to develop large internal simulation models and optimization programs. By using a system model that incorporates the engine, transmission, axle ratio, driver, and vehicle, engineers can precisely match powertrain components and optimize hardware variables, such as axle ratios, and calibration parameters, such as shift schedules, simultaneously. Instead of rough estimates of fuel economy impact derived from expensive technology alternatives, they then have hard metrics upon which to base crucial hardware-selection decisions.

For example, suppose we want to optimize the powertrain for an economy car with a five-speed, dual-clutch transmission (DCT) and a turbo-charged, 2-liter, 4-cylinder engine (Table 1). The goal is to use as little fuel as possible over a Federal Test Procedure (FTP75) drive cycle while maintaining a minimum performance threshold of 10 seconds for the 0–100 kph acceleration time (the time it takes to reach 100 kph from a standing start).

Table 1. Vehicle characteristics. For full resolution click here .

To find the combination of gear shift schedule calibrations and axle ratio that meets these requirements, we test a range of axle ratios. For each ratio, we use numerical optimization to find the most fuel-efficient shift schedule calibration for the FTP75 cycle, as well as a separate shift schedule calibration that minimizes 0–100 kph acceleration time. In keeping with current practice, the production powertrain controller chooses which

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