Patent Application
20140336889
The present disclosure relates to transmission control and, more particularly, relates to a system and method for minimizing transmission gear hunting while allowing necessary gear changes.
Because most power sources have a limited range of output RPM, machines employing such power sources will also typically employ a multispeed transmission to provide a greater range of machine speed and acceleration. One type of multispeed transmission is the planetary transmission, but many other transmission types are known. While transmissions having a number of discrete gears are useful in allowing a wider range of operation, such systems generally entail certain disadvantages.
For example, because of the abrupt change of gear ratio at each shift point, any slack or stretch in the power train is allowed to relax or “unwind,” causing system sensors to provide readings that will result in a gear change back to the previous gear. This process may then repeat after a change to the previous gear, and so on, resulting in what is referred to as gear “hunting,” wherein the transmission executes rapid repeated shifts between adjacent gears. Gear hunting can cause a degraded operator experience, and also often results in unnecessary wear on the entire power train.
In order to prevent hunting and the consequent problems, a number of systems have been devised to preclude rapid shifts between adjacent gears. Of these, one solution has been to provide a shift timer. The shift timer is started at the time that a gear shift occurs, and a transmission controller precludes a subsequent shift until the timer runs out. However, such systems can cause engine lugging or over speeding in the event that a legitimate change of gear ratio is required within the timer duration due to a change in actual machine operating conditions.
To try to prevent lugging, certain solutions have been devised. For example, in U.S. Pat. No. 7,660,657, entitled “Anti-Hunt System and Method for Parallel Path Variable Transmission,” a system is disclosed for controlling a split torque transmission having a plurality of contiguous selectable operating ranges, with adjacent operating ranges being separated by synchronous points. After an upshift, the system sets a lock-out timer to prevent a subsequent shift of the transmission until the timer has expired, with the timer being overridden if the transmission output ratio displays certain trends.
While the '657 system effectively prevents high-frequency hunting based on trend tracking, the existence of drive train ringing or unwinding may in some cases hide a transmission output ratio trend. It may also be desirable to further limit the override of the lockout timer in some way to prevent lower frequency shift oscillations.
The present disclosure is directed to a system that may exhibit numerous distinctions over prior systems. However, it should be appreciated that any such distinction is not a limitation on the scope of the disclosed principles or of the attached claims except to the extent expressly noted. Additionally, the discussion of any problem or solution in this Background section is not an indication that the problem or solution represents known prior art except as otherwise noted by the inclusion of a patent number. In the case of the identified patent, the foregoing is intended as a brief summary, not as a construction of the patent in question or its claims, and the reader is referred to the patent itself in the event that a full and accurate understanding is desired.
In accordance with one aspect of the present disclosure, a system is provided for grade-based anti-hunt shift control of a transmission powering a machine. The transmission is an automatic transmission having a number of discrete gears corresponding to different transmission ratios. A shift controller determines a recommended gear in which to operate the transmission and sets an anti-hunt timer upon recommending a shift from a first gear to a second gear, such that the anti-hunt timer prevents a subsequent shift back to the first gear while the anti-hunt timer is running. In cooperation, a grade-based controller employs an estimated payload and measured grade to calculate an estimated steady state gear. When the grade-based controller determines that the estimated steady state gear differs from the current gear, i.e., the machine has encountered a significant actual grade or load change, the grade-based controller clears the anti-hunt timer, and sets a secondary timer to prevent subsequent clearing of the anti-hunt timer until the secondary timer expires.
In accordance with another aspect of the present disclosure, a machine having anti-hunt shift control is provided. The machine includes a transmission powering the machine. The transmission is an automatic transmission with a number of discrete gears representing distinct transmission input/output ratios. An anti-hunt timer having a primary duration prevents a shift of the transmission when the anti-hunt timer is running, and a secondary timer prevents clearing of the anti-hunt timer when the secondary timer is running. A first controller requests a shift of the transmission, the first controller being further configured to set the anti-hunt timer upon requesting a shift, while a second controller determines a desirable steady state gear in which to operate the transmission, and determines whether the current gear differs from the estimated steady state gear. The second controller is further configured to clear the anti-hunt timer and set the secondary timer if the current gear differs from the desirable steady state gear.
In accordance with yet another aspect of the present disclosure, a method for controlling an automatic machine transmission is provided. The automatic machine transmission supports a plurality of discrete gears corresponding to respective distinct input/output ratios. The machine further including an anti-hunt timer to preclude a subsequent gear shift of the transmission after an initial gear shift for a duration of the anti-hunt timer, while a secondary timer prevents clearing of the anti-hunt timer for a duration of the secondary timer. After shifting the automatic machine transmission from the initial gear to a second gear and setting the anti-hunt timer, it is detected that a persistent change of machine operating conditions has occurred such that the second gear is less desirable than the initial gear. The anti-hunt timer is cleared to allow a shift from the second gear to the initial gear and the secondary timer is set.
Other features and advantages of the disclosed systems and principles will become apparent from reading the following detailed disclosure in conjunction with the included drawing figures.
The present disclosure provides a system and method for grade-based anti-hunt shift control of an automatic transmission powering a machine. The automatic transmission receives power from a machine power source, e.g., an engine, and provides power to a machine drive train, e.g., to drive one or more wheels, tracks, or other ground engaging mechanism. A shift controller determines a recommended gear in which to operate the transmission and sets an anti-hunt timer upon recommending a shift from a first gear to a second gear. The anti-hunt timer prevents a subsequent shift back to the first gear while the anti-hunt timer is running. A grade-based controller is configured to track machine operation and to determine when the machine encounters a change in machine operational conditions (e.g., load and/or grade) that would present a need for a gear shift during the pendency of the anti-hunt timer. When such a change is encountered, the grade-based controller then clears the anti-hunt timer and sets a secondary timer. The clearing of the anti-hunt timer allows a downshift to accommodate the detected change in conditions, while the setting of the secondary timer prevents a subsequent clearing of the anti-hunt timer while the secondary timer is running.
Having discussed various embodiments in overview, we turn now to detailed descriptions of certain embodiments.
In addition to the aforementioned parameters, the graph 1 also includes an upshift TOS level 6 and a downshift TOS level 7. The upshift TOS level 6 represents the TOS at which the calculated (nominal) transmission gear changes from a current gear to a higher gear. Although a single upshift TOS level 6 is shown, it will be appreciated that the TOS upshift level will be gear-dependent, e.g., with lower gears having lower upshift levels. Similarly, the downshift TOS level 7 represents the TOS at which the calculated transmission gear changes from a current gear to a lower gear, and it will be appreciated that the precise level is gear-dependent.
As noted above, the machine data graph 1 of
However, as the transmission unwinds, the actual TOS 2 drops momentarily, passing briefly below the downshift TOS level 7 at an intermediate time Tm. Because the TOS 2 has fallen below the downshift TOS level 7, the calculated gear reverts to G1. However, because the AHT has not yet expired at time Tm, the actual gear 3 remains at gear G2; by the time the AHT expires at time T2, the actual TOS 2 has risen above the downshift TOS level 7 and the actual gear 3 remains at G2. If the actual TOS 2 were to again drop below the downshift TOS level 7 after the AHT has expired, a downshift would ordinarily be executed.
Although an ordinary AHT system functions well in the TOS sequence shown in
However, shortly after the shift from G1 to G2, the machine encounters a change in grade as can be seen from the terrain grade plot 5. As a result of the change in grade, the actual TOS 2 begins to drop, and at time Tn the TOS 2 drops below the downshift TOS level 7. Thus at time Tn, the calculated gear 4 reverts from G2 to G1. However, since the AHT has not expired at time Tn, the actual gear 3 remains at G2. As a result, the actual TOS 2 drops far out of the ideal range for gear G2, causing engine lugging and loss of performance and efficiency.
In the following, a system having a number of controllers is discussed. It will be appreciated that a physical controller is a computing device for accepting data and/or command inputs, executing a control algorithm, and providing control outputs to control an entity or process. Similarly, a logical controller is a function or the associated range of programming code that performs a function normally associated with a physical controller. It will be appreciated that the discussed separate logical controllers may be associated with separate physical controllers or may be combined in a fewer number of physical controllers, even a single physical controller. Moreover, while the function of the various logical controllers and logical timers are separated for ease of understanding herein, it should be appreciated that the various separate logical entities may also be implemented as a fewer number of more complex logical entities.
In an embodiment of the disclosure, a process of shift control is provided wherein anti-hunt timing is provided, while allowing needed downshifts when terrain or load conditions require a shift to maintain optimum performance and efficiency. In particular, an AHT is employed to preclude rapid sequential shifting due to transient drive train conditions, while a grade-based override is provided in conjunction with a secondary shift timer. It will be appreciated that the term “grade-based controller” is used herein to denote a controller that considers grade in determining an estimated steady state gear as described, but that at any given moment during operation a change in the estimated steady state gear may be caused by a change in an operational condition or factor other than grade.
Referring now to
In operation, the logical shift controller 11 calculates or generates an indication of an appropriate or desired gear based on the status of the machine in question. For example, the logical shift controller 11 may map combinations of engine speed range, transmission output speed range and machine load to desired gears. Within this example, assume that a machine with a relatively light load is to operate at lower engine speeds in general since the torque needed to overcome inertia and account for rolling resistance may be lower. As such, the range of transmission output speeds mapped to a particular gear may correspond to a lower range of engine speed than would be the case for a more highly loaded machine.
In keeping with the calculation or generation of a desired gear, the logical shift controller 11 provides a gear recommendation output 19. In addition, based on the shift indication input 18, the logical shift controller 11 sets the anti-hunt timer 12 each time an upshift indication is received. The duration of the anti-hunt timer, herein referred to as a primary duration, may be user-settable or may be configured prior to delivery of the machine.
The gear recommendation output is essentially blocked or passed based on the anti-hunt timer 12. In particular, if the anti-hunt timer 12 is running (active and not yet expired), the gear recommendation of the gear recommendation output 19 is not passed to the transmission controller 20. Conversely, if the anti-hunt timer 12 is not running (expired or not active), then the gear recommendation of the gear recommendation output 19 is passed to the transmission controller 20.
However, the logical grade-based controller 13 may override the anti-hunt timer in certain circumstances, for example, to allow a downshift when a persistent change in load and/or terrain is encountered. The logical grade-based controller 13 operates in cooperation with a logical secondary timer 14 distinct from the anti-hunt timer 12. In an embodiment, the logical grade-based controller 13 does not command a shift, but rather forces the anti-hunt timer 12 to allow a shift if one is recommended by the logical shift controller 11. In addition, as can be seen in
In operation, the logical grade-based controller 13 provides a feed-forward behavior that identifies that the grade and/or payload conditions associated with the machine have changed sufficiently since the initiation of a shift that any loss of TOS immediately thereafter is due to such changes rather than to transient phenomena. In particular, the logical grade-based controller 13 calculates an estimated steady state gear based on the grade and payload conditions. If the estimated steady state gear is lower than the current gear, then the logical grade-based controller 13 clears the anti-hunt timer 12 to allow a downshift if one is recommended by the logical shift controller 11.
The calculation of the estimated steady state gear may be executed in any suitable fashion, with the goal of providing a gear that places the engine in its effective or fuel efficient range of output speed while allowing sufficient transmission output torque for continued motion and acceptable acceleration. In an embodiment, the steady state gear is calculated by deriving a drive train load based on machine weight, load and level rolling resistance, as well as machine grade.
However the estimated steady state gear is calculated, once a downshift is actually executed after the clearing of the anti-hunt timer, it is still possible for the drive train to oscillate or ring subsequent to the allowed shift, requiring the intervention of the anti-hunt timer 12. Thus, in an embodiment, the logical grade-based controller 13 sets the logical secondary timer 14 when it clears the anti-hunt timer 12. The logical grade-based controller 13 will then not clear the anti-hunt timer 12 again until the expiration of the logical secondary timer 14. In an embodiment, the anti-hunt timer 12 has a primary duration (e.g., 1-3 seconds) that is shorter than a secondary duration (e.g., 10 seconds) associated with the logical secondary timer 14. In this way, the logical grade-based controller 13 will not be able to repeatedly clear the anti-hunt timer 12 in rapid succession, as such may prevent setting of the anti-hunt timer 12 when it would otherwise be set to prevent anomalous gear selection due to driveline dynamics.
It will be appreciated that in an embodiment, the logical grade-based controller 13 does not explicitly command a downshift. Rather, the logical grade-based controller 13 simply allows the logical shift controller 11 to successfully request a downshift prior to the anti-hunt timer 12 expiring.
An example of machine behavior in keeping with the disclosure is shown in
The graph 25 further includes an upshift TOS level 30 and a downshift TOS level 31. The upshift TOS level 30 represents the TOS at which the calculated transmission gear changes from a current gear to a higher gear. As noted above, the upshift TOS level 30 may be gear-dependent. Similarly, the downshift TOS level 31 represents the TOS at which the calculated transmission gear changes from a current gear to a lower gear, and it will be appreciated that the precise level is similarly gear-dependent.
At the outset of the graph 25, the machine is travelling on relatively level terrain as seen in the terrain grade plot 29 and is accelerating in gear G1, as seen in the TOS plot 26 and the actual gear plot 27 respectively. As the machine progresses, the TOS reaches the upshift TOS level 30, as seen in the TOS plot 26, at time T5 and position x1. In this regard, the machine behavior is similar to that shown in
As the TOS plot 26 crosses the upshift TOS level 30, the logical shift controller 11 recalculates the recommended gear and changes its gear recommendation output 19 to indicate a higher gear, i.e., gear G2. This can be seen in the calculated gear plot 28 as it shifts from G1 to G2 at time T5. In response, since the anti-hunt timer 12 is not currently active, the change in gear recommendation is passed to the transmission controller 20, and the actual transmission gear also changes from gear G1 to gear G2 as seen in the actual gear plot 27. In this regard, the estimated steady state gear plot 32 matches the actual gear plot 27.
At the same time as, or generously contemporaneously with, the change in actual gear, the logical shift controller 11 sets the anti-hunt timer 12. As noted above, the anti-hunt timer 12 may have a duration that is generally long enough to avoid shifting during transmission unwinding or ringing, e.g., a duration from about one second to about three seconds.
However, also at approximately time T5, the terrain changes as well, and in particular, a persistent grade increase is encountered starting at about time T5 as seen in the terrain grade plot 29. As a result of the grade change, the TOS plot 26 begins to drop precipitously after time T5 to a much greater extent than would be expected on level terrain. As the TOS drops, as reflected in the TOS plot 26, the TOS plot 26 quickly crosses the downshift TOS level 31 at about time Tx, where the difference Tx−T5 is less than the duration of the anti-hunt timer 12, such that the anti-hunt timer 12 is still active at time Tx.
At this point, the logical shift controller 11 recalculates the recommended gear to be G1, and provides a corresponding recommendation at gear recommendation output 19 at time TX. Normally, the anti-hunt timer 12 being active at this time would prevent the shift recommendation from being passed to the transmission controller 20. However, at time T5, the grade-based controller 13 received an indication of the change in grade via the grade input 21. While the terrain upon which the machine travels may contain a great many transient grade changes, as evidenced by the slight roughness in the terrain grade plot 29, the grade change sensed starting at time T5 is determined by the grade-based controller 13 to be a persistent rather than transient change. As such, the grade-based controller 13, which maintains a running indication of an estimated steady state gear, changes the estimated steady state gear from G2 back to G1.
When the grade-based controller 13 changes the estimated steady state gear from G2 back to G1 after time T5, the grade-based controller 13 clears the anti-hunt timer 12 at about time Tx. At approximately the same time, allowing for computational delays and other unintentional delays, the grade-based controller 13 also sets the secondary timer 14. As noted above, while the secondary timer 14 is active, the grade-based controller 13 may not again clear the anti-hunt timer 12. In this way, anti-hunt protection generally remains available after an override of the anti-hunt timer 12 by the grade-based controller 13.
In general terms, the present disclosure sets forth a system and method for providing an anti-hunt functionality for an automatic transmission having discrete gears to provide different ranges of output speed and/or torque. Aspects of the disclosure may be utilized in systems having any of various types of power production and/or drive technology, including but not limited to electric, gas, diesel, propane, electro-hydraulic, and so on. While it is anticipated that the disclosure may provide the greatest benefit with respect to industrial or earth-working machines that carry or include a large load, e.g., dump trucks, it will be appreciated that the techniques described herein are of much wider applicability.
The described system operates by providing grade-based anti-hunt timer control. In particular, while the anti-hunt timer protects against hunting due to transient drive line dynamics when shifting gears, a grade-based controller is configured to clear the anti-hunt timer if a persistent change in grade and/or in load results in a change in estimated steady state gear. The grade-based controller is associated with a secondary timer that disallows subsequent clearing of the anti-hunt timer for a predetermined period or duration. The resultant system provides protection against hunting while allowing a rapid follow-up shift when needed due to a change in circumstance while the anti-hunt timer is still active.
In the foregoing description referring to
Further, it will be appreciated that that the execution of actions or steps by computing entities such as logical or physical controllers is implemented through the reading of computer-executable instructions from a non-transitory computer readable media. Suitable non-transitory computer readable media include any collection of one or more non-transitory memory devices such as hard drives, flash drives, RAM, ROM, magnetic drives, optical drives, and so on.
Referring now to
The initial conditions of the system for the given example assume that a machine being driven by the transmission is accelerating in a gear G1 having a lower gear ratio than a gear G2. From the range in which the automatic transmission is operating, the automatic transmission is set to upshift when the transmission output speed reaches a predetermined upshift level and to downshift when the transmission output speed drops below a predetermined downshift level, where the predetermined upshift level is higher than the predetermined downshift level.
For the sake of the given example, transmission control functions are divided among a transmission controller directly interfacing with the transmission, a shift controller interfacing with the transmission controller via an anti-hunt timer, and a grade-based controller interfacing with the anti-hunt timer and a secondary timer.
At a first stage 36 of the process 35, the shift controller determines that the transmission output speed is between the predetermined upshift level and the predetermined downshift level. As such, the shift controller does not recommend a shift into either a higher or lower gear. Subsequently at stage 37 of the process 35, the shift controller determines that the transmission output speed has risen past the predetermined upshift level and recommends a shift to the higher gear G2 from the current gear G1. At essentially the same time, in stage 38 of the process 35, the shift controller sets the anti-hunt timer to run for a predetermined duration Ta, ostensibly precluding a subsequent downshift until the predetermined duration Ta expires.
In parallel with stages 36-38, the grade-based controller has maintained, in stage 39, a current estimated steady state gear Gest based on current grade and machine load (potentially in combination with other factors such as known rolling resistance and so on). At stage 40 of the process 35, the transmission output speed begins to slow due to an increase in grade. In parallel, the grade-based controller determines at stage 41 that the estimated steady state gear Gest is now G1 which is different than the current gear G2. Thus at stage 42, the grade-based controller clears the anti-hunt timer and sets the secondary timer for a predetermined duration Ts (longer than the predetermined anti-hunt duration Ta) to prevent the grade-based controller from subsequently re-clearing the anti-hunt timer until the secondary timer expires.
At stage 43, the transmission output speed drops below the predetermined downshift level and the shift controller issues a recommendation that the transmission controller shift the transmission from current gear G2 to lower gear G1. Because the anti-hunt timer has been cleared by the grade-based controller, the transmission controller executes the recommendation in stage 44 and shifts the transmission to gear G1. As a result, the transmission output speed again increases, preventing engine lugging or stalling, and maintaining the engine speed in an efficient range.
It will be appreciated that the present disclosure provides a new and useful transmission system for use in a variety of machines. While only certain embodiments have been set forth, alternatives and modifications will be apparent from the above description to those skilled in the art. These and other alternatives are considered equivalents and within the spirit and scope of this disclosure and the appended claims.
