The Experts below are selected from a list of 249 Experts worldwide ranked by ideXlab platform
Xingyong Song - One of the best experts on this subject based on the ideXlab platform.
-
pressure based Clutch control for automotive transmissions using a sliding mode controller
IEEE-ASME Transactions on Mechatronics, 2012Co-Authors: Xingyong SongAbstract:Clutch shift control is critical for efficient and high-performance transmission designs, including automatic, dual Clutch, and hybrid transmissions. To ensure a smooth Clutch to Clutch shift, appropriate controls for two consecutive processes are critical. One is the precise coordination between the on-coming and off-going Clutches, which requires the on-coming Clutch to be filled and ready for engagement at the predetermined time (Clutch fill). The other is the proper torque control during Clutch engagement. In this paper, we will investigate the closed-loop “wet” Clutch control enabled by a pressure sensor in the Clutch chamber. The main challenges of the pressure-based “wet” Clutch control lie in the complex nonlinear dynamics due to the interactions between the fluid and the mechanical systems, the ON/OFF behavior of the Clutch Assembly, the time-varying Clutch loading condition, the required short time duration for a precise and robust Clutch shift, and the lack of the displacement information. To enable precise and robust pressure-based control, this paper focuses on the following three aspects. First, a Clutch dynamic model is constructed and validated, which precisely captures the system dynamics in a wide pressure range. Second, a sliding-mode controller is designed to achieve robust pressure control while avoiding the chattering effect. Finally, an observer is constructed to estimate the Clutch piston motion, which is not only a necessary term in the nonlinear controller design but also a diagnosis tool for the Clutch fill process. To validate the proposed methods, a transmission Clutch fixture has been designed and built in the laboratory. The experimental results demonstrate the effectiveness and robustness of the proposed controller and observer.
-
Automotive Transmission Clutch Fill Control Using a Customized Dynamic Programming Method
Journal of Dynamic Systems Measurement and Control, 2011Co-Authors: Xingyong Song, Mohd Azrin Mohd Zulkefli, Zongxuan Sun, Hsu Chiang MiaoAbstract:Clutch to Clutch shift control technology, which is the key enabler for a compact and low cost transmission design, is important for both automatic and hybrid transmissions. To ensure a smooth Clutch to Clutch shift, precise synchronization between the on-coming and off-going Clutches is critical. This further requires the on-coming Clutch to be filled and ready for engagement at the predetermined time. Due to the compact design, currently there is no pressure sensor inside the Clutch chamber, and therefore the Clutch fill can only be controlled in an open loop fashion. The traditional Clutch fill approach, by which the Clutch fill input pressure command is manually calibrated, has a couple of limitations. First, the pressure profile is not optimized to reduce the peak flow demand during Clutch fill. Moreover, it is not systematically designed to account for uncertainties in the system, such as variations of solenoid valve delay and parameters of the Clutch Assembly. In this paper, we present a systematic approach to evaluate the Clutch fill dynamics and synthesize the optimal pressure profile. First, a Clutch fill dynamic model, which captures the key dynamics in the Clutch fill process, is constructed and analyzed. Second, the applicability of the conventional numerical dynamic programming (DP) method to the Clutch fill control problem, which has a stiff dynamic model, is explored and shown to be ineffective. Thus, we proposed a customized DP method to obtain the optimal and robust pressure profile subject to specified constraints. The customized DP method not only reduces the computational burden significantly, but also improves the accuracy of the result by eliminating the interpolation errors. To validate the proposed method, a transmission Clutch fixture has been designed and built in the laboratory. Both simulation and experimental results demonstrate that the proposed customized DP approach is effective, efficient and robust for solving the Clutch fill optimal control problem.
-
transmission Clutch fill control using a customized dynamic programming method
ASME 2008 Dynamic Systems and Control Conference Parts A and B, 2008Co-Authors: Xingyong Song, Mohd Azrin Mohd Zulkefli, Hsu Chiang MiaoAbstract:Clutch fill control is critical for automotive transmission performance and fuel economy, including both automatic and hybrid transmissions. The traditional approach, by which the Clutch fill pressure command is manually calibrated, has a couple of limitations. First, the pressure profile is not optimized to reduce the peak Clutch fill flow demand. Moreover, it is not systematically designed to account for uncertainties in the system, such as variations of solenoid valve time delay and parameters of the Clutch Assembly. In this paper, we present a systematic approach to evaluate the Clutch fill dynamics and synthesize the optimal pressure profile. First, a Clutch fill dynamic model is constructed and analyzed. Second, the applicability of the conventional numerical Dynamic Programming (DP) algorithm to the Clutch fill control problem is explored and shown to be ineffective. Thus we developed a new customized DP method to obtain the optimal and robust pressure profile subject to specified constraints. After a series of simulations and case studies, the new customized DP approach is demonstrated to be effective, efficient, and robust for solving the Clutch fill optimal control problem.Copyright © 2008 by ASME
John W. Sutherland - One of the best experts on this subject based on the ideXlab platform.
-
Tolerance allocation: Balancing quality, cost, and waste through production rate optimization
Journal of Cleaner Production, 2021Co-Authors: Yue Wang, Aihua Huang, Carolyn A. Quigley, John W. SutherlandAbstract:Abstract Dimensional tolerance allocation is a very important and difficult task that traditionally seeks to balance cost/productivity and quality. Common tolerance allocation models have two shortcomings: i) they are overly reliant on models focused on minimizing cost and tend to ignore waste, and ii) they fail to connect to the root cause of many quality issues: process variation. This paper proposes a tolerance allocation model that addresses these shortcomings. The proposed model considers both product design (tolerance selection) and operation planning (or production rate selection). Relations among production rate, production cost, processing precision, and waste are considered. A gradient-based optimization method is proposed to minimize the cost and waste. A Clutch Assembly case study is analyzed to evaluate the method. Monte Carlo simulations are employed to validate the accuracy of the proposed cost model. The proposed method is compared with a heuristic method from the literature. The proposed method produced more satisfactory products at a lower cost while producing less waste. For the case study, it is found that when the precision of a process is high, it is not necessary from an economic standpoint to inspect the quality of individual components. For poor precision processes, inspecting the quality of individual components is the preferred approach from a cost/throughput standpoint.
-
Allocation of Assembly tolerances to minimize costs
CIRP Annals, 2019Co-Authors: Yue Wang, Nathan W. Hartman, John W. SutherlandAbstract:Abstract The cost and quality of an Assembly depend on the processes used to manufacture its components. The specific processes and process settings are often dictated by the tolerances on the components. One long-standing challenge is allocating the Assembly tolerance to components. Many methods have been proposed, most of which endeavor to minimize cost. We propose a tolerance allocation method that minimizes cost by jointly considering process variation and tolerance specifications. A cost model including processing cost, scrap cost, and quality loss is employed. The cost is minimized by a heuristic strategy. An overrunning Clutch Assembly case study is used to evaluate the method.
Matthew G. Hoffman - One of the best experts on this subject based on the ideXlab platform.
-
Development, Testing and Implementation of a Gas Turbine Starting Clutch With Manual Turning Feature for U.S. Navy Ships
Journal of Engineering for Gas Turbines and Power-transactions of The Asme, 2006Co-Authors: Morgan L. Hendry, Matthew G. HoffmanAbstract:Most gas turbine generators rely on an automatic-engaging, free-wheel Clutch to connect a starting motor to accelerate the gas turbine generator from zero to some intermediate speed to enable ignition and then provide torque assistance to a higher speed until the gas turbine is self-sustaining. The U.S. Navy has used various designs of starter motors and Clutches for its gas turbine fleet. In addition, there has been a requirement to periodically borescope each gas turbine, which has necessitated removal of the starting system and Clutch Assembly in each instance. This paper examines the U.S. Navy experience with starting Clutches and provides details of the development and testing of a synchronous-self-shifting Clutch with an additional, stationary, manual turning feature to provide very slow and precise gas turbine rotor rotation for borescope purposes. This paper also gives details of the installation of the first two prototype Clutches on the USS Ramage, DDG 61, operating experience for approximately four years, and possible future installations of this type of Clutch in U.S. Navy gas turbine generator sets.
-
Development, Testing and Implementation of a Gas Turbine Starting Clutch With Manual Turning Feature for U.S. Navy Ships
Volume 5: Marine; Microturbines and Small Turbomachinery; Oil and Gas Applications; Structures and Dynamics Parts A and B, 2006Co-Authors: Morgan L. Hendry, Matthew G. HoffmanAbstract:Most gas turbine generators rely on an automatic-engaging, free-wheel Clutch to connect a starting motor to accelerate the gas turbine generator from zero to some intermediate speed to enable ignition and then provide torque assistance to a higher speed until the gas turbine is self-sustaining. The U.S. Navy has used various designs of starter motors and Clutches for its gas turbine fleet. In addition, there has been a requirement to periodically borescope each gas turbine and this has necessitated removal of the starting system and Clutch Assembly in each instance. This paper examines the U.S. Navy experience with starting Clutches and provides details of the development and testing of a synchronous-self-shifting Clutch with an additional, stationary, manual turning feature to provide very slow and precise gas turbine rotor rotation for borescope purposes. This paper also gives details of the installation of the first two prototype Clutches on the USS Ramage, DDG 61, operating experience for approximately four years, and possible future installations of this type of Clutch in U.S Navy gas turbine generator sets.Copyright © 2006 by ASME
C. Balamurugan - One of the best experts on this subject based on the ideXlab platform.
-
Optimal Tolerance Allocation in a Complex Assembly Using Evolutionary Algorithms
International Journal of Simulation Modelling, 2016Co-Authors: L. Ramesh Kumar, K. P. Padmanaban, C. BalamuruganAbstract:Tolerance design is a vital factor which influences product and process development. Further, it determines the manufacturing cost, the functionality and quality of a product. It is evident that optimal tolerance normally leads to produce ample parts, better operation of mechanical systems and excellent assembling. In contrast, tight tolerance leads to increase in manufacturing cost for an Assembly. An ideal relationship exists among production cost and operation, while determining the optimum tolerance. Based on this relation a new approach by implementing the Non-traditional techniques: Genetic Algorithm (GA), Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) and Differential Evolution (DE) for determining the optimum tolerance, zero percentage rejection and manufacturing cost considering the varying quality loss constants for an Assembly namely overrunning Clutch Assembly, is discussed in this paper. From the result obtained, it is evident that, the proposed approach is best suitable for solving problems involving complex assemblies. (Received in May 2015, accepted in September 2015. This paper was with the authors 1 month for 1 revision.)
-
Technical note: allocation of optimal tolerances in a mechanical Assembly using DE and NSGA-II
International Journal of Computer Applications in Technology, 2010Co-Authors: K. Sivakumar, C. BalamuruganAbstract:This paper discusses a general methodology based on evolutionary algorithms (Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) and Differential Evolution (DE)) for allocation of optimal tolerance for an over-running Clutch Assembly. New hybrid models are developed for obtaining the manufacturing costs of hub, rollers and cage. The aim of this paper is to find optimal tolerances values that give minimum combined objective function value, minimum Manufacturing Cost (MC), minimum Quality Loss (QL) function and maximum Number of Standard Deviations (Z NSD) by satisfying stack-up conditions using non-traditional optimisation techniques. The results obtained from various techniques are compared and analysed.
Yue Wang - One of the best experts on this subject based on the ideXlab platform.
-
Tolerance allocation: Balancing quality, cost, and waste through production rate optimization
Journal of Cleaner Production, 2021Co-Authors: Yue Wang, Aihua Huang, Carolyn A. Quigley, John W. SutherlandAbstract:Abstract Dimensional tolerance allocation is a very important and difficult task that traditionally seeks to balance cost/productivity and quality. Common tolerance allocation models have two shortcomings: i) they are overly reliant on models focused on minimizing cost and tend to ignore waste, and ii) they fail to connect to the root cause of many quality issues: process variation. This paper proposes a tolerance allocation model that addresses these shortcomings. The proposed model considers both product design (tolerance selection) and operation planning (or production rate selection). Relations among production rate, production cost, processing precision, and waste are considered. A gradient-based optimization method is proposed to minimize the cost and waste. A Clutch Assembly case study is analyzed to evaluate the method. Monte Carlo simulations are employed to validate the accuracy of the proposed cost model. The proposed method is compared with a heuristic method from the literature. The proposed method produced more satisfactory products at a lower cost while producing less waste. For the case study, it is found that when the precision of a process is high, it is not necessary from an economic standpoint to inspect the quality of individual components. For poor precision processes, inspecting the quality of individual components is the preferred approach from a cost/throughput standpoint.
-
Allocation of Assembly tolerances to minimize costs
CIRP Annals, 2019Co-Authors: Yue Wang, Nathan W. Hartman, John W. SutherlandAbstract:Abstract The cost and quality of an Assembly depend on the processes used to manufacture its components. The specific processes and process settings are often dictated by the tolerances on the components. One long-standing challenge is allocating the Assembly tolerance to components. Many methods have been proposed, most of which endeavor to minimize cost. We propose a tolerance allocation method that minimizes cost by jointly considering process variation and tolerance specifications. A cost model including processing cost, scrap cost, and quality loss is employed. The cost is minimized by a heuristic strategy. An overrunning Clutch Assembly case study is used to evaluate the method.