New slip synthesis and theoretical approach of CVT slip control

Today's vehicle must be efficient in terms of gas (CO2, NOx) emissions and fuel consumption. Due to improvements in material and oil, the continuous variable transmission (CVT) is now making a breakthrough in the automotive market. The CVT decouples the engine from the wheel speed. CVT enables significant fuel gains by shifting the engine operating point for specific power demands. This optimization of the operating point enables a reduction of this fuel consumption. A CVT is constituted of two pulley sheaves, one fixed and the other one movable in its axial direction when subjected to an external axial force, in general hydraulic. The transition from the minimum to the maximum speed ratio is continuous and an infinite numbers of ratio is available between these two limits. An intermediate element (a metallic belt or chain) transmits the power from the input (the primary) to the exit (the secondary) of the CVT or variator. Further improvements of the fuel consumption and gas emission are still required for example by improving the variator efficiency. Increasing hydraulic performance or decreasing mechanical losses by reducing the axial forces are some solutions. The latter method is not without risks. The diminution of the clamping forces increases the slip between pulley sheaves and the intermediate element. If the axial forces decrease too much, high slip values can be reached and cause damage to the pulleys and the intermediate element. Control of the slip is an attractive solution to decrease the clamping forces in order to safely improve the variator efficiency. The objective of this thesis is to understand and model the slip of each pulley and establish analytic tools dedicate to the variator control. The slip study and the theoretical approach of the CVT variator is applied to the slip control of the variator with a chain. The contribution of this work is threefold. Firstly, the slip and the traction coefficient are analyzed for each pulley. The slip analysis of each pulley is then used to define a new slip synthesis as the summation of the slip of each pulley. It is demonstrated that the slip and the traction coefficient are different for each pulley and depend on the speed ratio of the variator. In low ratios, both the secondary pulley and the primary pulley slip, but only the primary reaches macro slip. For middle or higher ratios, only the secondary pulley slips and reaches high values of slip. Experiments show that the pulley with the smallest clamping force limits the system. Secondly, based on kinematics, force equilibrium, elastic deformations of the pulleys and the intermediate element, a detail model of the variator is proposed. The principal results are the estimation of the clamping forces, of the traction curve for each pulley and of the chain efficiency. These results are implemented in a simpler model that describes the variator dynamics. This last model considers the two pulleys and the intermediate element as free bodies. The hydraulic circuit and the actuators, which are important to take into account for control, are also modeled. Thirdly, the new slip synthesis and the results of the dynamic models are applied to the slip control of the variator in order to improve the efficiency. A pole placement law is applied to the actuators to control the flow that enters or exits the pulleys. With this law, the actuators are decoupled and the bandwidth is increased sufficiently for actuators dynamics to be neglected. The primary and the secondary pressures are decoupled and linearized by an input-output feedback linearization. The resulting system is linear and linear control theory can be applied to control the two pressures. The speed ratio is controlled by the primary clamping force. The secondary pressure is chosen as a function of the control mode of the variator: standard mode or slip mode. In standard mode, the intermediate element is overclamped by 30%, whereas in slip mode, the secondary clamping force is set as a function of the desired slip. By controlling the slip at 2%, the mechanical efficiency was increased by more than 2% and the clamping forces reduced by more than 30%. For the slip control, a proportional-integrator law and a model reference adaptive control (MRAC) are presented and the performances compared. The MRAC gives slightly better results.

Dynamics of torque control continuously variable transmissions

Robert Fuchs

With the increasing concerns in the impact of automotive emissions of CO2 and NOx on the environment combined with today's speculation on oil crude supply, the need to find solutions reducing the fuel consumption and emission of tomorrow's cars is more than ever present. Although the first continuously variable transmissions (CVT) appeared over a hundred years ago, it is only with the recent technological improvements in material durability, lubrication oil as well as control related hardware and software, that these transmissions have proved their capabilities. Because of their ability to decouple the engine from the wheel speed, CVTs enable significant fuel gains by shifting the engine operating point for a certain power demand toward higher torque and lower speed. A CVT can be regarded as a system dedicated to converting the torque delivered by the engine to the wheels. Conversely, for the engine speed control, it can be seen as an actuator applying a load to the engine. Two control concepts of CVTs are recognized. First is the concept of ratio control, which is a natural extension to fixed gear ratio transmissions, enabling an actuation of the transmission ratio. Second and less conventional, is the torque control concept, which sets the torque to be transmitted. It is the particular mechanism of these variators that allows the transmission to automatically shift to the appropriate ratio. Torque control CVTs extend the benefits obtained with conventional ratio control CVTs as they provide a direct control of the load applied on the engine, resulting in a straightforward control of the powertrain. Moreover, when such CVTs are combined with an epicyclic gear train in a split torque arrangement to form an infinitely variable transmission (IVT), virtually no control is required for the operation at the geared neutral point (infinite or zero speed ratio depending on the definition). However, the extended ability of torque control CVTs to decouple the engine and the vehicle speeds causes strong internal interactions, which must be fully understood for their development. The objective of this thesis is to provide a comprehensive and coherent set of analytical tools for the development and operation of torque control CVT powertrains. The classical method of modeling, performance analysis and control is applied to the Torotrak IVT Series 3 and its torque control full toroidal variator. Each of these steps gives a different perspective of the dynamics involved within the variator, of the interactions of the variator with the surrounding subsystems (hydraulics and driveline) and of the powertrain control. The contribution of this work is threefold. Firstly, the most relevant dynamics involved in TC/CVT-based powertrains are described with an application to the Torotrak torque control IVT. The main technical achievements are the development and validation of a model for simulation of the full toroidal variator, an open-loop performance analysis of the powertrain and the development of a control strategy for the engine operating point based on the nonlinear input-output feedback linearization technique. Secondly, this work broadens the general theoretical knowledge base of the operation of CVT powertrains. The two control concepts are compared and formally defined resulting in a new and original classification of transmissions. Also, the problem of powertrain control is formalized with the development of high-level, low bandwidth models of the engine, the transmission and the vehicle featuring properties similar to those of the ratio control CVT powertrain model. Thirdly, the formal and progressive analysis made throughout this work shows how the classical method of modeling, performance analysis and control can be applied to complex systems. This relies most of all on the development of models of varying complexity adapted to the requirements of the system analysis, design and control.

EPFL2006

An Energy Efficient Power Converter for Zero Power Wearable Devices

Milad Ataei Ashtiani

Early diagnosis of Alzheimer's and epilepsy requires monitoring a subject's development of symptoms through electroencephalography (EEG) signals over long periods. Wearable devices enable convenient monitoring of biosignals, unlike complex and costly hospital equipment. The key to achieving a fit and forgettable wearable device is to increase its operating cycle and decrease its size and weight. Instead of batteries, which limit the life cycle of electronic devices and set their form factor, body heat and environmental light can power wearable devices through energy-scavenging technologies. The harvester transducers should be tailored according to on the application and the sensor placement. This leaves a wide variety of transducers with an extensive range of impedances and voltages. To realize an autonomous wearable device, the power converter energy harvester, has to be very efficient and maintain its efficiency despite potential transducer replacement or variations in environmental conditions. This thesis presents a detailed design of an efficient integrated power converter for use in an autonomous wearable device. The design is based on the examination of both power losses and power transfer in the power converter. The efficiency bound of the converter is derived from the specifications of its transducer. The tuning ranges for the reconfigurable parameters are extracted to keep the converter efficient with variations in the transducer specifications. With the efficient design and the manual tuning of the reconfigurable parameters, the converter can work optimally with different types of transducers, and keeps its efficiency in the conversion of low voltages from the harvesters. Measurements of the designed converter demonstrate an efficiency of higher than 50% and 70% with two different transducers having an open-circuit voltage as low as 20 mV and 100 mV, respectively. The power converter should be able to reconfigure itself without manual tunings to keep its efficiency despite changes in the harvesters' specifications. The second portion of this dissertation addresses this issue with a proposed design methodology to implement a control section. The control section adjusts the converter's reconfigurable parameters by examining the power transfer and loss and through concurrent closed loops. The concurrent loops working together raise a serious concern regarding stability. The system is designed and analyzed in the time domain with the state-space averaging (SSA) model to address the stability issue. The ultra-low-power control section obtained from the SSA model estimates the power and loss with a reasonable accuracy, and adjusts the timings in a stable manner. The entire control section consumes only 30 nW dynamic power at 10 kHz. The control section tunes the converter's speed or its working frequency depending on the available power. The frequency clocks the entire architecture, which is designed asynchronously; therefore, the power consumption of the system depends on the power available from the transducer. The system is implemented using 0.18 µm CMOS technology. For an input as low as 7 mV, the converter is not only functional but also has an efficiency of more than 40%. The efficiency can reach 70% with an input voltage of 50 mV. The system operates in a range of just a few of millivolts to half a volt with ample efficiencies. It can work at an optimal point with different transducers and environmental conditions.

EPFL2018

Object-oriented approach for dynamic system modelling and simulation

Adel Besrour

Software engineering always cares to provide solutions for building applications as close as possible to what they should be, according to the requirements and the final users needs. Systems behavior simulation is a very common application to virtually reproduce and often predict the real-world behavior. Simulation is one of the most operational research tool in a large variety of engineering and scientific domains: Transport, telecommunication, medicine, chemical processes, physics, etc. The complexity of such application is relative to the increasing complexity of the systems. In this context, it is relevant to bring together different tools and formalisms such as markovian chain, Petri nets, etc., to improve the existent approaches and so to answer the simulations performances needs. The principle objective of this thesis is to bring together techniques from software engineering and safety engineering in order to improve the state of the art of modeling and simulation of dynamic systems in the industrial context. In addressing this objective, this work initially involves defining the essential limitations of the used formalisms, methods and tools regarding from one hand the software engineering modeling and simulation techniques and from the other hand the existent risk analysis methodologies. This work is conducted with respect to the problem of danger identification, considering the context of the complex systems behavior and their interaction with the human operator. In software engineering, it is well known that Petri/high-level nets have attractive characteristics to be used in systems simulation and behavior prediction such as the natural graphical representation, and their well-defined semantic. They are well-suited for the description of complex situations with concurrency (interleaving and true concurrency depending on the underlying semantics), conflict and confusion. However, the absence of structuring capabilities has been one of the main criticisms raised against Petri nets/high-level nets. Thus, there have been many attempts to introduce structuring principles in nets of this kind [BCM88] [Kie89] [JR91]. The attractive characteristics of Petri/high-level nets have prompted researchers to enrich these formalisms with object-oriented features. CO-OPN (Concurrent Object-Oriented Petri Net) approach, brings together the power of both Petri/high-level nets and object-orientation techniques, it has been devised so as to offer an adequate framework for the specification and design of large scale concurrent system [BG91]. CO-OPN, as a powerful modeling tool, has been used in a limited way to simulate systems. This work aims to provide a CO-OPN extension to allow a more realistic systems' simulation. Actually, its simulator semantic uses to be a suitable approach for modeling near closed systems and software components, because they need to loose coupling with external world. But, when we model more realistic problems like industrial processes, where human interaction is a relevant event, this approach is not sufficient to catch all system activity attributes. Moreover, the CO-OPN interpretation process does not allow interaction with the object internal states. This work provides a new solution to overcome CO-OPN simulation limitations and a set of prototypes to assist dynamic systems simulations. Furthermore, this work has been conducted in a Risk Analysis (RA) context, a domain where computer-based simulations research are of utmost interest. Actually, classical approaches used to address complex workplace hazard in a limited way, using checklists or sequence models. Moreover, the use of single oriented methods, such as AEA (man-oriented), FMEA (machine oriented) or HAZOP (process oriented), is not satisfactory to overcome the increasing sophistication of industrial processes. The automation of a part of the analysis process as well as the multiple-oriented approach allowed by dynamic modeling may indeed enhance significantly the analysis completeness and reduce the time analyzing time. This work, based on Object Oriented Petri net formalism (CO-OPN), propose an alternative multi-oriented approach where existent methods limitations have been criticized to develop a dynamic model, MORM (Man-machine Occupational Risk Modeling). A real industrial system (metal wire making process) has been specified to implement the different approach steps (system identification, model application, system simulation, system analysis).

EPFL2005