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The TCM sends out pressure command for the solenoid This system is installed in a production transmission,
output pressure. The closed loop pressure control and tested on a transmission spin dynamometer. The
system calculates required solenoid current based on spin dynamometer is controlled by the dSPACE unit.
pressure command, pressure sensor feedback, and The spin dynamometer is capable of hot testing. For
operating conditions. cold testing, the spin dynamometer is rolled into a cold
box.
TCM
Supply
Pressure
Analog to Digital
Conditioning
Conversion
Signal
PSup
Solenoid Driver
PSolAct
Circuit
SPI
To Control Valve
Sense
Resistor
Pressure
Sensor
Solenoid
Output
Pressure
Pressure
Command Feed forward i_sol OL Current Transmission
Solenoid
Control (open loop) + Controller Solenoid
+
i_sol_CL
+ - Pressure
Sensor
Pc
Observed Points
Figure 4: Dynamic Ideal Function
CONTROL FACTORS
Noise Factors
Ve (kPa^2)
1. Supply Pressure Low Temp
2. Temperature High Temp
3. Transmission Input Speed
4. Solenoid Pressure Command
Direction
Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed
High
High
High
High
Low
Low
Low
Low
5. Run-to-Run Variation
6. Aged Fluid Gear State Gear State Gear State Gear State
7. Aged Transmission Hardware 1 2 3 4
(sensors, clutches, etc)
Figure 5: Noise Test, Rising Pressure, Open Loop
To reduce the scope of the project, temperature and
transmission input speed are chosen as the primary
noise factors. The solenoid pressure command direction Variance Plotted by Gear State - Falling - Open Loop
is also included as this information can be derived from
the test profile. To further reduce the test effort,
temperature and transmission input speed can be
Ve (kPa^2)
Speed
Speed
Speed
Speed
Speed
Speed
Speed
High
High
High
High
Low
Low
Low
Low
system, by design, will eliminate any pressure offsets,
variance is used to assess the noise strategy. Gear State Gear State Gear State Gear State
1 2 3 4
Table 3: Noise Assessment Test Plan
Figure 6: Noise Test, Falling Pressure, Open Loop
Low Speed High Speed
Gear State 1 Gear State 1
Low Gear State 2 Gear State 2
Temp Gear State 3 Gear State 3 Variance Plotted by Gear State - Rising
Gear State 4 Gear State 4 Feed Forward Enabled
Gear State 1 Gear State 1
High Gear State 2 Gear State 2
Ve (kPa^2)
Speed
Speed
Speed
Speed
Speed
Speed
Speed
High
High
High
High
Low
Low
Low
Low
Low Temp
signal-to-noise ratio (S/N Ratio). Figure 11 shows the
High Temp
L18 summary for Gear State 4. Figure 12 and Figure
13 show the response plots from cycle 5 of Gear State
4.
Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed
High
High
High
High
Low
Low
Low
Low
Pressure
Gear State Gear State Gear State Gear State
1 2 3 4
Algorthim Calibration 1
Algorithm Calibration 2
Feed Forward Enabled
Controller Factor 1
Controller Factor 2
Figure 8: Noise Test, Falling Pressure, Feed
Forward Enabled
K-P Table
K-I Table
Cycle 3
Cycle 4
Cycle 5
P-DIAGRAM
Run A B C D E F G H U D U D U D
Figure 9 shows the final P-diagram after the noise 1 1 1 Y 1 1 1 1 1
assessment experiments are complete. The only noise 2 1 1 Y 2 2 2 2 2
factor that is considered is solenoid pressure command 3 1 1 Y 2 3 3 1 3
4 1 2 Y 1 2 2 1 3
direction since the test temperature and transmission 5 1 2 Y 2 3 3 1 1
input speed are fixed. 6 1 2 Y 2 1 1 2 2
7 1 3 Y 2 1 3 2 3
8 1 3 Y 2 2 1 1 1
9 1 3 Y 1 3 2 1 2
Control Factors 10 2 1 Y 2 3 2 2 1
K-I Gain Level 11 2 1 Y 1 1 3 1 2
K-P Gain Level 12 2 1 Y 2 2 1 1 3
Sensor Type 13 2 2 Y 2 3 1 1 2
Algorithm Calibration Factor 1 14 2 2 Y 2 1 2 1 3
Algorithm Calibration Factor 2 15 2 2 Y 1 2 3 2 1
Controller Factor 1
16 2 3 Y 2 2 3 1 2
Controller Factor 2
17 2 3 Y 1 3 1 2 3
18 2 3 Y 2 1 2 1 1
Desired Actual
Convert pressure command Pressure, Y
Figure 10: L18 Experimental Layout
Pressure, M
into pressure at solenoid
valve. ROBUST EXPERIMENT RESULTS
Algorithm Calibration 1
Algorithm Calibration 2
Feedforward Enabled
Controller Factor 1
Controller Factor 2
Sensor Type
K-P Table
K-I Table
Cycle 3
Cycle 3
Cycle 4
Cycle 4
Cycle 5
Cycle 5
Run A B C D E F G H U D U D U D
1 1 1 Y 1 1 1 1 1 -23.17 -23.34 -23.04 -23.39 -23.29 -23.69
2 1 1 Y 2 2 2 2 2 -24.20 -22.58 -23.32 -21.99 -23.39 -21.98
3 1 1 Y 2 3 3 1 3 -24.68 -23.05 -24.76 -22.75 -25.33 -23.79
4 1 2 Y 1 2 2 1 3 -22.71 -24.49 -22.28 -24.08 -22.26 -24.17
5 1 2 Y 2 3 3 1 1 -22.40 -22.57 -22.56 -22.23 -22.63 -22.22
6 1 2 Y 2 1 1 2 2 -22.60 -21.44 -23.36 -22.02 -22.40 -21.44
7 1 3 Y 2 1 3 2 3 -21.82 -21.81 -21.85 -21.51 -21.65 -21.78
8 1 3 Y 2 2 1 1 1 -21.90 -21.31 -21.37 -20.96 -21.72 -21.13
9 1 3 Y 1 3 2 1 2 -21.97 -21.11 -21.96 -21.32 -22.10 -21.32
10 2 1 Y 2 3 2 2 1 -22.07 -22.19 -22.18 -22.25 -22.18 -22.19
11 2 1 Y 1 1 3 1 2 -21.78 -22.63 -21.32 -22.73 -21.83 -22.17
12 2 1 Y 2 2 1 1 3 -21.75 -23.43 -22.42 -22.58 -23.65 -23.53
13 2 2 Y 2 3 1 1 2 -21.02 -21.68 -21.42 -22.04 -21.42 -22.26
14 2 2 Y 2 1 2 1 3 -22.14 -21.10 -22.19 -21.35 -22.33 -20.82
15 2 2 Y 1 2 3 2 1 -23.17 -21.55 -21.68 -21.89 -23.24 -22.31
16 2 3 Y 2 2 3 1 2 -21.11 -20.66 -21.15 -21.18 -21.08 -21.06
17 2 3 Y 1 3 1 2 3 -22.18 -21.37 -21.79 -21.43 -21.95 -21.93
18 2 3 Y 2 1 2 1 1 -20.81 -20.80 -21.05 -20.56 -20.88 -20.82
-20
B1
B2
B3
D1
D2
E1
E2
E3
F1
F2
F3
G1
G2
H1
H2
H3
A1
A2
-21
S/N
-22
-23
-24
-20
B1
B2
B3
D1
D2
E1
E2
E3
F1
F2
F3
G1
G2
H1
H2
H3
A1
A2
-21
S/N
-22
-23
-24
1.10
1.05
S/N
1.00
0.95
0.90
B1
B2
B3
D1
D2
E1
E2
E3
F1
F2
F3
G1
G2
H1
H2
H3
A1
A2
- Falling Dire ction
1.1
1.1
S/N
1.0
1.0
0.9 B1
B2
B3
D1
D2
E1
E2
E3
F1
F2
F3
G1
G2
H1
H2
H3
A1
A2
CONFIRMATION RESULTS Figure 14 shows the partial step test results for open
loop system, the “worst” closed loop system and the
Table 4 shows the results of confirmation testing for all optimal closed loop system. The “worst” closed loop
four gear states. Baseline in this case is the system here refers to the worst case of closed loop test
combination of factors that results the most economical case based on robust experiment. It is still a valid closed
system in terms of both cost and process efficiency. It loop design. The comparison clearly shows the closed
should be noted that not all of the gear states show loop system delivers much better performance in terms
equal levels of predictability. Part of the reason is the of tracking accuracy. The optimal closed loop design
placement choice of some of the pressure sensors. gives the best overall tracking performance.
Figure 15 shows the comparison of pressure tracking shown in the figure, open loop system has the biggest
errors for open loop, feed forward control only and tracking error as expected. The feed forward control
closed loop system. The figure shows results from alone brings the tracking error to a much smaller and
multiple cycles. Figure 15(a) and 15(b) show the error consistent levels. The closed loop control system
comparison for the rising and falling directions delivers the best performance, i.e. the smallest tracking
respectively. Open loop error has different levels, which errors.
represent the errors for different command levels. As
.
250
225
200
175
150
Error - KPa
125
100
75
50
CLOSED LOOP FF Only OPEN LOOP
25
-25
-50
yc 10
yc 11
2
yc 13
yc 14
15
yc 10
yc 11
yc 12
3
yc 14
15
0
yc 11
yc 12
3
yc 14
15
yc 1
yc 2
yc 3
yc 4
yc 5
yc 6
yc 7
C cle 8
9
yc 1
yc 2
yc 3
yc 4
yc 5
yc 6
yc 7
C ycl 8
C le 9
yc 1
yc 2
yc 3
yc 4
yc 5
yc 6
yc 7
y 8
C le 9
yc 1
yc 1
yc 1
yc 1
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
yc e
C le
C le
C le
C le
C le
C le
C le
C le
C cle
C le
C le
C le
C le
C le
le
C le
C le
C le
C le
le
C le
C le
C le
C le
le
yc
yc
yc
y
yc
yc
C
(a)
Solenoid 2 Error - Falling
250
225
200
175
150
Error - KPa
125
100
75
CLOSED LOOP FF Only
50
OPEN LOOP
25
0
-25
-50
yc 10
yc 11
2
yc 13
yc 14
15
yc 10
yc 11
yc 12
3
yc 14
15
0
yc 11
yc 12
3
yc 14
15
yc 1
yc 2
yc 3
yc 4
yc 5
yc 6
yc 7
C cle 8
9
yc 1
yc 2
yc 3
yc 4
yc 5
yc 6
yc 7
C ycl 8
C le 9
yc 1
yc 2
yc 3
yc 4
yc 5
yc 6
yc 7
y 8
C le 9
yc 1
yc 1
yc 1
yc 1
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
yc e
C le
C le
C le
C le
C le
C cle
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
C le
le
C le
C le
C le
C le
le
C le
C e
C le
C le
le
yc
yc
yc
l
y
yc
yc
C
C
(b)
Figure 15: Tracking Error Comparison for Closed Loop, Feed Forward Control Only and Open Loop Systems
The closed loop pressure control system is installed in a commanded pressures closely. Figure 17 shows the
test vehicle. Figure 16 shows the closed loop pressure pressure tracking results during high throttle upshifts and
tracking during 1-2-3 low to medium throttle upshifts. As downshifts. As shown in the figure, the actual pressure
shown in the figure, both oncoming and offgoing clutch tracks the commanded pressure throughout the whole
solenoid pressures follow their corresponding range.
1->2 shift
2->3 shift
Figure 16: DPRS Vehicle Test Result: 1-2 and 2-3 Upshifts (Low-Medium Throttle)
Figure 17: Vehicle Test Result: Upshift (High Throttle) and Downshifts
CONCLUSION REFERENCES
A closed loop pressure control system is developed for 1. American Supplier Institute, “Robust Engineering”,
an automatic transmission. The control system design Workshop Manuals, 2001
employs both feed forward and feedback controls. The
dynamic feed forward learning algorithm runs real time CONTACT
and adjusts the solenoid P-I characteristics based on the
learning results. The closed loop algorithm and dynamic Quan Zheng is a Staff Research Engineer in Delphi
feed forward learning algorithm run seamlessly to Powertrain Systems. Quan can be reached at:
provide accurate tracking performance. quan.zheng@delphi.com.
One contribution of this work is to apply Robust Jeremy Kraenzlein is an Electrical System Engineer in
Optimization techniques to optimize controller hardware Delphi Electronics and Safety. Jeremy can be reached
and calibration selections. The optimized design is at: Jeremy.J.Kraenzlein@delphi.com.
confirmed by L18 robust experiment carried out on spin
dynamometer. Finally, the optimized design is tested in Eunjoo Hopkins is a Staff Research Engineer in Delphi
vehicle. Powertrain Systems. Eunjoo can be reached at:
eunjoo.c.hopkins@delphi.com.
This paper presented the complete design process of
the closed loop pressure control system. Future Robert (Bob) Moses is a GM Technical Fellow and
development includes the fine tuning of the designed engineering group manager for the Advanced Power
system and making it production ready. Transfer group of General Motors Powertrain. Bob can
be reached at: robert.l.moses@gm.com.
ACKNOWLEDGMENTS
Bret Olson is a Transmission Controls Engineer for the
The authors wish to acknowledge the support of our Advanced Power Transfer group of General Motors
management and our many project team members. In Powertrain. Bret can be reached at bret.olson@gm.com.
particular, we would like to thank Lee Nunn and Wade
Roller for build support of test dynamometer and vehicle.
We would also like to thank Randall Dlugoss from
General Motors for vehicle implementation support.