Prediction of synchronization time for tractor power-shift transmission using multi-body dynamic simulation

Abstract

Synchronization time determines the capacity of a shift actuator for an automatic transmission system. Existing approaches for measuring this time only consider one rotational inertia and therefore cannot be applied to the power-shift transmission (PST) of a tractor with wet multi-plate clutches on both sides of the synchronizer. This study aims to predict the PST synchronization time by considering time-varying axial forces as first-order functions and the equivalent rotational inertias of the hub and the gear. First, we derive an analytical equation for the synchronization time. We then develop a multi-body dynamics (MBD) model that includes the drag torque of the wet multi-plate clutches. The MBD model is composed of a synchronizer, a linkage, and an output shaft of a shift actuator as a rigid-body system. A power-shift test was performed on the synchronizer at two shift stages requiring the maximum shift force of the system. The torque of the shift actuator (the input of the shift system) and the angular displacement of the output shaft of the shift actuator (the output of the shift system) were measured. The results of the simulation model were then compared with those of the shift test. Compared with the test results, the simulation results were validated within 7.63% accuracy, based on the maximum value for the torque of the shift actuator. The proposed equation was validated within a maximum error range of 8.25%. The proposed equation did not consider drag torque of the wet multi-plate clutches because that torque is much smaller than the cone torque of the synchronizer in the target shift system. The proposed equation can reduce computation time and will enable more precise sizing of the synchronizer and shift actuator in the early design stages of automatic transmissions.