2.1. Modeling of Wet Clutch Engagement Process
With the increase in oil pressure, the wet clutch will exist in three states:
- (1)
When the wet clutch is sliding, the dynamic equation of the clutch is:
In the formula, is the input torque of the wet clutch; is the friction torque of the wet clutch; is the resistance torque of the clutch driven shaft; is the rotational inertia of the clutch input shaft; is the rotational inertia of the clutch driven shaft; is the rotational speed of the clutch input shaft; is the rotational speed of the clutch driven shaft.
The calculation formula of wet clutch transmission torque is:
In the formula, is sliding friction coefficient, and its value is related to the rotational speed difference; is the number of friction plates; is the outer diameter of the friction plates; is the inner diameter of the friction plates; is the outer diameter of the piston; is the inner diameter of the piston, is the effective force area of the piston, is the stiffness of the return spring, is the displacement of the piston, and is the initial compression of return spring.
- (2)
When the wet clutch is fully engaged, the speed of the input end and the output end is equal, and the dynamic equation is:
- (3)
When the wet clutch is completely separated (assuming that the friction force can be neglected in this state), the dynamic equation is:
2.2. Establishment of Wet Clutch Hydraulic Control Platform
The hydraulic control system of the wet clutch consists of three parts: the power source, the oil pressure regulator, and the clutch hydraulic chamber.
Figure 1 is the structure diagram of the pressure proportional solenoid valve and the clutch hydraulic chamber. Its main components are the proportional solenoid, valve spool, valve body, return spring, channel, oil drain hole, oil inlet, and oil outlet. The valve spool divides the valve body into four hydraulic chambers. Chambers 1 and 4 are decompressing cavities, which are connected with pressure-regulating chamber 2 through channels 1 and 2. Chamber 3 is the pressure supply chamber connected with a constant pressure source. When the solenoid valve coil is not powered, the valve spool is in the leftmost position because of the return spring. The oil inlet is closed, and chamber 2 is connected to the oil drain hole. The oil outlet’s pressure is 0 MPa, and the wet clutch is not combined. When the solenoid valve coil is powered, the valve spool compresses the return spring and moves to the right, and the oil inlet is gradually opened. The oil flows into chamber 2 through an oil outlet, which makes the pressure of chamber 2 and the output pressure of the solenoid valve increase gradually. Therefore, the oil pressure in the wet clutch’s piston chamber increases, and the engagement of the wet clutch is promoted. As the solenoid valve’s output pressure increases gradually, the pressure in chamber 1 and chamber 4 also increases gradually. Due to the different areas of the two decompressing cavities, the forces acting on the pressure feedback cavities are also different. Finally, the electromagnetic force, the return spring force, and the force of the pressure feedback chamber on both sides are balanced, and the solenoid valve’s output pressure is stable.
For the pressure-proportional solenoid valve that has strong nonlinear properties, in order to simplify the system modeling, this paper makes three simplifications: ① to ignore the influence of oil leakage during valve movement; ② the pressure of chamber 1 and chamber 4 is approximately equal to the output pressure proportional solenoid valve; and ③ to ignore the volume of chamber 1 and chamber 4 and the flow of hydraulic oil [
15,
16].
The kinematic equations of pressure proportional solenoid valve spool are shown in Formula (5).
In which is the electromagnetic force caused by the powered solenoid valve coil (N), is the excitation current flowing through the solenoid valve coil (N/A), is the resultant force acting on chamber 1 and chamber 4 (N), is the proportion coefficient of electromagnetic force and the current of the solenoid valve coil (N/A), is the output pressure of the solenoid valve (pa), and are the force areas of the solenoid valve’s left and right sides (m2), is the mass of the valve spool (kg), is the displacement of the valve spool (m), is the damping coefficient of the valve spool (Ns/m), and is the stiffness of the return spring (N/m).
The flow balance equations of the pressure-proportional solenoid valve are:
In which is the flow rate of the solenoid valve’s oil inlet (L/min), is the flow rate of the solenoid valve’s oil drain hole (L/min), is the flow rate flowing from the solenoid valve into the wet clutch’s piston chamber (L/min), is the volume of the solenoid valve chamber (m3), is the bulk modulus of oil (indicating the ability of oil to resist compression), is the flow coefficient of the solenoid valve, is the diameter of the valve spool (m), is the density of the hydraulic oil (kg/m3), is the oil pressure of the solenoid valve’s stabilized supply source (pa), is the oil pressure of the tank which is connected to the oil drain hole (pa), is the length of the solenoid valve’s oil drain hole (m), and is the output pressure of the solenoid valve (pa).
The mathematical model of the pressure-proportional solenoid valve, obtained from formula (5) and (6), is as formula (7):
When a certain amount of hydraulic oil flows into the clutch piston chamber, the volume flow and dynamic oil pressure in the piston chamber can be expressed as:
is the effective force area of the piston, is the displacement of the piston, is the bulk modulus of oil (indicating the ability of oil to resist compression), is the output pressure of the solenoid valve (pa), and is the initial volume of the clutch piston chamber (m3).
Additionally, the dynamic model of the piston during clutch engagement is:
In the formula, is the reaction force of the piston under contact pressure, is the damping coefficient of the piston, and is the mass of the piston.
According to formulas (5) to (9), the hydraulic control simulation platform of the wet clutch is established based on AMESim software (Version 2019.1, Simcenter Amesim, Siemens Digital Industries Softwares, Berlin&Munuch, Germany), as shown in
Figure 2.
2.3. Design of Wet Clutch Oil Filling Controller Based on Backstepping Algorithm
Based on the mathematical model of the pressure-proportional solenoid valve, this paper adopts the backstepping algorithm [
17,
18,
19] to design the oil pressure following the controller of the wet clutch. The principle of backstepping is to split the research system into multiple subsystems with lower orders, and to design virtual controllers for each subsystem from the subsystem where the control variable is located to the end of the input subsystem, so that the subsystem is stable in the Lyapunov sense [
20]. The obtained system control input is obtained by backstepping and recursion.
By dividing formula (8) into three subsystems, and by selecting three state variables, (
,
,
), let the state variable
=
, where
is the velocity of the valve spool. The system control input is
, and the state equation of the wet clutch hydraulic control system is as follows:
The design of the backstepping controller is divided into three steps. First, to realize oil pressure following control, which is to make the solenoid valve’s output pressure
follow the ideal control curve, then
,
is the excepted value of
. Let error1 be
. At this time, the control target is converted into
. When taking the Lyapunov function
, then
According to Lyapunov stability theory, the system is stable when takes the virtual control value , , , and then .
To make
, let error2 be
, and take the Lyapunov function as
. Thus:
According to the Lyapunov stability theory, the system is stable when takes the virtual control value , and , (then ).
To make
, let error3 be
, and take the Lyapunov function as
. Thus:
According to the Lyapunov stability theory, the system is stable when the system control input satisfies formula (12):
and
,
,
(then
). Formula (14) is the control law of the system control input.
The co-simulation of Matlab/Simulink and AMESim is used to verify the control effect of the system input control law of formula (14) on the piston oil pressure. The controller in
Figure 3 is the oil pressure controller obtained by formula (15).
2.4. Wet Clutch Oil Filling Characteristics Influence Factor Divisions and Smoothness Evaluation Indexes
The wet clutch oil-filling process is generally divided into four stages [
21,
22,
23]:
Phase 1: after the solenoid valve coil of the wet clutch is electrified, the pressure in the piston cavity begins to build, and the gap between the friction plate and the steel plate is eliminated.
Phase 2: with the increase in piston oil pressure, the friction plates and steel plates are further pressed. At this time, the clutch relies on rough friction torque and viscous torque to transmit torque.
Phase 3: the piston oil pressure rises to the set value to ensure that the wet clutch has a certain reserve torque. At this time, there is no relative speed between friction plates and steel plates.
Phase 4: the piston oil pressure remains constant until the controller issues new instructions.
Through analysis, this study selected five factors that affect the oil-filling characteristics curve—the oil-filling rate of phase 1, the proportion of phase 1’s duration to the total oil filling time, the oil-filling rate of phase 2, the proportion of phase 2’s duration to the total oil filling time, and the proportion of phase 3’s duration to the total oil filling time—to explore the influence of different oil-filling control strategies on the engagement quality of the wet clutch. In this paper, dynamic load, sliding friction work, impact degree, and engagement time are selected to evaluate the engagement quality of the wet clutch, and the comprehensive evaluation index of engagement quality of the wet clutch is established [
24,
25,
26].
Dynamic load refers to the ratio of the maximum transmission torque to the stable transmission torque, indicating the fluctuation degree of the torque transmitted by the wet clutch.
In the formula, is dynamic load, is the maximum transmission torque during the wet clutch engagement process (Nm), and is the stable transmission torque during the wet clutch engagement process (Nm).
Sliding friction work is the work generated by the friction torque of the wet clutch when sliding, and sliding means there is a relative speed between friction plates and steel plates of the wet clutch. The friction work will accelerate the wear of clutch friction plates and reduce the service life of the clutch.
In the formula, is the sliding friction work (J), is the friction torque of the wet clutch (Nm), is the rotation speed of the friction plates (rad/s), is the rotation speed of the steel plates (rad/s), is the sliding start time (s), and is the sliding end time (s).
Impact degree refers to the change rate of the tractor’s longitudinal acceleration; the greater the impact, the lower the smoothness and the driving comfort of the tractor.
In the formula, is the impact degree (m/s3) and is the speed of tractor (m/s).
The engagement time refers to the time when the wet clutch receives the engagement instruction until there is no rotational speed difference between the friction plates and the steel plates.
In the formula, is the full engagement time (s), is the time when the wet clutch actuator receives the combined instruction (s), and is the time when there does not exist a speed difference(s) between the friction plate and the steel plate.
2.5. Simulation Test Platform for Oil Filling Control Strategy of Wet Clutch
Due to the noise interference in a bench test, this paper studies the oil filling control strategy of the wet clutch based on SimulationX software (Version 3.8, ESI ITI GmbH, Dresden, Germany), taking one stage of a stepped gearbox as an example. The specific parameters of the wet clutch in the oil-filled test platform are shown in
Table 1, and the simulation test platform is shown in
Figure 4. The working condition of the test is that a certain type of tractor (8.5 t) runs on flat ground without hanging agricultural machinery, and the engine speed is 1070 r/min. To validate the simulation model, this paper conducts simulation tests and bench tests of eight operating conditions (clutch oil pressure is 0.5, 1, 1.7, 2.4, 3.1, 3.8, 4.3, and 4.8 MPa, respectively) and compares the results (
Table 2). One should adjust the simulation platform to match the engine speed (1070 r/min) and load (85.17 Nm) of the bench (
Figure 5) and record the speed fluctuation of the gearbox output shaft. The comparison results are shown in
Table 1.
For these 8 conditions, the relative error between the simulation results and the test results of the maximum output speed of the gearbox is 5.3%, which verifies the correctness of the simulation model.
2.6. Experimental Design Based on RSM
In this paper, the central composite design (CCD) in response surface methodology (RSM) is selected to design the simulation test of clutch engagement quality [
27,
28], and the number of the test groups is 50 in total (
Table 3 and
Table 4). CCD has the advantages of flexible design and fewer test times, which are widely used in scientific experiments.
The RSM is based on the least squares regression method to fit the statistical model, to approximate the real functional relationship, and to describe the relationship between input and response scientifically. The model can optimize and predict the response.
The code value and the actual value of each factor can be selected when modeling. The items in the model established by the two methods are the same, but each parameter is different. The relationship between the factors (
,
,
,
, and
) and the response values (
,
,
,
, and
) is shown in formula (19) [
29,
30].
In the formula, is the oil filling rate of phase 1, is the proportion of phase 1’s duration to the total oil filling time, is the oil filling rate of phase 2, is the proportion of phase 2’s duration to the total oil filling time, is the proportion of phase 3’s duration to the total oil filling time, and is the variation from other sources that the model cannot explain.
The first-order or second-order Taylor expansion is used to approximate the function form of the model in a relatively small region. The second-order model is: