Virtual vehicle transmission test cell

• US 6,754,603 B2
• Filed: 02/25/2003
• Issued: 06/22/2004
• Est. Priority Date: 03/04/2002
• Status: Expired due to Fees

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: General Motors Corporation (Motors Liquidation Co. GUC Trust)
• Inventors: Treichel, Benjamin A., Surampudi, Bapiraju, Steiber, Joe, Hysko, Alfonso G., Piorkowski, Paul A., Nash, Steven D., Stark, David T., Senseney, Robert M., Tator, Robert W., Castiglione, Matthew S., Stecklein, Gary L., Turbett, Marlin R., Rosati, Michael R., Joseph, David L.
• Primary Examiner(s): Barlow, John
• Assistant Examiner(s): VO, HIEN XUAN
• Application Number:
  US10/374,682
• Publication Number:
  US 20030167143A1
• Time in Patent Office: 483 Days
• Field of Search: 702/113, 702/108, 702/114, 731/16, 731/17, 731/181, 738/659, 738/621.6, 738/664, 307/10.1, 701/51, 434/380, 180/337
• US Class Current: 702/113
• CPC Class Codes: G01M 13/021 Gearings
• CPC Class Codes: G01M 13/025 Test-benches with rotational drive means and loading means; Load or drive simulation
• CPC Class Codes: G06F 30/15 Vehicle, aircraft or watercraft design

Abstract

The virtual vehicle transmission test cell includes an electric motor which simulates a fuel driven engine, an output motor which simulates the load a transmission experiences in a vehicle, and an environmental element which controls the ambient environment of the transmission and the temperature of the transmission oil within the transmission. The virtual vehicle transmission test cell reduces in-vehicle testing, reduces testing with fuel-driven test cells, and enables development of a transmission design before a corresponding engine is completed and built for testing.

Claims

1. A system for testing an automotive transmission according to a predetermined test schedule which avoids having to install and drive the transmission in a vehicle to perform the testing, the system comprising:

an input motor operatively connectable to an input of the transmission for providing rational drive thereto in simulation of the predetermined test schedule;

an output motor operatively connectable to an output of the transmission for providing rational resistance thereto in simulation of the predetermined test schedule;

an environmental chamber for substantially enclosing the transmission;

an environment controller for controlling the ambient conditions within said environmental chamber; and

a transmission cooler for controlling the rejection of heat from the transmission;

wherein the predetermined test schedule includes gear shifting of the transmission between a plurality of speed ratios.

2. The system of claim 1, further comprising an apparatus for adjusting angular articulation of the transmission.

3. A system according to claim 1, further comprising:

an input motor controller for controlling rotational drive of said input motor to selectively simulate the speed, acceleration, torque, inertia and/or other performance aspects of an engine according to selected speed, throttle position, torque mapping and/or other parameters; and

an output motor controller for selectively controlling the rotational resistance of said output motor to selectively simulate the speed, deceleration, torque, inertia and/or other performance aspects of an after-transmission drivetrain of a selected vehicle according to selected vehicle aerodynamics, vehicle mass, road conditions, air/weather conditions, load-carrying, torque mapping and/or other parameters.

4. A system according to claim 3, further comprising a plurality of speed, torque, temperature, pressure, position, flow rate, humidity and/or other sensors operatively arranged to detect various speeds, torques, temperatures, pressures, positions, flow rates, humidities and/or the like at selected points in said system.

5. A system according to claim 3, wherein said after transmission drivetrain includes one or more of a drive shaft, a differential unit, a power take-off unit, and a set of wheels.

6. A system according to claim 1, wherein said transmission cooler includes:

means for selectively controlling the temperature differential between a supply of transmission fluid to the transmission and a return of transmission fluid from the transmission; and

/or

means for selectively controlling the flow rate of at least said supply of transmission fluid to the transmission.

7. A system according to claim 6, wherein said means for selectively controlling the temperature differential includes a first heat exchanger connected to said supply and return of transmission fluid, wherein said first heat exchanger is situated outside of said environmental chamber.

8. A system according to claim 6, wherein said means for selectively controlling the flow rate includes a variable orifice valve.

9. A system according to claim 7, further comprising:

a shunt between said supply and return of transmission fluid, wherein said shunt is situated inside of said environmental chamber; and

a second heat exchanger operatively connected with the first heat exchanger to enhance cooling capacity.

10. A system according to claim 1, further comprising:

a ratio-changing gear box operably connected to said output motor and operably connectable to the output of the transmission.

11. A system according to claim 1, further comprising:

a transmission controller for selectively controlling the gear shifting of the transmission in response to virtual vehicle speed and virtual throttle position according to a predetermined shift schedule.

12. A system according to claim 3, further comprising a test automation system controller (TAS) operatively connected with the input motor controller, the output motor controller, the environmental controller and the transmission cooler for controlling testing of the transmission.

13. A system according to claim 3, further comprising an input torquemeter operatively connected to the input motor and the input motor controller, and an output torquemeter operatively connected to the output motor and the output motor controller.

14. A system according to claim 2, wherein said apparatus for adjusting angular articulation comprises a platform supported by a plurality of hydraulically adjustable supports.

15. A system according to claim 1, wherein said input motor is an electric motor with an inertia simulation capability between approximately 0.05 and 0.25 kgm².

16. A system according to claim 15, wherein said input motor is a 330 kw, 9000 rpm AC motor.

17. A system according to claim 16, wherein inertia of the input motor is approximately 0.12 kgm² in order to simulate a V8 engine.

18. A system for testing an automotive transmission according to a predetermined test schedule which avoids having to install and drive the transmission in a vehicle to perform said testing, comprising:

a. an input motor operatively connectable to an input of the transmission for providing rotational drive thereto;

b. an output motor operatively connectable to an output of the transmission for providing rotational resistance thereto;

c. an environmental chamber for substantially enclosing the transmission;

d. means for selectively controlling the ambient temperature, pressure, and/or humidity within said environmental chamber;

e. means for selectively controlling the rate/amount of heat rejected by the transmission, including means for selectively controlling the temperature differential between a supply of transmission fluid to the transmission and a return of transmission fluid from the transmission, and/or means for selectively controlling the flow rate of at least said supply of transmission fluid to the transmission;

f. means for selectively controlling the angular articulation of the transmission with respect to its roll, pitch, and/or yaw axes in simulation of the predetermined test schedule;

g. means for selectively controlling the rotational drive of said input motor to selectively simulate the speed, acceleration, torque, inertia and/or other parameters in simulation of the predetermined test schedule;

h. means for selectively controlling the rotational resistance of said output motor to selectively simulate the speed, deceleration, torque, inertia and/or other aspects of an after-transmission drivetrain of a selected FWD, RWD and/or AWD vehicle according to selected vehicle aerodynamics, vehicle mass, road condition, air/weather conditions, load-carrying, torque mapping and/or other parameters in simulation of the predetermined test schedule;

i. a plurality of speed, torque, temperature, pressure, position, flow rate and/or other sensors operatively arranged to detect various speeds, torques, temperatures, pressures, positions, flow rates, and the like at selected points in said system; and

j. means for selectively controlling the shifting of the transmission in response to virtual vehicle speed and virtual throttle position according to a predetermined shift schedule.

19. A method for virtual vehicle testing of an automotive transmission according to a predetermined test schedule which avoids having to install and drive the transmission in a vehicle to perform said testing, said method comprising the steps of:

a. providing a virtual vehicle test system, comprising;

i. an input motor operatively connectable to an input of the transmission for providing rotational drive thereto;

ii. an output motor operatively connectable to an output of the transmission for providing rotational resistance thereto;

iii. an environmental chamber for substantially enclosing the transmission;

iv. means for selectively controlling the ambient temperature, pressure, and/or humidity within said environmental chamber;

v. means for selectively controlling the rate/amount of heat rejected by the transmission, including means for selectively controlling the temperature differential between a supply of transmission fluid to the transmission and a return of transmission fluid from the transmission, and/or means for selectively controlling the flow rate of at least said supply of transmission fluid to the transmission;

vi. means for selectively controlling the angular articulation of the transmission with respect to its roll, pitch, and/or yaw axes in simulation of the predetermined test schedule;

vii. means for selectively controlling the rotational drive of said input motor to selectively simulate the speed, acceleration, torque, inertia and/or other aspects of an engine according to selected speed, throttle position, torque mapping and/or other parameters in simulation of the predetermined test schedule;

viii. means for selectively controlling the rotational resistance of said output motor to selectively simulate the speed, deceleration, torque, inertia and/or other aspects of an after-transmission drivetrain of a selected FWD, RWD and/or AWD vehicle according to selected vehicle aerodynamics, vehicle mass, road condition, air/weather conditions, load-carrying, torque mapping and/or other parameters in simulation of the predetermined test schedule;

ix. a plurality of speed, torque, temperature, pressure, position, flow rate and/or other sensors operatively arranged to detect various speeds, torques, temperatures, pressures, positions, flow rates, and the like at selected points in said system; and

x. means for selectively controlling the shifting of the transmission in response to virtual vehicle speed and virtual throttle position according to a predetermined shift schedule;

b. installing a transmission into the virtual vehicle test system, such that the input and output of the transmission are operatively connected to the input motor and output motor, respectively;

c. operating the input motor through said means for selectively controlling the rotational drive thereof to simulate a selected engine according to the predetermined test schedule, and operating the output motor through said means for selectively controlling the rotational resistance thereof to simulate a selected vehicle and selected vehicle-affecting conditions according to the predetermined test schedule;

d. permitting the transmission to shift among its various gears according to the predetermined shift schedule in response to the virtual vehicle speed and virtual throttle position; and

e. evaluating the performance of the transmission in its execution of said step (d) according to preselected performance criteria.

20. A method according to claim 19, further comprising the steps of:

f. modifying the transmission and/or the predetermined shift schedule; and

g. repeating said steps (c), (d), and (e).

21. A method according to claim 20, where said steps (c) through (g) are repeated as needed until the performance of the transmission substantially meets the preselected performance criteria.

22. A process for optimally matching candidate vehicle and engine designs with candidate transmission designs which avoids having to install and drive a corresponding physical transmission in a corresponding physical vehicle having a corresponding physical engine, said process comprising the steps of:

a. selecting a candidate vehicle design and a candidate engine design;

b. obtaining respective performance characteristics for the candidate vehicle and engine designs according to at least one baseline test schedule;

c. selecting a candidate transmission design;

d. selecting a shift schedule for the candidate transmission design;

e. providing a physical transmission corresponding to the candidate transmission design;

f. testing the physical transmission in a virtual vehicle test system which provides;

i. rotational drive to the input of the transmission in simulation of the performance characteristics of the candidate engine, and

ii. rotational resistance to the output of the transmission in simulation of the performance characteristics of the candidate vehicle,

iii. while permitting the physical transmission to shift among its various gears according to the selected shift schedule in response to virtual vehicle speed and virtual throttle position;

g. evaluating the performance of the physical transmission according to preselected performance criteria;

h. executing at least one step selected from the group comprising;

i. modifying the physical transmission,

ii. selecting an alternate candidate vehicle design and obtaining performance characteristics therefor according to the previously selected at least one test schedule,

iii. selecting an alternate candidate engine design and obtaining performance characteristics therefor according to the previously selected at least one test schedule,

iv. obtaining new performance characteristics for the candidate vehicle and/or engine design(s) according to an alternate test schedule,

v. selecting an alternate candidate transmission design and providing an alternate physical transmission corresponding thereto, and

vi. selecting an alternate shift schedule; and

i. repeating at least said steps (f) and (g).

23. A process according to claim 22, wherein said steps (f) through (i) are repeated as needed until the performance of the physical transmission substantially meets the preselected performance criteria.

24. A system for testing an automotive transmission according to a predetermined test schedule which avoids having to install and drive the transmission in a vehicle to perform the testing, comprising:

an input motor operatively contactable to an input of the transmission for providing rotational drive thereto;

an output motor operatively contactable to an output of the transmission for providing rotational resistance thereto;

an environmental chamber for substantially enclosing the transmission;

an environmental controller for controlling ambient conditions in the environmental chamber;

a transmission cooler for controlling the rejection of heat from the transmission; and

a test automation system controller operatively connected to said input motor, said output motor, said environmental controller, and said transmission cooler for controlling testing of the transmission.

25. A system according to claim 24, wherein the predetermined test schedule includes gear shifting of the transmission between a plurality of speed ratios.

26. A system according to claim 24, wherein said input motor is a 330 kw, 900 rpm AC motor with an inertia of approximately 0.12 kgm².

27. A system for testing an automotive transmission and corresponding transmission controller according to a predetermined test schedule which avoids having to install and drive the transmission and corresponding transmission controller in a vehicle to perform said testing, comprising:

a motor operatively connectable to an input of the transmission for providing rotational drive thereto in simulation of the predetermined test schedule;

an output motor operatively connectable to an output of the transmission for providing rotational resistance thereto in simulation of the predetermined test schedule;

an environmental chamber for substantially enclosing the transmission;

an environmental controller for controlling the ambient conditions with said environmental chamber;

a transmission cooler for controlling the rejection of heat from the transmission;

a test automation system controller operatively connected to the input motor, output motor, environmental controller, and transmission cooler, and connectable to the corresponding transmission controller for controlling testing of the transmission; and

wherein the predetermined test schedule includes gear shifting of the transmission between a plurality of speed ratios.