CN117028556B - Automatic gearbox gear-shifting position signal fault redundancy processing method - Google Patents
Automatic gearbox gear-shifting position signal fault redundancy processing method Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H61/00—Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing
- F16H61/02—Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing characterised by the signals used
- F16H61/0202—Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing characterised by the signals used the signals being electric
- F16H61/0204—Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing characterised by the signals used the signals being electric for gearshift control, e.g. control functions for performing shifting or generation of shift signal
- F16H61/0213—Control functions within control units of change-speed- or reversing-gearings for conveying rotary motion ; Control of exclusively fluid gearing, friction gearing, gearings with endless flexible members or other particular types of gearing characterised by the signals used the signals being electric for gearshift control, e.g. control functions for performing shifting or generation of shift signal characterised by the method for generating shift signals
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Abstract
The invention discloses a fault redundancy processing method for a gear shifting position signal of an automatic gearbox, wherein a BLDC motor normally controls gear shifting of the automatic gearbox, records a gear angle after successful gear shifting is finished, judges whether an absolute position sensor sampling signal is normal, if the absolute position sensor sampling signal is abnormal, switches an angle value fed back by an absolute position sensor input by a position ring into an angle value fed back by a Hall sensor, marks zero electric angle information recorded by the Hall sensor of the BLDC motor at each gear shifting starting time, takes the gear angle after the last successful gear shifting as a reference value, then calculates the stroke angle required by the gear shifting by subtracting the reference value from a target gear, and realizes the control of the gear position by performing error adjustment through a PI controller of the position ring. When the absolute position sensor fails, the Hall sensor of the BLDC motor replaces the function of the absolute position sensor, so that the gear shifting action is not influenced, and the safety of the vehicle is improved.
Description
Technical Field
The invention relates to a fault redundancy processing method, in particular to a fault redundancy processing method for a gear shifting position signal of an automatic gearbox, and belongs to the technical field of new energy electric vehicles.
Background
The control system of BLDC controlled automatic transmission gear shifting in the prior art is shown in fig. 3, and the SCU is responsible for converting the gear instruction of TCU gear shifting into an input signal of BLDC control, such as a target angle signal, and transmitting the input signal to the BLDC control module. The BLDC control module then re-acquires the BLDC motion control required angle feedback signal. It is currently common practice to obtain feedback signals by mounting an absolute position sensor on an automatic transmission. The absolute position sensor can acquire the circumferential angle position of the shifting fork, so that the operation of the position ring is participated.
The HALL sensor of the BLDC motor is installed on the motor body only for rotation control of the BLDC motor. The absolute position sensor is arranged on the automatic gearbox and used as a detection tool for the angle position of the sliding block of the gear shifting fork. The absolute position signal detected by the sensor is used as a feedback value of a position control loop to participate in PI operation. However, if the sensor fails, no feedback signal can be provided for calculation of the position control loop, resulting in a failure to shift gears.
Disclosure of Invention
The invention aims to solve the technical problem of incapability of shifting gears when an absolute position sensor fails.
In order to solve the technical problems, the invention adopts the following technical scheme:
the automatic gearbox gear shifting position signal fault redundancy processing method is characterized by comprising the following steps of:
s1, a BLDC motor normally controls an automatic gearbox to shift gears, and records a gear angle after successful gear shifting is finished;
s2, judging whether the sampling signal of the absolute position sensor is normal or not;
s3, if the sampling signal of the absolute position sensor is abnormal, switching the angle value fed back by the absolute position sensor input by the position loop into the angle value fed back by the Hall sensor;
s4, marking the electric angle information recorded by the Hall sensor of the BLDC motor to zero at each gear shifting starting time;
s5, taking the gear angle after the last successful gear shift is finished as a reference value, and then subtracting the reference value from a target gear to calculate and obtain the stroke angle required by the current gear shift;
s6, performing error adjustment through a PI controller of the position ring to control the gear position.
Further, in the step S1, the normal control of the BLDC motor to shift the automatic gearbox specifically includes:
1.1, inputting a certain angle value a0 of a shifting fork in a range of 0-360 degrees, wherein the position of one gear is an angle range value a1-a2, and a0 is the intermediate value of the angle range value a1-a2;
1.2, obtaining an angle value b0 of a gear shifting fork through an absolute position angle sensor;
1.3, respectively taking an angle value a0 and an angle value b0 as input of a position ring, wherein the angle value a0 is a target position of the position ring, the angle value b0 is a feedback position of the position ring, outputting a value c through PI proportional integral adjustment after the angle value a0 and the angle value b0 are differenced, and then converting the value c into a speed value nr in a (-Nmax, nmax) range, and taking the speed value nr as a speed target value to be input into a speed ring of a coprocessor;
1.4, converting a Hall signal calculated by a Hall sensor of the BLDC motor into an actual speed value nb, taking a difference between the speed value nr and the actual speed value nb, and outputting a value Ir after PI operation processing, wherein the value Tr is used as a target current value of a current loop;
1.5, collecting the voltage V of a bus sampling resistor of a BLDC motor control circuit, converting the voltage V into a feedback current value Ib through ohm law, and outputting a result which is output by PI operation processing after the difference between a target current value Tr of a current loop and the feedback current value Ib to a calculation module of a coprocessor for operation, and outputting six paths of pwm waves with different duty ratios;
and 1.6, six pwm waves with different duty ratios are processed by a driving chip to control the switching action of 6 paths of IGBTs, so that the control of the BLDC motor is realized.
Further, in step S1, the gear angle after the successful shift is recorded in the nonvolatile memory, a dedicated address is opened up in the nonvolatile memory to store the gear angle array a [ n ] after the successful shift is finished, and the information in the gear angle array a [ n ] after the successful shift is the gear coding information or the gear corresponding angle information after the successful shift is finished.
Further, in the step S1, the gear angle after the successful gear shift is completed is recorded in a nonvolatile memory in the VCU or TCU, and the gear angle after the successful gear shift is completed is obtained by a signal transmission method at the moment of position loop input switching.
Further, the step S2 specifically includes: if the position sensor sampling signal has the following conditions, judging that the fault occurs;
2.1, the signal fluctuation is larger;
and 2.2, the signal exceeds the value range.
Further, in the step S4, the electrical angle information recorded by the hall sensor of the BLDC motor is specifically zero-marked as follows: and at the starting time of each gear shift, setting the counted value of the rotating electrical cycle of the motor rotor recorded by the Hall sensor of the BLDC motor to zero.
Further, in the step S4, the electrical angle information recorded by the hall sensor of the BLDC motor is specifically zero-marked as follows: and recording the rotation number of the BLDC motor at the starting time of each gear shift, then collecting the rotation number of the BLDC motor at the current time, and subtracting the rotation number of the BLDC motor at the starting time from the rotation number of the BLDC motor at the current time to obtain the relative rotation number value of the BLDC motor.
Further, the step S5 specifically includes:
5.1, reading a gear angle a2 after the last successful gear shifting is finished;
5.2, a target gear Angle a1, which is converted into a relative position Angle angle_c=a1-a 2;
5.3, acquiring the number hd_counter_mp of high level of Hall signal of a Hall sensor of the BLDC motor, and judging the angle value Angle_E of the BLDC motor in the current electrical period by detecting the sector of the BLDC motor in each electrical period;
5.4, calculating a mechanical Angle value angle_m= (angle_e+ (hd_counter_mp) x 360)/Polepairs of the rotation of the BLDC motor, wherein Polepairs is the pole pair number of the rotor of the BLDC motor;
5.5 calculating the Angle value Angle_Fb=Angle_M/(i) fed back to the position loop 1 *i 2 ) Wherein i is 1 Is the transmission ratio of the primary gear in the secondary reduction gear, i 2 Is the transmission ratio of the secondary gear in the secondary reduction gear;
difference e=angle_c-angle_fb of 5.6, target Angle and feedback Angle.
Compared with the prior art, the invention has the following advantages and effects: the invention provides a fault redundancy processing method for a gear shifting position signal of an automatic gearbox, which is characterized in that when an absolute position sensor fails, the fault redundancy processing method is switched to a backup scheme in time, the Hall signal of a Hall sensor of a BLDC motor is converted into a gear shifting stroke angle, the function of the absolute position sensor is temporarily replaced, the gear shifting action is not affected, the gear shifting failure caused by the failure of the absolute position sensor is avoided, and the safety of a vehicle is improved.
Drawings
FIG. 1 is a flow chart of a method for redundant processing of automatic transmission shift position signal faults according to the present invention.
FIG. 2 is a system schematic diagram of a method for redundant processing of automatic transmission shift position signal faults according to the present invention.
Fig. 3 is a schematic diagram of a system for controlling gear shifting of a gearbox by a BLDC motor of the present invention.
Fig. 4 is a schematic diagram of the transmission relationship of the BLDC motor and the gear shifting mechanism of the present invention.
Detailed Description
In order to explain in detail the technical solutions adopted by the present invention to achieve the predetermined technical purposes, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments, and that technical means or technical features in the embodiments of the present invention may be replaced without inventive effort, and the present invention will be described in detail below with reference to the accompanying drawings in combination with the embodiments.
As shown in fig. 4, a schematic diagram of a transmission relationship between the BLDC motor and a gear shifting mechanism according to the present invention is shown, wherein a motor gear on an output shaft of the BLDC motor 1 is meshed with a primary gear shaft large gear 2, the primary gear shaft large gear 2 and a primary gear shaft small gear 3 are disposed on the same primary gear shaft, a secondary gear shaft gear 4 is meshed with the primary gear shaft small gear 3, the secondary gear shaft gear 4 and an absolute position sensor 5 are disposed on a secondary gear shaft 6, and the BLDC motor 1 is provided with a hall sensor.
As shown in fig. 1, according to the automatic gearbox gear shifting position signal fault redundancy processing method, when an absolute position sensor fails, the absolute position signal can be switched into an angle signal provided by a Hall sensor of a BLDC motor through the scheme, so that the problem of gear shifting failure and emergency stop accidents when the absolute position sensor fails are avoided. The method specifically comprises the following steps:
s1, the BLDC motor normally controls the automatic gearbox to shift gears, and the gear angle after successful gear shifting is recorded.
The normal control automatic gearbox gear shifting of the BLDC motor is specifically as follows:
1.1, the input of the position ring is a certain angle value a0 of the shifting fork in the range of 0-360 degrees, the position of one gear is an angle range value a1-a2, and a0 is the intermediate value of the angle range value a1-a2.
1.2, obtaining an angle value b0 of a gear shifting fork through an absolute position angle sensor.
1.3, respectively taking an angle value a0 and an angle value b0 as input of a position ring, wherein the angle value a0 is a target position of the position ring, the angle value b0 is a feedback position of the position ring, and after the angle value a0 and the angle value b0 are differenced, a value c is output through PI proportional integral adjustment, and then the value c is converted into a speed value nr in a range (-Nmax, nmax), and the speed value nr is taken as a speed target value and input to a speed ring of the coprocessor, as shown in figure 2.
1.4, converting a Hall signal calculated by a Hall sensor of the BLDC motor into an actual speed value nb, taking a difference between the speed value nr and the actual speed value nb, and outputting a value Ir after PI operation processing, wherein the value Tr is used as a target current value of a current loop.
1.5, collecting the voltage V of a bus sampling resistor of a BLDC motor control circuit, converting the voltage V into a feedback current value Ib through ohm law, and outputting a result which is output through PI operation processing after the difference between a target current value Tr of a current loop and the feedback current value Ib to a calculation module of a coprocessor for operation, and outputting six paths of pwm waves with different duty ratios.
And 1.6, six pwm waves with different duty ratios are processed by a driving chip to control the switching action of 6 paths of IGBTs, so that the control of the BLDC motor is realized.
The absolute position sensor detects the circumferential position of the sliding block associated with the shifting fork to judge whether the shifting fork moves to a target gear or not. If the target gear is reached, the operation of the actuator BLDC is stopped, and the rotation is immediately stopped. Otherwise, according to the resistance of the sliding block in the sliding groove, the moving speed and the output current value of the BLDC are continuously adjusted to enable the BLDC to move to reach the target position.
The gear angle after the successful shift is finished is recorded in a nonvolatile memory, and the nonvolatile memory can be EEPROM or other types of memories which are not lost when power is cut off. A section of exclusive address is opened up in the nonvolatile memory and is used for storing a gear angle array a [ n ] after successful gear shifting is finished, and in one embodiment of the invention, the information in the gear angle array a [ n ] after the successful gear shifting is finished is gear coding information or gear corresponding angle information after the successful gear shifting is finished. The gear angle array a [ n ] after the successful gear shifting is finished can be a structural body array, and comprises information such as whether the gear shifting is successful or not, a time stamp and the like.
In one embodiment of the invention, the gear angle after the successful gear shifting is recorded in a nonvolatile memory in the VCU or the TCU, and the gear angle after the successful gear shifting is obtained through a signal transmission method such as CAN at the moment of position loop input switching. The gear angle information can also be obtained by other data transmission modes, such as reading information of the on-board memory through SPI or IIC.
S2, judging whether the sampling signal of the absolute position sensor is normal or not, and judging whether the value of the sampling signal is within the range or not.
If the position sensor sampling signal has the following conditions, judging that the fault occurs:
2.1, the signal fluctuation is larger. I.e. the amplitude of the signal fluctuations of the absolute position sensor is larger than a preset amplitude threshold.
And 2.2, the signal exceeds the value range. I.e. the maximum value of the signal of the absolute position sensor is greater than a preset maximum threshold or the minimum value is less than a preset minimum threshold.
And S3, if the sampling signal of the absolute position sensor is abnormal, automatically switching to an alternative scheme, namely switching the angle value fed back by the absolute position sensor input by the position loop to the angle value fed back by the Hall sensor. And meanwhile, reporting the fault to the TCU for processing.
S4, marking the electric angle information recorded by the Hall sensor of the BLDC motor to zero at each gear shifting starting time.
And at the starting time of each gear shift, setting the counted value of the rotating electrical cycle of the motor rotor recorded by the Hall sensor of the BLDC motor to zero.
Or, at the beginning time of each gear shift, recording the rotation number of the BLDC motor at the beginning time, then collecting the rotation number of the BLDC motor at the current time, and subtracting the rotation number of the BLDC motor at the beginning time from the rotation number of the BLDC motor at the current time to obtain the rotation number relative value of the BLDC motor.
And S5, taking the gear angle after the last successful gear shift is finished as a reference value, and then subtracting the reference value from the target gear to calculate the required stroke angle of the current gear shift.
And 5.1, detecting that the absolute position sensor fails when the gear shift starts, and reading the gear angle a2 after the last successful gear shift from the gear angle array a [ n ] after the last successful gear shift in the nonvolatile memory.
5.2, target gear Angle a1, which is converted into relative position Angle angle_c=a1-a 2. The relative position angle_c may be a positive value or a negative value, and is related to the shift position corresponding to the time of occurrence of the failure. After the gear shifting target angle is determined, the PI operation of the position loop can be performed only by acquiring the feedback angle and making a difference between the target angle and the feedback angle.
5.3, the acquisition method of the feedback angle can be realized by installing a Hall signal sensor on the BLDC motor body, the Hall signal sensor can acquire the high level and the low level of the current phase, and the Hall signal of the Hall sensor can appear 1 high level in each electric period, so that the number of times of the high level of the Hall signal of the Hall sensor can be recorded by a software counter. The method comprises the steps of obtaining the number hd_counter_mp of high level of a Hall signal of a Hall sensor of the BLDC motor, and judging an angle value Angle_E of the BLDC motor in a current electrical period by detecting a sector of the BLDC motor in each electrical period.
5.4 calculating a mechanical angle value of rotation of the BLDC Motor
Angle_M = (AnglePos_E+(hd_counter_mp)*360) /Polepairs，
Where Polepairs is the pole pair number of the BLDC motor rotor.
5.5 the mechanical angle_m of the BLDC rotor obtained needs to be further converted into an Angle value corresponding to the commanded Angle corresponding to the shift fork, typically by means of a two-stage reduction gear. Calculate feedback to position loopAngle_fb=angle_m/(i) 1 *i 2 ) Wherein i is 1 Is the transmission ratio of the primary gear in the secondary reduction gear, as shown in figure 4, the transformation ratio of the motor rotating shaft transmitted to the primary gear shaft big gear 2, i 2 Is the transmission ratio of the secondary gear in the secondary reduction gear, and the primary gear shaft pinion 3 is transmitted to the secondary gear shaft gear 4 as shown in fig. 4.
Difference e=angle_c-angle_fb of 5.6, target Angle and feedback Angle.
S6, performing error adjustment through a PI controller of the position ring to control the gear position.
The invention provides a fault redundancy processing method for a gear shifting position signal of an automatic gearbox, which is characterized in that when an absolute position sensor fails, the fault redundancy processing method is switched to a backup scheme in time, the Hall signal of a Hall sensor of a BLDC motor is converted into a gear shifting stroke angle, the function of the absolute position sensor is temporarily replaced, the gear shifting action is not affected, the gear shifting failure caused by the failure of the absolute position sensor is avoided, and the safety of a vehicle is improved.
The present invention is not limited to the preferred embodiments, but is capable of modification and variation in detail, and other embodiments, such as those described above, of making various modifications and equivalents will fall within the spirit and scope of the present invention.
Claims (6)
1. The automatic gearbox gear shifting position signal fault redundancy processing method is characterized by comprising the following steps of:
s1, a BLDC motor normally controls an automatic gearbox to shift gears, and records a gear angle after successful shifting is finished;
in the step S1, the BLDC motor normally controls the automatic gearbox to shift gears specifically includes:
1.1, inputting a certain angle value a0 of a shifting fork within a range of 0-360 degrees, wherein the position of one gear is an angle range value a1-a2, and a0 is the intermediate value of the angle range value a1-a2;
1.2, obtaining an angle value b0 of a gear shifting fork through an absolute position angle sensor;
1.3, respectively taking an angle value a0 and an angle value b0 as input of a position ring, wherein the angle value a0 is a target position of the position ring, the angle value b0 is a feedback position of the position ring, outputting a value c through PI proportional integral adjustment after the angle value a0 and the angle value b0 are differenced, and then converting the value c into a speed value nr in a (-Nmax, nmax) range, and taking the speed value nr as a speed target value to be input into a speed ring of a coprocessor;
1.4, converting a Hall signal calculated by a Hall sensor of the BLDC motor into an actual speed value nb, taking a difference between the speed value nr and the actual speed value nb, and outputting a value Ir after PI operation processing, wherein the value Ir is used as a target current value of a current loop;
1.5, collecting the voltage V of a bus sampling resistor of a BLDC motor control circuit, converting the voltage V into a feedback current value Ib through ohm law, and outputting a result which is output through PI operation processing after the difference between a target current value Ir of a current loop and the feedback current value Ib to a calculation module of a coprocessor for operation, and outputting six paths of pwm waves with different duty ratios;
1.6, six pwm waves with different duty ratios are processed by a driving chip to control the switching action of 6 paths of IGBTs, so as to realize the control of the BLDC motor;
s2, judging whether the sampling signal of the absolute position sensor is normal or not;
s3, if the sampling signal of the absolute position sensor is abnormal, switching the angle value fed back by the absolute position sensor input by the position loop into the angle value fed back by the Hall sensor;
s4, marking the electric angle information recorded by the Hall sensor of the BLDC motor to zero at each gear shifting starting time;
s5, taking the gear angle after the last successful gear shifting is finished as a reference value, and then subtracting the reference value from a target gear to calculate and obtain the stroke angle required by the current gear shifting;
the step S5 specifically comprises the following steps:
5.1, reading a gear angle a2 after the last successful gear shifting is finished;
5.2, a target gear Angle a1, which is converted into a relative position Angle angle_c=a1-a 2;
5.3, acquiring the number hd_counter_mp of high level of Hall signal of a Hall sensor of the BLDC motor, and judging the angle value Angle_E of the BLDC motor in the current electrical period by detecting the sector of the BLDC motor in each electrical period;
5.4, calculating a mechanical Angle value angle_m= (angle_e+ (hd_counter_mp) x 360)/Polepairs of the rotation of the BLDC motor, wherein Polepairs is the pole pair number of the rotor of the BLDC motor;
5.5 calculating the Angle value Angle_Fb=Angle_M/(i) fed back to the position loop 1 *i 2 ) Wherein i is 1 Is the transmission ratio of the primary gear in the secondary reduction gear, i 2 Is the transmission ratio of the secondary gear in the secondary reduction gear;
difference e=angle_c-angle_fb of 5.6, target Angle and feedback Angle;
s6, error adjustment is carried out through a PI controller of the position ring, and control of the gear position is achieved.
2. The automatic transmission shift position signal failure redundancy processing method according to claim 1, characterized in that: in the step S1, the gear angle after the successful shift is recorded in a nonvolatile memory, a section of exclusive address is opened up in the nonvolatile memory for storing a gear angle array a [ n ] after the successful shift is finished, and the information in the gear angle array a [ n ] after the successful shift is the gear coding information or the gear corresponding angle information after the successful shift is finished.
3. The automatic transmission shift position signal failure redundancy processing method according to claim 1, characterized in that: in the step S1, the gear angle after the successful gear shift is finished is recorded in a nonvolatile memory in the VCU or TCU, and the gear angle after the successful gear shift is finished is obtained through a signal transmission method at the moment of position loop input switching.
4. The automatic transmission shift position signal failure redundancy processing method according to claim 1, characterized in that: the step S2 specifically comprises the following steps: if the position sensor sampling signal has the following conditions, judging that the fault occurs;
2.1, signal fluctuation exceeds a threshold range;
and 2.2, the signal exceeds the value range.
5. The automatic transmission shift position signal failure redundancy processing method according to claim 1, characterized in that: in the step S4, the electrical angle information recorded by the hall sensor of the BLDC motor is specifically zero-marked as follows: and at the starting time of each gear shift, setting the counted value of the rotating electrical cycle of the motor rotor recorded by the Hall sensor of the BLDC motor to zero.
6. The automatic transmission shift position signal failure redundancy processing method according to claim 1, characterized in that: in the step S4, the electrical angle information recorded by the hall sensor of the BLDC motor is specifically zero-marked as follows: and recording the rotation number of the BLDC motor at the starting time of each gear shift, then collecting the rotation number of the BLDC motor at the current time, and subtracting the rotation number of the BLDC motor at the starting time from the rotation number of the BLDC motor at the current time to obtain the relative rotation number value of the BLDC motor.
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