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Keywords:
Geminichain,systemdesign,noisecharacteristic,dynamiccharacteristic,transmissionerror.
1Introduction
Transmissionsystemisthecorecomponentoftheautomotivepowertrain.Itsexcellentperformanceandperfection,playdecisiverolesintheautomobilepowerperformance,economy,comfortableandreliability.Dualclutchtransmission(DCT)cantransmitpowerwithoutinterruption.Thustheshifttimeisshortenedandtheshiftqualityiseffectivelyimproved.DCThasinheritedmanyadvantagesofthemanualtransmission,suchashightransmissionefficiency,compactinstallationspace,lightweight,lowcostetc.Soitisthedevelopmentdirectionintheautomatictransmissionindustry.
DCTavailableinautomotivetechnologyisshowninFig.
1.Theroundpinsilentchaintransmissionsystemisappliedinthechaintransmissionsystemstudiedinthispaper.
Uptonow,manyscholarshavedonealotofresearchinrelatedareas.Basedonthemeshingtheoryofsilentchainandsprocket,MENGFanzhong,etal[1–4],presentedamethodwhichcancalculatetheparametersofplateandsprocket.Themeshingdesignsystemofchainplate-sprocket-hobwhenplateandsprocketismeshingwasstudiedinthosepapers.Andthemultivariatevariationcharacteristicofsilentchainplateandsprocketisexpounded.Basedonthesilentchainsimulationmodels,FENGZengming,etal[5–6],researchedthemeshingcharacteristicofchaindrivesystembyanalyzingthecontactforceandstressofplateandpinindifferentmeshingperiod.Basedontheabrasiontestofchaindrivesystem,CHENGYabing,etal[7–9],studiedtheabrasionpositionsurfacemorphologyofplate,sprocketandpin.Thetransversefluctuationsofaxialmovingofsilentchainusingmulti-bodydynamicswereanalyzedbyZHANGWM,etal[10].ThewearcharacteristicsofautomotivechaindrivesystemfromthemicroscopicviewandanalyzedtheforcecharacteristicsofchainplateandpinattheNano-levelwasstudiedbyLIBaolin,etal[11].MicrostructureandperformanceofcontactsurfacesofthetoothchainplateafterquenchinginthemicroscopewasresearchedbyFUZhenming,etal[12].DynamicresponseofthechaintransmissionsystemincompositeandalternatingconditionswasstudiedbyXULixin,etal[13].BasedonthemeshingmechanismofchainplateandsprocketwithinvolutetoothproposedbyXUEYunna,etal[14–15],WANGYong,etal[16],analyzedthemodificationcoefficientofsprocketwhilethechainplateandsprocketmeshing.Theyhaveachievedthechangerulesofdifferenttoothprofilefromthemodificationcoefficientchanges.Newdoublepitchrocker-pinsilentchainforconveyorsandsprockettoothprofilewerestudiedbyWANGWencheng,etal[17],SUNWei,etal[18],theyproposedanewtypeofdoublepitchrocker-pinsilentconveyorchainandstudiedsprockettoothprofileandinvolutesprockettoothprofileforeffectsondynamictensionofchainsinthesilentchaindrive.
Fig.1.SchematicofDCTtransmissionsystem
Manyotherfamousscholarshaveconductedin-depthresearchinthechaintransmissionrelatedfields.PERAIRACM,etal[19],presentedamethodtoestablishmulti-bodydynamicsmodelofachaindrivesystemwithgeometricmathematics,andanalyzedthelinkvelocity,acceleration,forceandtrajectory.YOUNGJD,etal[20],proposedanarrangementofanon-symmetricandalternatingengagementtoothprofile,andamethodforinstallingthedampingrubberringintheoutsidesprockettoreducemeshingimpactandvibrationofrollerchaindrivesystem.FUJIMOTON,etal[21],developedamethodtoachievechainnoisereductionbychangingmeshingtoothprofileoftheplateandthechainsprocket.MATSUDAal[22]presentedanewsilentchainanddevelopedasilentchainwithdouble-sidedengagement,whichcanachievemultiaxisdriveinspace.BasedonbyTROEDSSONI,etal[23],presentedamathematicalmodel,anddevelopedamathematicalmodel.Bythismodel,oscillationandforceofthechaintransmissionsystemcanbecalculateddirectly.ThechoralactionandtransmissionerrorsofasimplesilentchainsystemwasinvestigatedbyHUANGC,etal[24],theyanalyzedthechoralactionbasedonthetoothcontactanalysisofthechainwiththedrivingsprocket.
DCTtransmissionsystemstudiedinthispaperisanewtypeGeminichainsystemofDCTbasedonanimprovedDCTchaintransmissionsystem.Basedonthemeshingtheoryofsilentchain,anewGeminichaintransmissionsystemisdesignedandthedynamicanalysismodelisestablished.BasedonRecurDynsoftware,thedynamiccharacteristicsareanalyzedandevaluated.ThenoisecharacteristicsoftheGeminichaintransmissionsystemareanalyzedthroughnoiseexperimental.Theinnovationofthispaperisthefirsttimecombinedthedesign,simulationanalysisandnoiseexperimentalwhichcanimprovethedesignandsimulation.Wecanverificationtherationalofdesignthroughsimulationanalysisandexperimental.
2MathematicModelingEstablished
Parametersdesignofplate
AccordingtothemeshingtheoryofsilentchainandsprocketandthedesignconditionsofGeminichainsystemindualclutchtransmission,theplatedesignoftheDCTGeminichaintransmissionsystemisshowninFig.2.Themainparametersare:
holepitcha,apothemf,halfangleoftoothprofileα.
Fig.2.Plateparameter
Theholepitcha=mm,apothemf=mm,thehalfangleoftoothprofileα=30°
.
Parametersdesignofsprocket
ThesprocketdesignoftheDCTGeminichaintransmissionsystemisshowninFig.3.Themainparametersare:
teethnumberZ,pitchp,pitchdiameterd,tipdiameterdaandrootdiameterdf,measurementoverpinsMR,measuringpindiameterdR.TheGeminichainsystemconsistsofcrankshaftsprocket(Geminisprocket),clutchsprocket1,clutchsprocket2,chain1andchain2.ThedesignparametersofsprocketsareshowninTable1.
Fig.3.Sprocketparameter
Parametersdefinition
(1)Accordingtothedesignrequirements,thespeedrangeofGeminisprocketisdefinedfrom0to6500r/min.
(2)ThenumberofwholechainlinksmustbecalculatedintheprocessofdesignandcalculationofDCTGeminichainsystem.Bycalculation,thenumberofchainlinksbetweenGeminisprocketandclutchsprocket1(chain1)is70,thenumberofchainlinksbetweenGeminisprocketandclutchsprocket2(chain2)is88.
(3)Relativecoordinatecentersofthethreesprocketsare:
theGeminisprocket(0,0,0),clutchsprocket1,,
0),theclutchsprocket2,,0)。
(4)Accordingtoabovecalculation,thelengthofthe
chain1isL1=m.Thelengthofchain2isL2=
m[22–23]。
3SystemDynamicCharacteristicsAnalysis
Systemdynamicmodel
AccordingtotheaboveparameterscalculationofGeminiplateandsprockets,thethree-dimensional(3D)modelwasestablishedinCATIAasbelow.Theplate3DmodelisshowninFig.4(a)withplatematerial50CrVA.Thepindiameterismmwithpinmaterial20CrMnMo.The3DmodelofGeminisprocketisshowninFig.4(b).Itsteethnumberis24andtheworkingtoothprofileisinvolutewithsprocketmaterial40Cr.The3Dmodelofclutchsprocket2isshowninFig.4(c).Thetoothnumberis42andtheworkingtoothprofileisinvolutewithsprocketmaterial40Cr.The3Dmodelofclutchsprocket1isshowninFig.4(d).Thetoothnumberis56andtheworkingtoothprofileisinvolutewithsprocketmaterial40Cr.ThematerialpropertiesareshowninTable2.
Systemdynamiccharacteristics
Accordingtothestructureandlayoutofthedualclutch,theGeminichaintransmissionsystemshowedinFig.5issimulated.Theforceandtorquehavebeentransferredthroughtwodifferentchains.ThedrivingsprocketisGeminisprocketwhichphasedifferenceishalfofthetoothprofileangle.Themeshingnoiseandvibrationcanbereducedeffectivelythroughadjustingrhythmandfrequency.
Fig.4.3Dmodelofchainplateandsprockets
Fig.5.Geminichainsystem
Contactforceofpinandplate
Thecontactforceofthepinandtheplateinmeshi