Optimization of a pressure control valve for high power automatic transmission considering stability

The pilot-operated electrohydraulic clutch-actuator system is widely utilized by high power automatic transmission because of the demand of large flowrate and the excellent pressure regulating capability. However, a self-excited vibration induced by the inherent non-linear characteristics of valve spool motion coupled with the fluid dynamics can be generated during the working state of hydraulic systems due to inappropriate system parameters, which causes sustaining instability in the system and leads to unexpected performance deterioration and hardware damage. To ensure a stable and fast response performance of the clutch actuator system, an optimal design method for the pressure control valve considering stability is proposed in this paper. A non-linear dynamic model of the clutch actuator system is established based on the motion of the valve spool and coupling fluid dynamics in the system. The stability boundary in the parameter space is obtained by numerical stability analysis. Sensitivity of the stability boundary and output pressure response time corresponding to the valve parameters are identified using design of experiment (DOE) approach. The pressure control valve is optimized using particle swarm optimization (PSO) algorithm with the stability boundary as constraint. The simulation and experimental results reveal that the optimization method proposed in this paper helps in improving the response characteristics while ensuring the stability of the clutch actuator system during the entire gear shift process.