A short presentation on the use of: NI CompactRIO and ...download.ni.com/pub/branches/uk/ats_2010/alan_boulton_ricardo.pdf · A short presentation on the use of: NI CompactRIO and

A short presentation on the use of:NI CompactRIO and LabVIEWNI CompactRIO and LabVIEW

for testing automotive transmissions atfor testing automotive transmissions at Ricardo UK

Midlands Technical Centre UKMidlands Technical Centre UK

NI Automated Test Summit 2010Royal Berkshire Conference CentreThursday 10th June 2010Thursday 10th June 2010By Alan C BoultonPrincipal Engineer – Test OperationsRicardo UK Ltd

www.ricardo.com© Ricardo plc 2010RD.10/261001.1

Ricardo UK Ltd

Agenda

Introduction

B h ki D l Cl h T i iBenchmarking Dual Clutch Transmissions

Automatic Transmission Valve Block Characterisation

C l iConclusions

2© Ricardo plc 2010RD.10/261001.110th June 2010

Ricardo OverviewRicardo delivers world class strategy, engineering and technology programmes

Company Positioning

ca do de e s o d c ass st ategy, e g ee g a d tec o ogy p og a esto the global automotive, transportation, defence and energy industries

Established in 1915 and independent

£81 million revenue (1st half, FY 09/10)

More than 1 600 employees with more

Emphasis on achieving enhanced value propositions for our clientsMulti-sector oriented with relevant domain

tiMore than 1,600 employees with more than 1,300 technically qualified and engineering staff

Global presence in 17 locations

expertiseGlobal footprint with local understandingStrategic perspectives and consultingUnique holistic vehicle and powertrainGlobal presence in 17 locations

ValuesUnique holistic vehicle and powertrain experienceSystems engineering approach that considers integrated solutions for theconsiders integrated solutions for the entire product lifecycleSignificant self-funded R&D investment Technology led product innovationExtensive production vehicle and major sub-system introduction experience Delivery focused


Specialist manufacturing and assembly capability niche product applications

Ricardo Client BaseRepresented across a number of key market sectors each with unique driversep ese ted ac oss a u be o ey a et secto s eac t u que d e s

Passenger Car High PerformanceVehicles & Motorsport

Commercial Vehicles

Agricultural & Industrial Vehicles

Motorcycles &Personal Transportation

Marine Rail Clean Energy & Power Generation

Defence Government

UK MoDTACOM

Power Generation


Transmission rig test facilities and experience

Transmission test facilities– 2WD rig (3E)g ( )– 4WD rig (5E)– Powerful rig control system

(communication with TCU via (fast CAN, data simulation)

– Option for additional dyno (power take-off test)

– Semi Anechoic Chamber– Gearshift durability test rig– Functionality test rigFunctionality test rig– Lubrication, deflection & tilting

rigs Core Expertise Delivered Projects• Bugatti Veyron DCT and Driveline &

• Manual Transmissions• Dual Clutch Transmissions (DCT’s)• CVT’s and Automatics

• Bugatti Veyron DCT and Driveline & TCU

• Ford GT Development & Product’ Supply

Driveline & Transmission


• Heavy duty/military • Driveline and Transmission Control

• BMW Mini development to production• Jaguar X Type AWD and Diesels• Renault Megane Sport

Systems

Agenda

Introduction



C l iConclusions


Benchmarking Dual Clutch Transmissions

In 2003 VW launched the world’s first dual clutch transmission in a series production car in thetransmission in a series production car, in the Volkswagen Golf Mk4 R32.

As a significant development in the automotive transmission world Ricardo decided to “benchmark” this transmission.

As part of this exercise Ricardo needed toAs part of this exercise Ricardo needed to “reverse engineer” the control system / strategy and to perform an efficiency test on the vehicle.

Th t i i h l t h d liThe transmission has an electro-hydraulic control system utilising three main types of solenoid valve in the hydraulic block:-

S l id t d h k l– Solenoid operated check valve– Pressure relief solenoid– Variable force solenoid valve (Proportional


( ppressure control valve)

Benchmarking Dual Clutch Transmissions – The Task

Remove the transmission from the vehicle.

Instrument the transmission in order to measure the control signals from the transmission control unit (TCU) to the hydraulic valve block solenoids.

Instrument the vehicle in order to measure vehicle conditions (CAN, temperatures etc..).vehicle conditions (CAN, temperatures etc..).

Refit the transmission in to the vehicle and perform a vehicle test (NEDC on Ricardo’s

lli d f ilit )rolling road facility).

“Reverse engineer” the control strategy.

Remove the instrumented transmission from theRemove the instrumented transmission from the vehicle and perform an efficiency / drag loss measurements on the transmission alone.


Benchmarking Dual Clutch Transmissions – Why CompactRIO?Co pact O

In order to carry out this exercise Ricardo required:required:-– A data-logging capability in order to log

vehicle conditions in conjunction with the i t t d t i iinstrumented transmission.

– The data-logging capability needed to be fastenough to capture appropriate data to allow “ i i ” f th t i i“reverse engineering” of the transmission control unit (TCU) signals to the hydraulic control valve solenoids.

– A controller capability. For the standalone transmission efficiency / drag loss measurements the transmission needed to be

t ll d ith t it ’ TCU H t llcontrolled without its’ TCU. Hence a controller was required that was capable of controlling the electro- hydraulic valves in the valve block (thi i l d d l idth d l ti PWM)


(this included pulse width modulation PWM).

The NI CompactRIO and LabVIEW software was purchased to be used for this project.

Agenda

Introduction


Transmission Valve Block Characterisation

C l iConclusions



NI CompactRIO and LabVIEW are used to support the development of new Transmissionsupport the development of new Transmission Control Units (TCU’s).

Ricardo uses its’ R-Cube system for development of TCU’s and data generated by the NI tools is used to facilitate the process.

Automotive transmissions utilisingAutomotive transmissions utilising predetermined shift strategies use electro-hydraulic valve blocks.

Th f f th i di id l l d thThe performance of the individual valves and the complete valve block is critical to the control system development and the overall performance of the end productperformance of the end product.

The valves are normally controlled using pulse width modulation (PWM) signals together with a


dither signal applied in order to improve the mechanical performance of the valve.


Transmission valve block characterisation includes measuring the effect of:includes measuring the effect of:-– applied valve current / PWM duty to the

hydraulic pressure and or flow that the valve i t lliis controlling

– valve oil temperature on the performance of an individual valve

– valve oil temperature on the performance of the complete valve block

– system pressure on the valve block y pperformance

– system flow on the valve block performancesystem leakage on the valve block– system leakage on the valve block performance

In order to asses the above criteria Ricardo use


the CompactRIO and LabVIEW system together with a hydraulic test bench to perform the tests.

Agenda

Introduction



C l iConclusions


Conclusions

The use of CompactRIO and LabVIEW has helped Ricardo in the development and exploitation of its TCU technologyand exploitation of its TCU technology.

The system has proved to be reliable.

The system has proved to be flexible and adaptable to Ricardo’s ever changingThe system has proved to be flexible and adaptable to Ricardo s ever changing needs.

Thank you.


Presented By

Alan Boulton

Principal Engineer – Test Ops

Midlands Technical Centre (MTC) Ricardo UK Ltd Midlands Technical Centre S th R dSoutham Road Radford Semele Leamington Spa W i k hi CV31 1FQWarwickshire CV31 1FQ United Kingdom

Phone:+44 (0) 1926 319319Phone:+44 (0) 1926 319319 Fax:+44 (0) 1926 319300

Email: [email protected]


Documents

A short presentation on the use of: NI CompactRIO and ...download.ni.com/pub/branches/uk/ats_2010/alan_boulton_ricardo.pdf · A short presentation on the use of: NI CompactRIO and