CTI-Symposium

Automotive Transmissions North America June 12-14, 2007, Detroit (MI), USA

Torque Measurement With Speed Sensors

TOMCAT
(TOrque Measurement Control for All Transmission Types)

Thomas Karer / MAGNA Powertrain – Engineering Center Steyr

Author: Thomas Karer / ECS Date: 06/12/2007 1
 Torque measurement in vehicles

Only a dream till today?

Author: Thomas Karer / ECS Date: 06/12/2007 2

 General situation at the moment

Powertrain components deal with torque

- combustion engine
- clutch
- gearboxes and T-cases
- differential and diff-locks
- break systems, ESP

Dream of every vehicle developer

Knowledge of all torque values in the powertrain

Till today only a dream, because

Torque measurement is cost-intensive

Author: Thomas Karer / ECS Date: 06/12/2007 3

 General situation at the moment

Torque will be calculated indirectly

- pressure
- length
- angle
- current, voltage
- injected fuel quantity
- ....

less accuracy
Torque of powertrain is barely usable

corrective factors
narrow and expensive tolerances

Author: Thomas Karer / ECS Date: 06/12/2007 4

 Basic condition specification

costs function
- non or low cost standard parts - accuracy: +/- 15 Nm for cars
- replace hardware by software +/- 50 Nm for trucks
- no additional ECU - no temperature dependency
- no wear

TOrque Measurement Control for All Transmission Types

result
- torque signal + guaranteed tolerance
- clearance of the powertrain
Author: Thomas Karer / ECS Date: 06/12/2007 5
 Advantages

• Major advantages of TOMCAT:

• Online measurement of torque in the powertrain

• Measurement of clearance size and wear in the powertrain
• Method for plausibilisation of transmission functions
• Optimization of gear shift strategy for all kind of automated transmissions
(AT, DSG, CVT, DKG, Torque Vectoring, ....)
• Evaluation of real stress for the whole series
- Detection of overdimensioned components -> increase service intervals
• Improvement of ESP
• extended diagnosis
- Gets important at high SIL level

Author: Thomas Karer / ECS Date: 06/12/2007 6

 Contents

• Measuring principle

• Basics
• Demonstration movie
• Measurement setup for different vehicle applications

• Test setup: Steyr truck 12M18, BMW X3/X5

• Solution for serial production
• Algorithm
• Measurement results
• Possible applications – functional advantages
• Test drive vehicles

Author: Thomas Karer / ECS Date: 06/12/2007 7

 Measuring principle

Measurement of powertrain torsion

ABS sensors Method of resolution:

By using 2 existing ABS-sensors
an one additional speed sensor in
the transmission or T-case the
torsion will be calculated relatively.
The relative torsion is proportional
to the transferred torque.

Challenges:
- Elimination of mech. clearance
- Conversion of relative torsion to
Speed sensor an absolute value in [Nm].

Movie
Author: Thomas Karer / ECS Date: 06/12/2007 8
 Measuring principle

600
Effect of the mechanical clearance and the
550

500
offset to the torque signal
450

400
Vorderachsdrehmoment [Nm]

350

300 mech. clearance

250

200

150
Md-TOMCAT
M d=
-V Acalculated
-g e m e sse n
100

50
Md-reference = measured
M d -V A -b e rec h n e t
0

-5 0

-1 0 0 Offset
-1 5 0

-2 0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Z eit [s ]

Author: Thomas Karer / ECS Date: 06/12/2007 9

 Measuring principle

3 sensor method 5 sensor method

(rear- or all wheel drive) (double axle drive)

TOMCAT TC TM ENG
Md ABS (opt.)
algorithm

TOMCAT Md
ABS TC TM ENG
algorithm (opt.)

Md

Author: Thomas Karer / ECS Date: 06/12/2007 10

 Contents

• Measuring principle
• Test setup: Steyr truck 12M18, BMW X3/X5

• First test on truck Steyr 12M18 4x4

• Measuring setup
• Different assembly of speed sensor in T-case
• Illustration CAN-bus structure

• Solution for serial production

• Algorithm
• Measurement results
• Possible applications – functional advantages
• Test drive vehicles

Author: Thomas Karer / ECS Date: 06/12/2007 11

 Test setup 12M18

First test of torque measuring with Steyr 12M18

4x4 without strain gage measurement.
Because of the high resolution of ca.
2,2 Nm on the rear cardan shaft Start of
Torque sensor development (TOMCAT)

Speed sensor near rear differential

Author: Thomas Karer / ECS Date: 06/12/2007 12

 Test setup BMW X3

reference torque (strain gage) - front

4 variants

torque (calculated)
front
TOMCAT
ABS algorithm torque (calculated)
4
ESP rear
DXC
reference torque (strain gage) - rear

Author: Thomas Karer / ECS Date: 06/12/2007 13

 Test setup BMW X3

• Application of 3rd speed sensor (4 variants)

1. Variant
T-case output to front axle
(Inductive sensor)

2. and 3. Variant
T-case output to rear axle
(Inductive sensor)

Author: Thomas Karer / ECS Date: 06/12/2007 14

 Test setup BMW X3

• Application of 3rd speed sensor

4. Variant
T-case – output to front axle (Hall sensor)

Version for serial

production

Author: Thomas Karer / ECS Date: 06/12/2007 15

 Test setup BMW X3

• Reference measurement with strain gages

Front cardan shaft

Rear cardan shaft

Author: Thomas Karer / ECS Date: 06/12/2007 16
 Test setup BMW X3

• Measurement instrumentation

Signal amplification, signal conditioning,

measurement device

Data acquisition

Author: Thomas Karer / ECS Date: 06/12/2007 17

 Contents

• Measuring principle
• Test setup: Steyr truck 12M18, BMW X3/X5
• Solution for serial production

• Solution for serial production (FA- and RA-torque measurement)

• Solution for serial production for all vehicle variants

• Algorithm
• Measurement results
• Possible applications – functional advantages
• Test drive vehicles

Author: Thomas Karer / ECS Date: 06/12/2007 18

 Serial solution

• Serial solution (front- and rear axle torque measurement)

CAN or Flexray
Wheel speeds with time stamp

ABS Transmission ECU +

TOMCAT

ABS sensors

speed sensor
in transmission

- TOMCAT algorithm runs in transmission- or ABS- ECU

- Speed sensor in transmission
- Wheel speed via CAN with time stamp or via Flexray
Author: Thomas Karer / ECS Date: 06/12/2007 19
 Serial solution

• Summary for requirements

• Necessary hardware
• FA-measurement: 1 speed sensor in T-case
• RA-measurement: no hardware using transmissions with output speed sensor

• Wheel speed information

• Speed signals via Flexray
• alternative: Speed signals via CAN with time information from ABS
• alternative: Wiring ABS-hardware-outputs
• No additional ECU
• Calculation algorithm runs in transmission-, ABS- or Torque Vectoring ECU
• ECU requires speed sensor input

Author: Thomas Karer / ECS Date: 06/12/2007 20

 Contents

• Measuring principle
• Test setup: Steyr truck 12M18, BMW X3/X5
• Solution for serial production
• Algorithm
• Measurement results
• Possible applications – functional advantages
• Test drive vehicles

Author: Thomas Karer / ECS Date: 06/12/2007 21

 Algorithm

Speed- Calculation of disturbance (car, truck):

sensors angle differences • deformation of vehicle
(can be reduced to a minimum with
Relative alternation of torque models for a defined type of vehicle)

Vehicle data Finding absolute

via CAN value [Nm]

Mech.
clearance

Absolute torque signal

[Nm]

Author: Thomas Karer / ECS Date: 06/12/2007 22

 Algorithm

• Measurement principle is independent of temperature

- TOMCAT provides better results at very cold temperatures

as strain gage shafts

• Measurement principle is contactless

- no wear

• Algorithm is free of drift

Author: Thomas Karer / ECS Date: 06/12/2007 23

 Contents

• Measuring principle
• Test setup: Steyr truck 12M18, BMW X3/X5
• Solution for serial production
• Algorithm
• Measurement results

• Torque signal
• Tolerance of torque signal
• Availability of torque signal
• Measurement of mechanical clearance

• Possible applications – functional advantages

• Test drive vehicles

Author: Thomas Karer / ECS Date: 06/12/2007 24

 Torque signal quality

Md-FA-TOMCAT
Offsetcorrections
Md-FA-reference
FA-State

Author: Thomas Karer / ECS Date: 06/12/2007 25

 Torque signal quality

Long time measurement ca. 6 min

ENTWURF Md-FA-TOMCAT
Md-FA-reference
FA-State
Messsignal ist spiel- und offsetkorrigiert
Author: Thomas Karer / ECS Date: 06/12/2007 26
 Torque signal quality

Max. deviation [Nm]

with longer drive time or
different drive manoeuvres like:
- overrun condition,
- narrow curves,
- acceleration
signal quality improves to ca. +/- 15 Nm

45
30
15
0 Drive time
-15
-30
-45

1. deceleration (C,D)
narrow curve (F) accuracy:
acceleration (K)
+/- 30 Nm: after 5 – 25 sec
Speed > 3 km/h (O,M)
+/- 15 Nm: after 5 – 80 sec

Author: Thomas Karer / ECS Date: 06/12/2007 27

 Torque signal quality

speedway 98%
100 km without stops

95% highway
with stops

15%
75% city
with ‚Stop and Go‘ traffic

Author: Thomas Karer / ECS Date: 06/12/2007 28

 Size of mechanical clearance

Summation of all torque 350 80

Md-VA-berechnet
free conditions. 325 75

v Fahrzeug [km/h]; Winkel Fahrpedal [%]

Md [Nm]
300 Md-VA-gemessen 70

275 VA-Spiel 65

250 v Fahrzeug 60

Shaft is always between 225 55

0 and maximum of 200 50

mechanical clearance 175 Size of clearance 45

150 40

125 35

100 30

75 25

50 20
Result: 25 15

0 10
Size of clearance -25 5

-50 0

Author: Thomas Karer / ECS Date: 06/12/2007 29

 Basic necessities

Measurement possible for a:

Relative altering torque signal:

• vehicle speed > 3 km/h (passive inductive speed sensor)

• vehicle speed > 1 km/h (active hall sensor)

Absolute torque value [Nm] – 2 additional conditions:

• Completion at least 1 drive manoeuvre

- eg. vehicle acceleration, narrow curve, overrun condition, ...

• calculation of clearance

- Only necessary for new vehicles or modifications

- later only for monitoring clearance eg. every 1000 km

Author: Thomas Karer / ECS Date: 06/12/2007 30

 Contents

• Measuring principle
• Test setup: Steyr truck 12M18, BMW X3/X5
• Solution for serial production
• Algorithm
• Measurement results
• Possible applications – functional advantages

• Possible configurations: cars, trucks

• Test drive vehicles

Author: Thomas Karer / ECS Date: 06/12/2007 31

 Applications

• Standard passenger car (4x2)

Sensor position Measuring position Necessary hardware

1 speed sensor in manual transmission

Transmission- or
output torque RA no hardware if transmission has output
speed sensor

1 speed sensor in manual transmission

Transmission- or
output torque FA no hardware if transmission has output
speed sensor

Author: Thomas Karer / ECS Date: 06/12/2007 32

 Applications

• All wheel driven cars (4x4)

Sensor position Measuring position Necessary hardware

Transmission- 1 speed sensor in T-case (fixed gear wheels)

output torque FA or in manual transmission
or
no hardware if T-case (fixed gear wheels) in
Transmission-
combination with transmission with output
output torque RA speed sensor

Transmission- 1 speed sensor in T-case with friction clutch

output torque FA

Author: Thomas Karer / ECS Date: 06/12/2007 33

 Applications

• Torque Vectoring cars, Hybrid

Sensor position Measuring position Necessary hardware

Lateral shaft –
torque left 2 speed sensors in Torque Vectoring unit

Lateral shaft –
torque right

1 speed sensor in manual transmission

Total torque of or

combustion engine no hardware if transmission has output

+ electric motor speed sensor

Author: Thomas Karer / ECS Date: 06/12/2007 34

 Applications

• Standard trucks (4x2, 6x4, ...)

Sensor position Measuring position Necessary hardware

Transmission- No hardware
output torque RA (transmission output speed sensor is
available in trucks)

Transmission- No hardware
output torque RA (transmission output speed sensor is
available in trucks)

Author: Thomas Karer / ECS Date: 06/12/2007 35

 Applications

• All wheel driven trucks (4x4, 6x6, ...)

Sensor position Measuring position Necessary hardware

Transmission-
output torque FA No hardware
(transmission output speed sensor is
Transmission- available in trucks)
output torque RA

Transmission-
output torque FA No hardware
(transmission output speed sensor is
Transmission- available in trucks)
output torque RA

Author: Thomas Karer / ECS Date: 06/12/2007 36

 Contact

Dipl.-Ing. Thomas Karer

Project Manager TOMCAT

MAGNA POWERTRAIN
Engineering Center Steyr GmbH & Co KG

Steyrer Str. 32, 4300 St. Valentin, Austria

Phone: +43-7435-501-621
Fax: +43-7435-501-9621

Email: [email protected]
Homepage:www.magnapowertrain.com

Author: Thomas Karer / ECS Date: 06/12/2007 37