Hydraulic Control System of AT

Hydraulic Control System of AT
The hydraulic control system is divided into four parts: main hydraulic control system, shift
control system, shift quality control system and hydraulic torque converter control system. The
hydraulic control system provides the required hydraulic oil for all parts of AT. Its specific
functions are:
(1) Supply oil to the control system and maintain the operating oil pressure of the main oil
circuit to ensure the smooth operation of the control mechanisms.
(2) Ensure the oil supply of the shift actuators to meet the need of shift and other operations.
(3) Provide the lubricating oil for all moving parts of the transmission, such as gear, bearing,
thrust washer and clutch friction plate and ensure normal lubricating oil temperature
(4) Dissipate the heat of the whole AT through the circular cooling of the oil and keep the
transmission working in the reasonable temperature range.
(5) Control the work of the hydraulic torque converter and timely take away the heat from the
hydraulic torque converter in time to maintain normal operating temperature.
Main hydraulic control system
The main hydraulic control system is the power
source of the whole hydraulic system, including
hydraulic pump and hydraulic regulating system.
The hydraulic pressure supplied by the hydraulic
pump is distributed to the control actuator through
the control valve. The hydraulic circuit consists of
the valve body shown in Fig. and the spool valve for
hydraulic switching and adjustment is placed in the
valve body. The current is delivered to the
solenoid valve for hydraulic control (Fig a,b,c)
through the A/T control unit for hydraulic control.
The solenoid valves can be divided into three
categories: ON-OFF solenoid valve, which
changes the hydraulic pressure through ON-OFF
switching according to the electrical wave
signals; DUTY solenoid valve, which regularly
supplies the pulse current and simulates and
adjusts the hydraulic pressure by changing the
current additional width (DUTY) of each pulse;
linear solenoid valve, which is equipped with a
pressure regulator valve to convert the
electromagnetic force into hydraulic pressure
Shift control system
The shift control system is composed of manual valve, shift valve and other hydraulic valves
and solenoid valves as well as the corresponding oil circuit. The oil circuit makes the AT in
different gears according to the gear lever handle position In addition, in each forward gear,
according to the engine load, vehicle speed and other signals, the shift control system can
automatically control the upshift or downshift, so that the AT gear adapts to the driving state.
Structure and principle of shift actuators
Manual valve: the manual valve stem is connected to the gear lever handle.When the driver
controls the gear lever handle in different positions, the manual valve element is also moved
to the corresponding position, to achieve the
switching of gear and oil circuit. As shown in figure
the left end of the manual valve is connected to the
gear lever handle by a connecting rod. The gear
lever handle is controlled to make the manual valve
in P, R, N, D, 2 and L respectively. As shown in Fig
a, when the gear lever handle is in N, the oil passage
from the manual valve to the control circuit is closed
and there is no oil pressure in the control oil circuit.
When the gear lever handle is in P, D, 2, L and R
respectively, the manual valve connects the main
control oil circuit from the hydraulic pump to the
control oil circuit of each gear to complete the
corresponding work. For example, when the gear lever
handle is in R (figure B) the manual valve connects the
main oil circuit to the reverse oil circuit and controls
the oil through the shift valve to control the high-gear/reverse clutch and low-gear/reverse gear
brake.
Shift valve: as a reversing valve, the shift valve is used to change the flow direction of the
control oil, so that the oil pressure of the main oil circuit controls different shift actuators to
achieve each gear ratio of the AT. A 4-speed AT is usually provided with 3 shift valves, i.e.
1–2 gear, 2–3 gear and 3.4 gear shift valves respectively.
Figure below shows the 1–2 gear shift
valve of the AT in the electro-hydraulic
Simpson planetary gear train, which is
controlled by solenoid valve 2. When the
solenoid valve is powered on, the oil of the
main oil circuit is drained through the
drainage port of the solenoid valve, there is
no control oil pressure in the upper end of
the shift valve element, and the valve
element is at the top end under the spring
force; when the solenoid valve is powered
off, the oil of the main oil circuit acts on the
top end of the shift valve element and
overcomes the lower spring force, making
the valve element at the bottom.
Shift quality control system

AT realizes gear shift by controlling the work of shift actuators, and the work of shift actuators
when engaged or separated will directly affect the shift quality. If the oil pressure is established
too fast, the clutch will be engaged with the brake too fast, easy to produce shift impact; if the
oil discharge is too slow, the clutch will be disengaged from the brake too slow, resulting in
slippage. Therefore, the hydraulic control system of the AT shall be equipped with the buffer
and safety devices, mainly including accumulator, regulating valve and one-way valve.
Shift quality control elements
(1) Accumulator: generally, a corresponding accumulator is configured in each forward
oil circuit of the AT and located in the oil circuit between the shift valve in each gear
of control oil circuit and the shift actuators. It is generally composed of the cylinder
tube, damping piston, and spring. During the shift, the control oil from the shift valve
acts on the clutch, brake and other shift actuators and flows into the corresponding
accumulator. At the beginning of the work, the oil pressure cannot promote the action
of the accumulator piston, so the oil pressure in the working cylinder of the controlled
actuator increases quickly, so that the actuator can quickly eliminate the free
clearance. With the increase of oil entering the accumulator, the oil pressure
overcomes the spring force to press the piston down, the volume increases and
controls the slow increase rate of the oil pressure in the pipeline, so that the actuator is
engaged gently, reducing the shift impact and absorbing the impact from the oil to
ensure the stability of working pressure in the hydraulic control system. When the
actuator is released from work, the oil will release quickly under the spring action of
the accumulator, which can ensure the complete separation of the actuator and prevent
the actuator from slipping.
(2) Regulating valve: a low-gear slide regulating valve and 2 speed intermediate
regulating valve are configured in the oil circuit and mainly consist of the slide valve
and spring, When the gear lever handle is in L and 2, the regulating valve reduces the
pipeline pressure from the main oil circuit to reduce the oil pressure acting on the
piston of the actuator.
(3) One-way valve: many ball valves are installed in the AT valve plate to use as one-
way valves and have other functions:
• The safety valve is generally connected
in the main oil circuit in parallel and
blocks the drainage port when the oil
pressure in the main oil circuit is below
the spring force. When the oil pressure
in the main oil circuit is larger than the
spring force, the drainage port is opened
and part of the oil in the main oil circuit
is discharged from the drainage port,
ensuring the safety of the hydraulic
control system.
• The reverse quick release valve.
During oil filling, the ball valve is
closed to reduce the shift impact;
during oil return, the ball valve is
open without throttling, which
accelerates the oil drainage process
and quickly separates the shift actuator.
Ref
Springer,” Automotive Transmissions Design, Theory and Applications”. China (2021)
ISBN 978-981-15-6702-5

Hydraulic Control System of AT

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