Title of Invention

A METHOD AND AN APPARATUS FOR CONTROLLING AN ELECTRO-MECHANICAL TRANSMISSION DURING A SHIFT- EXECUTION

Abstract A method and apparatus to control an electro-mechanical transmission during a shift event, including identifying a fault in an off-going clutch, is provided. The method includes deactivating an off-going torque-transfer clutch, monitoring slippage of the off-going torque-transfer clutch, and limiting a change in operation of an electrical machine operatively connected to the transmission until the slippage of the off-going torque-transfer clutch exceeds a threshold. Limiting a change in operation of the electrical machine comprises limiting an output torque of the electrical machine, comprising limiting a time-rate change in the output torque and limiting a magnitude of the output torque. The limit of the change is discontinued when the slippage of the off-going torque-transfer clutch exceeds the threshold.
Full Text GP-307817-PTH-CD
1
METHOD AND APPARATUS FOR CONTROLLING AN ELECTRO-MECHANICAL
TRANSMISSION DURING A SHIFT EXECUTION
TECHNICAL FIELD
[0001] This invention pertains generally to powertrain control systems for
fuel/electric hybrid powertrain systems, and more specifically to powertrain
control during transmission shifts.
BACKGROUND OF THE INVENTION
[0002] Fuel/electric hybrid powertrain architectures comprise torque-
generative devices, including internal combustion engines and electric
machines, which transmit torque through a transmission device to a vehicle
driveline. One such transmission includes a two-mode, compound-split,
electro-mechanical transmission which utilizes an input member for receiving
motive torque from an internal combustion engine, and an output member for
delivering motive torque from the transmission to the vehicle driveline
Exemplary electro-mechanical transmissions are selectively operative in fixed
gear modes and continuously variable modes through actuation of torque-
transfer clutches. A fixed gear mode occurs when rotational speed of the
transmission output member is a fixed ratio of rotational speed of the input
member from the engine, typically due to actuation of one or more torque-
transfer clutches. A continuously variable mode occurs when rotational speed
of the transmission output member is variable based upon operating speeds of
one or more electrical machines. The electrical machines can be connected to
the output shaft via actuation of a clutch, or by direct connection. Clutch
actuation and deactivation is typically effected through a hydraulic circuit,
including electrically-actuated hydraulic flow management valves, pressure
control solenoids, and pressure monitoring devices controlled by a control
module.

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operatively connected to the electrically variable transmission device until the
slippage of the off-going torque-transfer clutch exceeds a threshold. Limiting
a change in operation of the electrical machine comprises limiting an output
torque of the electrical machine, comprising limiting a time-rate change in the
output torque and limiting a magnitude of the output torque. The limit of the
change in operation of the electrical machine is discontinued when the
slippage of the off-going torque-transfer clutch exceeds the threshold.
[0007] These and other aspects of the invention will become apparent to
those skilled.in the art upon reading and understanding the following detailed
description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
|0008j The invention may take physical form in certain parts and
arrangement of parts, the preferred embodiment of which will be described in
detail and illustrated in the accompanying drawings which form a part hereof,
and wherein:
[0009] Fig. 1 is a schematic diagram of an exemplar)' powettrain. in
accordance with the present invention;
[0010| Fig. 2 is a schematic diagram of an exemplary architecture for a
control system and powertrain, in accordance with the present invention;
[0011] Fig. 3 is a graphical depiction, in accordance with the present
invention;
[0012] Fig. 4 is a schematic diagram of a hydraulic circuit, in accordance
with the present invention; and.
[0013] Fig. 5 is a logic flowchart, in accordance with the present invention

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DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION
[0014| Referring now to the drawings, wherein the depictions are for the
purpose of illustrating the invention only and not for the purpose of limiting
the same. Figs. 1 and 2 depict a system comprising an engine 14, transmission
10, control system, and driveline which has been constructed in accordance
with an embodiment of the present invention.
[0015] Mechanical aspects of exemplary transmission 10 are disclosed in
detail in commonly assigned U.S. Patent No. 6.953.409, entitled "Two-Mode,
Compound-Split, Hybrid Electro-Mechanical Transmission having Four Fixed
Ratios", which is incorporated herein by reference The exemplary two-mode.
compound-split, electro-mechanical hybrid transmission embodying ihe
concepts of the present invention is depicted in Fig 1, and is designated
generally by the numeral 10. The transmission 10 has an input shaft 12 that is
preferably directly driven by an internal combustion engine 14. The
transmission 10 utilizes three planetary-gear sets 24, 26 and 28, and four
torque-transmitting devices, i.e., clutches Cl 70, C2 62, C3 73, and C4 75. An
electro-hydraulic control system 42, preferably controlled by transmission
control module 17, is operative to control actuation and deactivation of the
clutches. Clutches C2 and C4 preferably comprise hydraulically-actuated
rotating friction clutches. Clutches Cl and C3 preferably comprise
comprising hydraulically-actuated stationary devices grounded to the
transmission case 68.
[0016] The three planetary gear sets 24, 26 and 28 each comprise simple
planetary gear sets. Furthermore, the first and second planetary' gear sets 24
and 26 are compounded in that the inner gear member of the first planetary
gear set 24 is conjoined to an outer gear member of the second planetary gear
set 26, and connected to a first electrical machine comprising a
motor/generator 56, also referred to as "MG-A".

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[0017] The planetary gear sets 24 and 26 are further compounded in that
carrier 36 of the first planetary gear set 24 is conjoined through a shaft 60, to
the carrier 44 of the second planetary gear set 26. As such, carriers 36 and 44
of the first and second planetary gear sets 24 and 26, respectively, are
conjoined. The shaft 60 is also selectively connected to the carrier 52 of the
third planetary gear set 28, through clutch C2 62. The carrier 52 of the third
planetary gear set 28 is connected directly to the transmission output member
64. An inner gear member of the second planetary gear set 26 is connected to
an inner gear member of the third planetary gear set 28 through a sleeve shaft
66 that circumscribes shaft 60. and is connected to a second electrical machine
comprising a motor/generator 72, referred to as MG-B.
[0018] All the planetary gear sets 24, 26 and 28 as well as MG-A and MG-B
56 and 72 are preferably coaxially oriented, as about the axially disposed shaft
60. MG-A and MG-B 56 and 72 are both of an annular configuration which
permits them to circumscribe the three planetary gear sets 24, 26 and 28 such
that the planetary gear sets 24, 26 and 28 are disposed radially inwardly of the
MG-A and MG-B 56 and 72. Transmission output member 64 is operably
connected to a vehicle driveline 90 to provide motive torque. Each dutch is
preferably hydraulic-ally actuated, receiving pressurized hydraulic fluid from a
pump, described below, via an electro-hydraulic control circuit 42 described
hereinbelow with reference to Fig. 4.
[0019] The transmission 10 receives input motive torque from the torque-
generative devices, including the engine 14 and the VIG-A 56 and MG-B 72,
as a result of energy conversion from fuel or electrical potential stored in an
electrical energy storage device (ESD) 74. The ESD 74 typically comprises
one or more electrochemical energy storage batteries. Other electrical energy
and electrochemical energy storage devices that have the ability to store
electric power and dispense electric power may be used in place of the
batteries without altering the concepts of the present invention. The PSD 74 is
preferably sized based upon factors including regenerative requirements.

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application issues related to typical road grade and temperature, and
propulsion requirements such as emissions, power assist and electric range
The ESD 74 is, high voltage DC-coupled to transmission power inverter
module ('TPIM') 19 via DC transfer conductors 27. The TP1M 19 is an
element of the control system described hereinafter with regard to Fig. 2. The
TPIM 19 transmits electrical energy to and from MG-A 56 by transfer
conductors 29, and the TPIM 19 similarly transmits electrical energy to and
from MG-B 72 by transfer conductors 31 Electrical current is transmitted to
and from the.ESD 74 in accordance with whether the ESD 74 is being charged
or discharged. TPIM 19 includes the pair of power inverters and respective
motor control modules configured to receive motor control commands and
control inverter states therefrom for providing motor drive or regeneration
functionality.
[0020] In motoring control, the respective inverter receives current from the
DC transmission lines and provides AC current to the respective electrical
machine, i.e., MG-A and MG-B, over transfer conductors 29 and 31 In
regeneration control, the respective inverter receives AC current from the
electrical machine over transfer conductors 29 and 3 I and transmits current to
the DC lines 27. The net DC current provided to or from the inverters
determines the charge or discharge operating mode of the electrical energy
storage device 74 Preferably, MG-A 56 and MG-B 72 are three-phase AC
machines each having a rotor operable to rotate within a stator that is mounted
on a case of the transmission. The inverters comprise known complementary
three-phase power electronics devices.
[0021] Referring again to Fig. 1, a drive gear SO may be presented from the
input member 12, As depicted, the drive gear 80 fixedly connects the input
member 12 to the outer gear member 30 of the first planetary gear set 24. and
the drive gear 80, therefore, receives power from the engine 14 and/or the
electrical machines 56 and/or 72 through planetary gear sets 24 and/or 26. The
drive gear 80 meshingly engages an idler gear 82 which, in turn, meshing!v

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engages a transfer gear 84 that is secured to one end of a shaft 86. The other
end of the shaft 86 may be secured to a hydraulic/transmission fluid pump 88
Hydraulic pump 88 is a known device preferably sized to supply hydraulic
fluid to the hydraulic circuit of the transmission at pressure/flow rates
sufficient to meet system requirements, including pressure levels for clutch
actuation, and flow rates sufficient to meet needs for system cooling and
lubrication. Further details of the exemplary hydraulic circuit are depicted
with reference to Fig 4, described hereinbelow.
[0022] Referring now to Fig. 2, a schematic block diagram of the control
system, comprising a distributed control module architecture, is depicted. The
elements described hereinafter comprise a subset of an overall vehicle control
architecture, and are operable to provide coordinated system control of the
powertrain system described herein. The control system is operable to
synthesize pertinent information and inputs, and execute algorithms to control
various actuators to achieve control targets, including such parameters as fuel
economy, emissions, performance, driveability, and protection of hardware,
including batteries of ESD 74 and MG-A and MG-B 56, 72. The distributed
control module architecture includes engine control module ("ECM") 23.
transmission control module (TCM') 17, battery pack control module
('BPCM') 21, and TPIM 19. A hybrid control module ('HCP') 5 provides
overarching control and coordination of the aforementioned control modules.
There is a User Interface ('UF) 13 operably connected to a plurality of devices
through which a vehicle operator typically controls or directs operation of the
powertrain through a request for torque, T,,, including the transmission 10.
Exemplary vehicle operator inputs to the UI 13 include an accelerator pedal., a
brake pedal, transmission gear selector, and, vehicle speed cruise control.
Each of the aforementioned control modules communicates with other control
modules, sensors, and actuators via a local area network ("LAN') bus 6. The
FAN bus 6 allows for structured communication of control parameters and
commands between the various control modules. The specific communication

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protocol utilized is application-specific. The LAN bus and appropriate
protocols provide for robust messaging and multi-control module interfacing
between the aforementioned control modules, and other control modules
providing functionality such as antilock brakes, traction control, and vehicle
stability.
[0023] The HCP 5 provides overarching control of the hybrid powertrain
system, serving to coordinate operation of the ECM 23, TCM 17. TPIM 19,
and BPO1Y1 21 Based upon various input signals from the 1,1 13 and the
powertrain, including the battery pack, the HCP 5 generates various
commands, including: an operator torque T,,, an engine torque command.
clulch torque commands foi the various clutches Cl, C2, C3, C4 of the
transmission 10; and motor torque commands for MG-A and MG-B. The
TCM is operatively connected to the electro-hydraulic control circuit 42 of
Fig. 4. including monitoring various pressure sensing devices, depicted
generally as sensing device 78, and generating and executing control signals
for various solenoids to control pressure switches and control valves contained
therein
[0024] The ECM 23 is operably connected to the engine 14, and functions to
acquire data from a variety of sensors and control a variety of actuators,
respectively, of the engine 14 over a plurality of discrete lines collectively
depicted as aggregate line 35. The ECM 23 receives the engine torque
command from the HCP 5, and generates a desired axle torque, and an
indication of actual input torque, T1 from the engine to the transmission, which
is communicated to the HCP 5. For simplicity, ECM 23 is depicted generally
having bi-directional interface with engine 14 via aggregate line 35. Various
other parameters that may be sensed by ECM 23 include engine coolant
temperature, input speed, N1. from the engine to shaft 12 leading to the
transmission, manifold pressure, ambient air temperature, and ambient
pressure Various actuators that may be controlled by the ECM 23 include fuel
injectors, ignition modules, and throttle control modules.

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[0025] The TCM 17 is operably connected to the transmission 10 and
functions to acquire data from a variety of sensors and provide command
signals to the transmission. Inputs from the TCM 17 to the HCP 5 include
estimated clutch torques for each of the clutches Cl, C2, C3, and, C4 and
rotational speed, N,,, of the output shaft 64. Other actuators and sensors may
be used to provide additional information from the TCM to the HCP for
control purposes.
[0026] The BPCM 21 is signally connected one or more sensors operable to
monitor electrical current or voltage parameters of the ESD 74 to provide
information about the state of the batteries to the HCP 5. Such information
includes batteiy state-of-eharge, battery voltage and available battery power.
[0027] The TPI.M 19 includes previously referenced power inverters and
motor control modules configured to receive motor control commands and
control inverter states therefrom to provide motor drive or regeneration
functionality. The TPIM 19 is operable to generate torque commands for MG-
A 56 and MG-B 72, based upon input from the HCP 5, which is driven by
operator input through UI 13 and system operating parameters. The motor
torque commands for MG-A and MG-B are implemented by the control
system, including the TPIM 19, to control MG-A and MG-B. Individual
motor speed signals for MG-A and MG-B are derived by the TPIM 19 from
the motor phase information or conventional rotation sensors. The TPIM 19
determines and communicates motor speeds to the HCP 5. The electrical
energy storage device 74 is high-voltage DC-coupled to the TPIM 19 via DC
lines 27. Electrical current is transferable to or from the TPIM 19 in
accordance with whether the ESD 74 is being charged or discharged.
[0028] Each of the aforementioned control modules is preferably a general -
purpose digital computer generally comprising a microprocessor or central
processing unit, storage mediums comprising read-only-memory (ROM),
random access memory (RAM), electrically programmable read-only-memory
(EPROM), high speed clock, analog to digital (A/D) and digital to analog

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(D/A) conversion circuitry, and input/output circuitry and devices (I/O) and
appropriate signal conditioning and buffer circuitry. Each control module has
a set of control algorithms, comprising machine-readable code consisting of
resident program instructions and calibrations stored in ROM and executed to
provide the respective functions of each computer. Information transfer
between the various computers is preferably accomplished using the
aforementioned LAN 6.
[0029] Algorithms for control and state estimation in each of the control
modules are. typically executed during preset loop cycles such that each
algorithm is executed at least once each loop cycle. Algorithms stored in the
non-volatile memory devices are executed by one of the central processing
units and are operable to monitor inputs from the sensing devices and execute
control and diagnostic routines to control operation of the respective device.
using preset calibrations. Loop cycles are typically executed at regular
intervals, for example each 3.125, 6.25, 12.5, 25 and 100 milliseconds during
ongoing engine and vehicle operation. Alternatively, algorithms may be
executed in response to occurrence of an event.
[0030] In response to an operator's action, as captured by the U1 13. the
supervisory HCP control module 5 and one or more of the other control
modules determine requested output torque, T1, at shaft 64, also referred to as
an operator torque request. Selectively operated components of the
transmission 10 are appropriately controlled and manipulated to respond to the
operator demand. For example, in the exemplary embodiment depicted in
Fig 1 and 2. when the operator has selected a forward drive range and
manipulates either the accelerator pedal or the brake pedal, the HCP 5
determines output torque, TV,, which affects how and when the vehicle
accelerates or decelerates. Final vehicle acceleration is affected by other
factors, including, e.g., road load, road grade, and vehicle mass. The HCP 5
monitors the parametric states of the torque-generative devices, and
determines the output of the transmission required to arrive at the desired

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torque output. Under the direction of the HCP 5, the transmission 10 operates
over a range of output speeds from slow to fast in order to meet the operator
demand.
[0031] The two-mode, compound-split, electro-mechanical transmission,
includes output member 64 which receives output torque through two distinct
gear trains within the transmission 10, and operates in several transmission
operating modes, described with reference now to Fig. 1, and Table 1, below.
Table 1

Transmission Operating Mode Actuated Clutches
Mode I Cl 70
Fixed Ratio 1 (GR1) Cl 70 C4 75
Fixed Ratio 2 (GR2) Cl 70 C2 62
Mode 11 C2 62
Fixed Ratio 3 (GR3) C2 62 C4 75
Fixed Ratio 4(GR4) C2 62 C3 73
[0032] The various transmission operating modes described in the table
indicate which of the specific clutches Cl, C2, C3 and C4 are engaged or
actuated for each of the operating modes. Additionally, in various
transmission operating modes. MG-A and MG-B may each operate as
electrical motors to generate motive torque, or as a generator to generate
electrical energy.
[0033] The control system, depicted primarily in Fig. 2, is operable to
provide a range of transmission output speeds. N,,. of shaft 64 from relatively
slow to relatively fast within each mode of operation. The combination of two
continuously variable modes with a slow-to-fast output speed range in each
mode allows the transmission 10 to propel a vehicle from a stationary
condition to highway speeds, and meet various other requirements as
previously described. Additionally, the control system coordinates operation
of the transmission 10 so as to allow synchronized shifts between the modes

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[0034] The first and second modes of operation refer to circumstances in
which the transmission functions are controlled by one clutch, i.e., either
clulch Cl 62 or C2 70, and by the controlled speed and torque of the electrical
machines 56 and 72, referred to as a continuously variable transmission mode.
Certain ranges of operation are described below in which fixed ratios are
achieved by applying an additional clutch. This additional clutch may be
clutch C3 73 or C4 75, as depicted in Table 1, above.
[0035] When the additional clutch is applied, fixed ratio operation of input-
to-output speed of the transmission, i.e., N1,N1,-,, is achieved. The rotations of
machines MG-A and MG-B 56, 72 are dependent on internal rotation of the
mechanism as defined by the clutching and proportional to the input speed, N:,
determined or measured at shaft 12. The machines MG-A and MG-B function
as motors or generators. They are completely independent of engine to output
power flow, thereby enabling both to be motors, both to function as
generators, or any combination thereof This allows, for instance, during
operation in Fixed Ratio I that motive power output from the transmission at
shaft 64 is provided by power from the engine and power from MG-A and
MG-B, through planetary gear set 28 by accepting power from the energy
storage device 74.
[0036] Referring now to Fig. 3, various transmission operating modes are
plotted as a function of transmission output speed, N,, and transmission input
speed, N1 for the exemplary transmission and control system depicted in Fig. 1
and 2 The Fixed Ratio operating operation is depicted as individual lines for
each of the specific gear ratios. GR1, GR2, GR3, and GR4. as described with
reference to Table 1, above. The continuously variable Mode operation is
depicted as ranges of operation for each of Mode I and Mode 11. The
transmission operating mode is switched between Fixed Ratio operation and
continuously variable Mode operation by activating or deactivating specific
clutches The control system is operative to determine a specific transmission

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operating mode based upon various criteria, using algorithms and calibrations
executed by the control system, and is outside the scope of this invention
[00371 Selection of the transmission operating mode depends primarily on
operator input and the ability of the powertrain to meet that input The first
fixed gear ratio, GR1, is available during continuously variable mode i. when
clutches Cl and C4 are engaged. The second fixed gear ratio, GR2, is
available during mode I, when clutches Cl and C2 are engaged. The third
fixed ratio range, GR3 is available during continuously variable mode I, and
during continuously variable mode 11 when clutches C2 62 and C4 75 are
engaged, and the fourth fixed ratio range, GR4, is available during mode II
when clutches C2 62 and C3 73 are engaged. It should be recognized that
ranges of continuously variable operation for Mode 1 and Mode 11 may
overlap.
[0038] Output of the exemplary powertrain system described hereinabove is
constrained due to mechanical and system limitations The output speed, N'o.
of the transmission measured at shaft 64 is limited due to limitations of engine
output speed measured at shaft 18, and transmission input speed, N , measured
at shaft 12, and speed limitations of machines MG-A and MG-B. Output
torque, T0,,, of the transmission 64 is similarly limited due to limitations of the
input torque, T1,, measured at shaft 12 after a transient torque damper and
torque limitations of MG-A and MG-B 56, 72.
[0039] Referring again to Fig. 4, a schematic diagram is depicted which
provides a more detailed description of the exemplary electro-hydraulic
system for controlling flow of hydraulic fluid in the exemplar}' transmission.
As previously described with reference to Fig. I, the main hydraulic pump 88
is driven by gears 82 and 84 that are operatively driven off the input shaft
from the engine 10, The main hydraulic pump 88 receives input torque from
the engine and pumps hydraulic fluid drawn from a sump into a hvdraulic
circuit of the transmission, initially passing through control valve 140 The
auxiliary' pump 1 10 is operatively controlled by an auxiliary operating pump

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control module ('TAOP') (not shown), which is operatively controlled by the
TP1M 19. The auxiliary pump 110 preferably comprises an electrically-
powered pump of an appropriate size and capacity to provide sufficient flow
of pressurized hydraulic fluid into the hydraulic system when operational. The
TPIM preferably generates a pulse-width-modulated signal of fixed frequency
and a duty cycle which varies from a low value to high value to drive the
pump 1 10, the duty cycle depending upon the desired output from the pump
The pump 1 10 receives the signal and pumps hydraulic fluid drawn from the
sump into the hydraulic circuit which flows to fluid control valve 140.
[0040] Pressurized hydraulic fluid flows into electro-hydraulic control circuit
42, which is operable to selectively distribute hydraulic pressure to a series of
devices, including the torque-transfer clutches Cl 70, C2 62, C3 73, and C4
75, active cooling circuits for machines MG-A and MG-B, and a base cooling
circuit for cooling and lubricating the transmission 10 via passages 142, 144
(not depicted in detail). As previously stated, the TCM 17 is preferably
operable to actuate the various clutches to achieve various transmission
operating modes through selective actuation of hydraulic circuit flow control
devices comprising pressure control solenoids ("PCS") PCS] 108, PCS2 112.
PC S3 114, PCS4 116 and solenoid-controlled flow management valves X-
valve 118 and Y-valve 120. The circuit is fluidly connected to pressure
switches PS1, PS2. PS3, and PS4 via passages 124, 122, 126, and 128,
respectively. The pressure control solenoid PCS I 108 has a control position
of normally high and is operative to provide modulation of fluidic pressure in
the hydraulic circuit through fluidic interaction with pressure regulator 109
Pressure control solenoid PCS2 112 has a control position of normally low.
and is fluidly connected to spool valve 113 and operative to effect flow
therethrough when actuated. Spool valve 1 13 is fluidly connected to pressure
switch PS3 via passage 126. Pressure control solenoid PCS3 114 has a control
position of normally low, and is fluidly connected to spool valve 115 and
operative to effect flow therethrough when actuated. Spool valve 115 is

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fluidly connected to pressure switch PS1 via passage 124. Pressure control
solenoid PCS4 116 has a control position of normally low, and is fluidly
connected to spool valve 117 and operative to effect How therethrough when
actuated. Spool valve 117 is fluidly connected to pressure switch PS4 via
passage 128.
[0041] The X-Valve 119 and Y-Valve 121 comprise flow management
valves controlled by shift solenoids 1 18, 120, respectively, in the exemplary
system, and have control states of High (' 1') and Low ('0'). The control states
reference positions of each valve effecting flow control to different devices in
the hydraulic circuit 42 and the transmission 10. The X-valve 1 19 is operative
to direct pressurized fluid to clutches C3 and C4 and cooling systems for
stators of MG-A and MG-B via fluidic passages 136, 138, 144, 142
respectively, depending upon the source of the fluidic input, as is described
hereinafter. The Y-valve 121 is operative to direct pressurized fluid to
clutches Cl and C2 via tluidic passages 132 and 134 respectively, depending
upon the source of the fluidic input, as is described hereinafter The Y-valve
121 is fluidly connected to pressure switch PS2 via passage 122. Selective
control of the X- and Y-valves and actuation of the solenoids PCS2, PCS3.
and PCS4 facilitate flow of hydraulic fluid to actuate clutches C 1, C2, C3, and
C4, and provide cooling for the stators of MG-A and MG-B.
[0042] The TCM 17 is preferably operable to actuate various clutches to
achieve various transmission operating states through selective actuation of
the pressure control solenoids and shift solenoids. An exemplary logic table to
accomplish such control using the electro-hydraulic control circuit 42 is
provided with reference to Table 2, below.

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Table 2

X- Y_ PCS I PCS2 PCS 3 PCS4
Valve Valve
Logic Logic
Operating No C2 Normal Normal Normal Normal
Mode Latch Latch High High 1 High Low
Mode 1 0 0 Line MG-B Cl MG-A
Modulation Stator Stator
Cooling Cooling
Mode 11 0 1 Line C2 MG-B MG-A
Modulation Stator Stator
Cooling Cooling
GRl. GR2. 1 0 Line C2 Cl C4
GR3 Modulation
GR3. GR4 1 I Line C2 C3 C4
Modulation
[0043] Selective control of the X and Y valves and actuation of the solenoids
PCS 1 to PCS4 facilitate flow of hydraulic fluid to actuate clutches C1, C2, C3.
and C4, and provide cooling for the stators of MG-A and MG-B ("MG-A
Stator Cooling". "MG-B Stator Cooling"). Thus, by way of example with
reference to Table 1 and Table 2, the exemplars' transmission can be operated
in fixed gear GR4 through actuation of clutches C2 and C3, which is
accomplished through controlling the X-Y flow switching valves in control
states of High (' 1'), and operating PCS 2 and PCS 3 in 'High' states

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|0044[ In operation, a shift occurs in the exemplary transmission due to a
variety of operating characteristics of the powertrain. There may be a change
in demand for an operator demand for torque. Such demands are typically
communicated through inputs to the UI 13 as previously described.
Additionally, a change in demand for output torque may be predicated on a
change in external conditions, including, e.g., changes in road grade, road
surface conditions, or wind load. A shift change may be predicated on a
change in powertrain torque demand caused by a control module command to
change one of the electrical machines between electrical energy generating
mode and torque generating mode. A shift change may be predicated on a
change in an optimization algorithm or routine operable to determine optimum
system efficiency based upon operator demand for power, batter)-' state of
charge, and energy efficiencies of the engine 14 and MG-A and MG-B 56, 72.
The control system manages torque inputs from the engine 14 and MG-A and
MG-B 56, 72 based upon an outcome of the executed optimization routine,
and there can be changes in system optimization that compel a shift change in
order to optimize system efficiencies to improve fuel economy and manage
battery charging. Furthermore, a shift change may be predicated upon a fault
in a component or system. The distributed control module architecture acts in
concert to determine a need for a change in the transmission operating mode,
and executes the forgoing to effect the change. A shift change in the
exemplary system comprises one of at least four possible situations There
can be a shift from one fixed gear to a second fixed gear There can be a shift
from a fixed gear to one of the continuously variable modes. There can be a
shift from one of the continuously variable modes to a fixed gear. There can
be a shift from one of the continuously variable modes to the other
continuously variable mode.

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|0045) Referring now to Fig. 5, a logic flow chart provides a description of
operation of the invention, executed in the exemplary system described with
reference to Figs 1 - 4. The invention generally comprises an algorithm
resident in one of the control modules and executed therein, which acts to
implement a method to effect a shift from a first operating mode to a second
operating mode, based upon criteria previously described. As an introduction,
when a shift is executed from one fixed gear to a second fixed gear, the shift
process includes deactivating an off-going ('(XV) clutch, and actuating an
oncoming clutch. By way of example, in shifting from GR1 to GR2, off-going
clutch C4 75 is deactivated, and oncoming clutch C2 62 is actuated, permitting
it to transmit torque. Clutch Cl 70 remains actuated throughout the shift
process. Actuating the oncoming clutch preferably includes synchronizing the
speeds of the elements of the oncoming clutch by controlling operation of the
torque-generative devices and, if necessary, controlling slippage of the
oncoming clutch, A shift change out of any of the fixed gear operating modes
preferably comprises a process wherein torque transmitted across the off-
going clutch is offloaded prior to its deactivation. Offloading torque across
the off-going clutch includes adjusting torque-carrying capacity across other
torque-transmission paths, e.g., using MG-A, MG-B, and the oncoming clutch.
Deactivating an off-going clutch preferably comprises decreasing the torque-
carrying capacity of the off-going clutch by reducing hydraulic pressure
through control of one of the solenoids, as previously described.
[0046] Referring again to Fig. 5, a command to execute a shift out a fixed
gear is issued (Block 200). Torque is off-loaded from the off-going COG1)
clutch. The OG clutch is deactivated (Block 202) by selectively controlling
elements in the electro-hydraulic control circuit 42, including reducing flow of
pressurized hydraulic fluid to the OG clutch. The control system imposes
limits on change in torque outputs (TA, T,A) and absolute torque outputs (TA
TH) from the electric machines MG-A and MG-B (Block 204). Input speed.

GP-307817-PTH-CD
19
K, and output speed, K, are monitored, preferably using known sensing
devices (Block 206).
[0047] Clutch slip is characterized in terms of speed and elapsed time,
wherein the parametric value for input speed. N,, is compared to the
parametric value for the output speed, N,-. multiplied by the gear ratio of the
off-going gear (' GR_OG__Gear'), represented as N1 - [N1, * GR OG_Gear ]
Clutch slip is monitored (Block 208), and compared to a threshold difference,
Slip Thr. When the clutch slip exceeds the threshold difference. Slip Thr
and does so for an elapsed time greater than a first threshold time
(TimeThr 1') (Block 210), the imposed limits on change in torque output
and absolute torque output from the electric machines MG-A and MG-B are
discontinued (Block 212), and shift execution continues (Block 214). When
clutch slip does not exceed the slip threshold, Slip_Thr, and does not exceed
the slip threshold for an elapsed time greater than a second threshold time
(Time_Thrjn (Block 220), a fault is detected (Block 222). and the control
system undertakes remedial action (Block 224).
[0048] The control system-imposed limits on the change in torque outputs
(AT.,, T13) and absolute torque outputs (TA, T,,) from the electric machines
MG-A and MG-B (depicted in Block 204) preferably comprise torque values
dynamically determined in the control system based upon the operating
conditions of the powertrain at the time of the shift execution. The intent in
programming the control system to dynamically determine imposed limits is to
have limits which minimize effect on torque output to the driveline, including
occurrence of jerks and other unanticipated changes in vehicle torque. The
elapsed time threshold. Time Thr 2, is calibrated at a magnitude which
minimizes risk of unintended torque, and is preferably in the range of 50
milliseconds for the exemplary embodiment.

GP-307817-PTH-CD
20
[0049] When, during shift execution, the clutch slip of the OG clutch does
not exceed the slip threshold after the elapsed time period, the control system
executes remedial actions (Block 224). The remedial actions preferably
include actions comprising controlling clutch actuation and managing torque
outputs of the engine 14 and the electrical machines MG-A and MG-B. 56. 72.
The intent of the control scheme is to continue to meet the operator demand
for torque while preventing harm to the powertrain hardware. The remedial
action can comprise executing a revised shift operation, e.g., into a third
operating mode, to substantially meet the operator request for output torque.
The third operating mode comprises, for example, shifting into a permissible
transmission operating mode and adjusting torque inputs from the engine and
the electrical machines. Other remedial actions can include informing the
operator of the presence of a fault through illuminating a lamp on the vehicle
dashboard, and executing some form of 'limp-home1 operation, each which is
outside the scope of the invention.
[0050] The invention has been described with specific reference to the
embodiments and modifications thereto. Further modifications and alterations
may occur to others upon reading and understanding the specification. It is
intended to include all such modifications and alterations insofar as they come
within the scope of the invention.

GP-307817-PTH-CD
21
Having thus described the invention, it is claimed;
1. Method for controlling an electro-mechanical transmission during a
shift execution, comprising:
deactivating an off-going torque-transfer clutch;
monitoring slippage of the off-going torque-transfer clutch; and,
limiting a change in operation of an electrical machine operative to transmit
torque to the electro-mechanical transmission until the slippage of the
off-going torque-transfer clutch exceeds a threshold.
2. The method of claim 1, wherein limiting a change in operation of the
electrical machine comprises limiting a change in output torque of the
electrical machine.
3. The method of claim 2, wherein limiting the change in output torque of
the electrical machine further comprises limiting a time-rate change in the
output torque and limiting a magnitude of the output torque
4. The method of claim 1, further comprising discontinuing the limiting
of change in operation of the electrical machine when the slippage of the off-
going torque-transfer clutch exceeds the threshold.
5. The method of claim 4, wherein the threshold comprises a magnitude
of the slippage of the off-going clutch and an elapsed period of time
6. The method of claim 1, further comprising identifying presence of a
fault, and, executing a remedial transmission operation when the slippage of
the off-going torque-transfer clutch does not exceed the threshold after an
elapsed period of time

GP-307817-PTH-CD
22
7. The method of claim 6, wherein executing remedial transmission
operation comprises executing a revised shift operation into a third operating
mode effective to substantially meet an operator request for output torque.
8, The method of claim I, wherein the electro-mechanical transmission is
selectively operative to transmit torque between an internal combustion
engine, first and second electrical machines and an output shaft, and further
comprising:
limiting a change in torque outputs from the first and second electrical
machines to the electro-mechanical transmission until the slippage of
the off-going torque-transfer clutch exceeds the threshold.
9. Method for controlling a poweitrain system during clutch deactivation,
comprising:
commanding deactivation of an off-going torque-transfer clutch,
determining slippage, comprising a difference between a transmission input
speed and a second speed comprising a transmission output speed
factored by a gear ratio,
limiting changes in torque inputs from first and second electrical machines to
the electro-mechanical transmission when the slippage does not exceed
a threshold; and,
identifying a fault when the slippage fails to exceed the threshold after an
elapsed period of time.
10. The method of claim 9, further comprising executing remedial control
of the powertrain system when a fault is identified.

GP-307817-PTH-CD
23
11, Article of manufacture, comprising a storage medium having a
computer program encoded therein for effecting a method to control operation
of an electromechanical transmission during execution of a shift, the program
comprising:
code to deactivate an off-going torque-transfer clutch;
code to monitor slippage of the off-going torque-transfer clutch; and,
code to limit a magnitude of and a time-rate change in torque output from an
electrical machine to the electro-mechanical transmission until the
slippage of the off-going torque-transfer clutch exceeds a threshold
12. The article of manufacture of claim 11, further comprising code to
discontinue the limit of the magnitude of and the time-rate change in the
torque output from the electrical machine when the slippage of the off-going
torque-transfer clutch exceeds the threshold.
13. The article of manufacture of claim 12, wherein the threshold
comprises a magnitude of the slippage of the off-going clutch and an elapsed
period of time.
14. The article of manufacture of claim 11, further comprising code to
identify presence of a fault, and, execute a remedial transmission operation
when the slippage of the off-going torque-transfer clutch does not exceed the
threshold after an elapsed period of time.
15, Powertrain system, comprising:
an internal combustion engine and first and second electrical machines and an
electro-mechanical transmission selectively operative to transmit
torque therebetween the transmission selectively operative in one of a
plurality of operating modes through selective actuation of a plurality
of torque-transfer clutches;

GP-307817-PTH-CD
24
a control system: adapted to control the internal combustion engine, the
electrical machines, and the transmission,
the control system adapted to execute machine-readable code comprising a
10 method to control operation of the transmission during a shift
execution, the algorithm comprising:
i) code to deactivate an off-going torque-transfer clutch;
ii) code to monitor slippage of the off-going torque-transfer clutch; and,
iii) code to limit a change in output of each of the electrical machines until
is the slippage of the off-going torque-transfer clutch exceeds a threshold.
16. The powertram system of claim 15, wherein the electrical machines
each comprise motor/generator devices.
17. The powertrain system of claim 16, wherein code to limit a change in
output of each of the electrical machines comprises code to limit torque
transmitted between each of the electrical machines and the transmission
18. The powertrain system of claim 17, wherein the code to limit torque
transmitted between each of the electrical machines and the transmission
comprises code to limit a change in the transmitted torque and limit a
magnitude of the transmitted torque.
19. The powertrain system of claim 17, wherein code to monitor slippage
of the off-going torque-transfer clutch comprises: code to compare an input
speed from the internal combustion engine with a speed of an output shaft of
the transmission multiplied by a gear ratio of a gear associated with the off-
5 going clutch.

GP-307817-PTH-CD
25
20, The powertrain system of claim 17. wherein the electro-mechanical
transmission comprises a two-mode, compound-split torque transmission
device selectively operative in one of the plurality of operating modes
comprising fixed gear modes and two continuously variable modes.

A method and apparatus to control an electro-mechanical transmission
during a shift event, including identifying a fault in an off-going clutch, is
provided. The method includes deactivating an off-going torque-transfer
clutch, monitoring slippage of the off-going torque-transfer clutch, and
limiting a change in operation of an electrical machine operatively connected
to the transmission until the slippage of the off-going torque-transfer clutch
exceeds a threshold. Limiting a change in operation of the electrical machine
comprises limiting an output torque of the electrical machine, comprising
limiting a time-rate change in the output torque and limiting a magnitude of
the output torque. The limit of the change is discontinued when the slippage
of the off-going torque-transfer clutch exceeds the threshold.

Documents:

01554-kol-2007-abstract.pdf

01554-kol-2007-assignment.pdf

01554-kol-2007-claims.pdf

01554-kol-2007-correspondence others 1.1.pdf

01554-kol-2007-correspondence others.pdf

01554-kol-2007-description complete.pdf

01554-kol-2007-drawings.pdf

01554-kol-2007-form 1.pdf

01554-kol-2007-form 2.pdf

01554-kol-2007-form 3.pdf

01554-kol-2007-form 5.pdf

01554-kol-2007-priority document.pdf

1554-KOL-2007-(10-02-2012)-ABSTRACT.pdf

1554-KOL-2007-(10-02-2012)-CLAIMS.pdf

1554-KOL-2007-(10-02-2012)-CORRESPONDENCE.pdf

1554-KOL-2007-(10-02-2012)-DESCRIPTION (COMPLETE).pdf

1554-KOL-2007-(10-02-2012)-DRAWINGS.pdf

1554-KOL-2007-(10-02-2012)-FORM-1.pdf

1554-KOL-2007-(10-02-2012)-FORM-2.pdf

1554-KOL-2007-(10-02-2012)-FORM-3.pdf

1554-KOL-2007-(10-02-2012)-OTHERS.pdf

1554-KOL-2007-ABSTRACT 1.1.pdf

1554-KOL-2007-AMANDED CLAIMS.pdf

1554-KOL-2007-AMANDED PAGES OF SPECIFICATION.pdf

1554-KOL-2007-ASSIGNMENT.pdf

1554-KOL-2007-CORRESPONDENCE 1.1.pdf

1554-KOL-2007-CORRESPONDENCE 1.2.pdf

1554-KOL-2007-CORRESPONDENCE OTHERS 1.2.pdf

1554-KOL-2007-CORRESPONDENCE OTHERS 1.3.pdf

1554-KOL-2007-DESCRIPTION (COMPLETE) 1.1.pdf

1554-KOL-2007-DRAWINGS 1.1.pdf

1554-KOL-2007-EXAMINATION REPORT REPLY RECIEVED.pdf

1554-KOL-2007-EXAMINATION REPORT.pdf

1554-KOL-2007-FORM 1-1.1.pdf

1554-KOL-2007-FORM 18.pdf

1554-KOL-2007-FORM 2-1.1.pdf

1554-KOL-2007-FORM 26.pdf

1554-KOL-2007-FORM 3 1.2.pdf

1554-KOL-2007-FORM 3-1.1.pdf

1554-KOL-2007-FORM 5.pdf

1554-KOL-2007-GRANTED-ABSTRACT.pdf

1554-KOL-2007-GRANTED-CLAIMS.pdf

1554-KOL-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

1554-KOL-2007-GRANTED-DRAWINGS.pdf

1554-KOL-2007-GRANTED-FORM 1.pdf

1554-KOL-2007-GRANTED-FORM 2.pdf

1554-KOL-2007-GRANTED-LETTER PATENT.pdf

1554-KOL-2007-GRANTED-SPECIFICATION.pdf

1554-KOL-2007-OTHERS 1.1.pdf

1554-KOL-2007-OTHERS.pdf

1554-KOL-2007-PETITION UNDER RULE 137.pdf

1554-KOL-2007-REPLY TO EXAMINATION REPORT.pdf

1554-KOL-2007-TRANSLATED COPY OF PRIORITY DOCUMENT.pdf

abstract-01554-kol-2007.jpg


Patent Number 253001
Indian Patent Application Number 1554/KOL/2007
PG Journal Number 24/2012
Publication Date 15-Jun-2012
Grant Date 13-Jun-2012
Date of Filing 15-Nov-2007
Name of Patentee GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Applicant Address 300 GM RENAISSANCE CENTER DETROIT, MICHIGAN
Inventors:
# Inventor's Name Inventor's Address
1 PETER E. WU 5230 RED FOX DRIVE BRIGHTON, MICHIGAN 48114
2 ANTHONY H. HEAP 2969 LESLIE PARK CIRCLE ANN ARBOR, MICHIGAN 48105
3 THYAGARAJAN SADASIWAN 4610 SOLOMON COURT YPSILANTI, MICHIGAN 48197
PCT International Classification Number F16H61/662; F16H61/66
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 11/561,048 2006-11-17 U.S.A.