Completely Integrated Electromagnetic Dog Clutch Actuator for Automotive Applications

State of the art vehicle drive train solutions move from internal combustion engine powered systems to hybrid and battery powered electrical systems. As a consequence also gearboxes and clutch systems change fundamentally. A viable solution for the next generation of automotive transport are electromagnetically direct actuated dog clutch systems. These solutions convince with a mechanically minimized and simplified design. Moreover, when designed as smart actuators they offer a significantly improved performance with respect to the applications requirements and comfort. This paper analyzes the requirements and limiting factors of an smart electromagnetic direct shift actuator solution resulting from spacial dimensions and performance criteria. The proposed solution is integrated into a conventional gearbox, reduces engagement shift times to the range of 10ms and convinces with a high shift comfort thanks to aligned engagement and softlanding. The potential of the robust non-impact engage control strategy is presented and evaluated on the test-rig. The experimental results of the control demonstrate that one control strategy can realize (i) a conventional contact-mode control and (ii) a non-impact sailing-mode control approach. Thus the engagement performance improves significantly. An engagement can still be guaranteed in the case of a sensor failure.