Design Automation of Complex Hydromechanical Transmissions

This thesis proposes an automated methodology for the design of complex multiple-mode hydromechanical transmissions.High fuel prices and strict emission regulations are today drivers of the development of new fuel-efficient drive transmissions for construction machinery.Hydromechanical transmissions have high energy efficiency and a wide torque/speed conversion range.They are today strong candidates to replace the fuel-thirsty torque converters conventionally used in heavy construction machines.The trend towards more complex transmission architectures increases the need for more sophisticated product development methods.Complex multiple-mode transmissions are difficult to design and prototype and can be realised in a great number of different architectures.This increases the need for reliable concept evaluation in early design stages.The design of the transmission is also strongly coupled to its energy consumption and for a fair comparison between transmission concepts optimal designs are necessary.Design automation and optimisation with detailed simulation models can support the industrial engineer in the design task and increase the available knowledge early in the design process.The proposed methodology uses simulation-based optimisation to design the transmission for a specific vehicle application.Various aspects of the transmission's characteristics may be targeted, although energy efficiency is in great focus in this work.To evaluate the energy efficiency, the transmission designs are simulated using backward-facing simulations with detailed power loss models.The methodology is applicable for designing the drive transmissions of construction machines and other mobile working vehicles such as agricultural machines, forest machines and mobile mining equipment.i w Weight factor [-] xii Little work has been done on the design process of HMTs.In his dissertation, Erkkilä [2] proposed a design methodology where a preliminary design is iteratively redesigned by the engineer until the technical requirements are fulfilled.Volpe et al.[3] suggest an optimisation-based design process for power-split transmissions using kinematic models of the transmission.The objective was to avoid recirculative energy at the most frequently used operating points of the vehicle's working cycle.In this work, power loss models are not used; instead it is assumed that the operating range with the most recirculating power has the worst efficiency.Macor and Rosetti [4] also applied optimisation on the design of basic hydromechanical power-split concepts.The proposed design methodology uses more detailed simulation models of the components.The single objective was to minimise the consumed energy from a zero to a maximum speed acceleration and does not take into account the operating behaviour of the vehicle.It is highlighted that optimisation

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