Innovative dog clutch actuator with integrated sensor function for 48V ZF hybrid drives: How an electromagnetic actuated dog clutch with 'sensorless' position detection meets the requirements of P2 mild-hybrids with maximum efficiency and optimized packa

摘要

Concepts for hybrid drives becomes more and more important because of increasing requirements on the efficiency of vehicles and the reduction of local emissions in metropolitan areas. Therefore a mild-hybrid module based on 48V was developed by ZF, which can be placed between the internal combustion and the gearbox. An electric machine with fully integrated control electronics and also an electromagnetically actuated dog clutch are included. This allows the disengaging of the internal combustion engine (P2 configuration) and thus a efficient purely electric driving and coasting. The presentation first describes the demands of the disconnect function to be implemented with regard to dynamics, packaging and efficiency. The fulfillment of the interacting requirements using model-based development of the electromagnetic actuator and the dog clutch are illustrated. In addition, the functional integration of a "sensorless" positioning measurement method is discussed. The presentation concludes with the optimization of the shifting dynamics and the implementation of new control functions.