The paper presents the modeling and control design of a floating piston electro-pneumatic gearbox actuator and, moreover, the industrial validation of the controller system. As part of a heavy-duty vehicle, it needs to meet strict and contradictory requirements and units applying the system with different supply pressures in order to operate under various environmental conditions. Because of the high control frequency domain of the real system, post-modern control methods with high computational demands could not be used as they do not meet real-time requirements on automotive level. During the modeling phase, the essential simplifications are shown with the awareness of the trade-off between calculation speed and numerical accuracy to generate a multi-state piecewise-linear system. Two LTI control methods are introduced, i.e., a PD and an Linear-Quadratic Regulators (LQR) solution, in which the continuous control signals are transformed into discrete voltage solenoid commands for the valves. The validation of both the model and the control system are performed on a real physical implementation. The results show that both modeling and control design are suitable for the control tasks using floating piston cylinders and, moreover, these methods can be extended to electro-pneumatic cylinders with different layouts.
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