Journal of Jilin University(Engineering and Technology Edition) ›› 2025, Vol. 55 ›› Issue (5): 1806-1816.doi: 10.13229/j.cnki.jdxbgxb.20230825

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Design and test of hydraulic system for new dual-clutch full-powershift transmission of heavy-duty tractor

Jian WANG1,Wen-hu MA1,Tai-lin XIE2,Hua GUO2,Bi-feng YIN1   

  1. 1.School of Automotive and Traffic Engineering，Jiangsu University，Zhenjiang 212013，China
    2.Changzhou Changfa Technology Development Co. ，Ltd. ，Changzhou 213000，China
  • Received:2023-08-04 Online:2025-05-01 Published:2025-07-18

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Abstract:

A hydraulic system was designed for the new dual-clutch full-powershift transmission of the newly developed 223.7 kW （300 hp） heavy-duty tractor， in order to achieve the purpose of uninterrupted shift and transmission cooling and lubrication. The AMESim dynamic shift simulation model was established， the flow and oil pressure properties of the hydraulic system as well as the dynamics of the clutches and synchronizers have been analyzed. The simulation results show that the pressure building time of the clutch hydraulic cylinder is less than 1 s， the pressure relief time is less than 0.6 s， and the pressure is stable during the pressure building/relief. The synchronizer hydraulic cylinder establishes stable oil pressure within 0.3 s； The cooling and lubrication subsystem takes 0.5 s to establish a stable oil pressure of 0.22 MPa， and the maximum flow rate is 57.6 L/min. The clutch completes the smooth transition of power during the shift， and the synchronizer completes the pre-selection before the shift. A new dual-clutch full-powershift transmission test bench was set up for further verification， the oil pressure test results of the clutch and synchronizer hydraulic cylinders are basically consistent with the simulation results， the output speed of the transmission increases from 270 r/min to 310 r/min， and the maximum wave momentum is 31 r/min， the output torque of the transmission is stable around 2 910 N·m， the maximum wave momentum is 10.1% of the stable value， and there is no power interruption during the shifting process. The simulation and test results verify that the hydraulic system can meet the working requirements of the new dual-clutch full-powershift transmission of heavy-duty tractor. The work in this paper can provide reference and guidance for the design and calculation of the hydraulic system of the dual-clutch full-powershift transmission of heavy-duty tractor.

Key words: power machinery and engineering, heavy-duty tractor, dual-clutch, full-powershift transmission, hydraulic system

CLC Number: 

  • TK5

Table 1

Parameters of new dual-clutch full-powershift transmission"

参数数值
功率/kW223.7
连续输入转矩/（N·m）1 050
最大输入转矩/（N·m）1 450
额定输入转速/（r·min-1）2 200
平均速比1.21
挡位数量24F+8R
传动效率≥90%
离合器数量4
同步器数量11

Fig.1

Powertrain system structure diagram of new dual -clutch full-powershift transmission"

Fig.2

Overall design diagram of hydraulic system"

Fig.3

Diagram of main oil pressure control circuit"

Fig.4

Diagram hydraulic control subsystem"

Fig.5

Diagram cooling and lubrication subsystem"

Fig.6

Principle diagram of hydraulic system"

Fig.7

Simulation model of power shift"

Table 2

Main parameters of AMESim simulation"

参　数数值
离合器摩擦因数0.14
离合器回位弹簧刚度/（N·mm-1）2 159
同步器摩擦因数0.11
同步器回位弹簧刚度/（N·mm-1）304
1挡传动比8.17
2挡传动比7.05
主减速比4.96
轮边减速比8.31

Fig.8

Flow curves of cooling lubrication subsystem"

Fig.9

Oil pressure curves of cooling lubrication subsystem"

Fig.10

Oil pressure curves of clutch cylinders"

Fig.11

Torque curves of clutches"

Fig.12

Pressure curve of synchronizers cylinder"

Fig.13

Speed curves of synchronizer gear sleeves and engaging gears"

Fig.14

Flow curves of hydraulic control subsystem"

Fig.15

New dual-clutch full power shift transmission test bench"

Fig.16

Clutch hydraulic cylinders oil pressure change test curves"

Fig.17

Synchronizer hydraulic cylinder oil pressure change test curve"

Fig.18

Transmission output speed and torque curves"

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