Simulating gearbox, transmission, synchronizers and powertrain in real-time
HOERBIGER’s history dates back to the year 1895 – today, the company has more than 6,700 employees and is a leading global player in the areas of compressor and automation technologies and powertrain engineering. HOERBIGER’s business unit for drive technology develops synchronizers for manual and dual clutch transmissions amongst others using ITI software for offline simulations. For the adjustment and optimization of synchronizer devices during the development phase, various parameters, such as complex, interacting geometries of locking and meshing teeth, are being altered to simulate the impact on the final product. So far, it has only been possible to determine resulting effects and experience the gear shifting behavior realistically through a physical prototype. Requirements for new products in regards to haptics are usually agreed on through verbal communication. Their interpretation, however, remains a highly subjective matter.
Since judgment about a vehicle is also influenced by the gear shifting behavior, it is of great importance to define those requirements on an objective, reproducible basis and to get a realistic impression of the final gear shifting behaviour early on. The objective was to develop an HiL simulator with a physical gear stick that could mimic the gearbox, internal and external shift mechanisms, the synchronizer and the powertrain within a single real-time simulation. The simulator was supposed to handle shifting gears with all that is to it as if it was in a real car. HOERBIGER was hoping to be able to immediately assess the impact of design measures on the gear shifting behavior already at the beginning of the development process without the need for a prototype. By using a real-time system, parameters and geometries were supposed to be editable on the fly.