Keywords

General Theses

Test Equipment for Production
Line of Transmission for Plug-inHybrid Electric Vehicle (PHEV )Norihiro Maezato,Kiyohide Abe

PHEV, Transmission, Test equipment

Abstract

We have been manufacturing automatic transmission test equipment for theAutomatic Transmission (AT) with a torque converter and for the Continuously
Variable Transmission (CVT). We recently delivered transmission test equipment
to an overseas automotive manufacturer. This is a transmission to be loaded on
the Plug-in Hybrid Electric Vehicle (PHEV).
This type of test equipment is intended to create conditions close to thoseof actual vehicles.
The prominent features of this equipment are as follows:( 1 ) Adoption of a three-axis motor system( 2 ) Layout is designed to ﬁt the setup position for the PHEV control unit.

1 PrefaceIn the auto industry ﬁeld, hybrid cars are
becoming more popular because of its fuel efﬁciency and low CO2 emission addressing issues of global warming and depletion of fossil fuel resources.
The transmission unit, a major assembly ofautomobiles, is an important component that transfers the engine power to the wheels. We are a supplier of transmission test equipment for productionlines. Currently, the Automatic Transmission (AT)and the Continuously Variable Transmission (CVT)
are mainstream. The AT features high power transmission capability and outstanding environmental
performance (high fuel efﬁciency and reduced CO2emission). It is urgent to address climate change
and energy shift from gasoline. As part of such challenges, wider penetration of transmissions for thePlug-in Hybrid Electric Vehicle (PHEV) becomes
necessary
This paper introduces a case study of our supply of a transmission test equipment for PHEV for
an overseas automaker.

2 System Overview
Fig. 1 shows an overall layout (top view diagram) of this system. A transmission set on the dedicated pallet in the previous process is ﬁlled with an
Automatic Transmission Fluid (ATF) oil at the oilinjection Station (ST) and then is carried to the test
ST. This transmission unit undergoes various measurement tests at the test ST and the result of testingis identiﬁed by OK or NG judgment. The test result
is recorded in the ID unit that is attached to the dedicated pallet. The transmission unit is then carried tothe oil drainage ST. After the ATF oil has been
extracted at the oil drainage ST, the transmission
unit is moved to the post-process.
At the ATF tank unit, supply and recovery of oil
and temperature control are carried out. At the various control panels, transmission control, I/O axis
motor control, and transport control are carried out.
At the CPU unit, measurement control, noise measurement, and data collection are performed.
Table 1 shows a list of major equipment speciﬁcations of this system and Table 2 shows a list ofmeasuring items.

3 System Conﬁguration
Fig. 2 shows the system diagram of the controlequipment. A PHEV control unit, which is used on areal car, is mounted as the control equipment sothat a control system equivalent to that of a real car
can be constructed. This PHEV control unit isinstalled in the vicinity of the main body of the transmission.
By this layout arrangement diffusion of electrical noise generated by high voltage and high freMEIDEN REVIEW Series No.172 2018 No.1

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Output axis motor 2

ATF temperature regulator tank unit
ATF sub-tank

Power supply panel

CB panel

Post-testing buffer ST

Battery simulator panelBreaker panel
PHEV transmission

Chiller unit
POD・TCU box
IPU box

Oil injection/drainage ST

Test STTransmission unit
Pre-testing buffer ST
Operation and measuring panel

Motor panel
Output axis motor 1Fig. 1

Input axis motor

Overall Layout Diagram ( Top View)

The overall arrangement of each main component is shown. The PHEV transmission unit is carried from the carry-out exit on the right of
the test ST on the left. After testing, it is carried to the right.

Table 1 List of Major Equipment Specifications
A list of major equipment for this test equipment is shown.
Facility name

36Specifications, configuration, function

Test ST

Input-axis motor capacity: 36kW
rpm: 3283/6200min−1
Output-axis motor capacity: 22kW
rpm: 1450/4500min−1

ATF temperature
regulator tank unit

Oil temperature regulator: 80±5℃
Tank capacity Dirty side: 125L
Clean side: 250L
Heating capacity: 20℃ → 80℃/40min
Sub-tank capacity: 500L

Work carrier

Carry system: Conveyer transport
Carry-in/out port used in common
Pre-testing buffer ST: 1ST
Post-testing buffer ST: 1ST
A maximum of 3 works can be loaded
continuously.

Oil injection/drainage ST

A work and a pre-dressed pallet can be
automatically joined and separated
through a coupler.

Controller panel(Installed with CPUunit)

Breaker panel, power supply panel, CBpanel, motor panel, operation and measuring panel (CPU unit functions:waveform display, data storage)

Battery simulator
panel

Source for HEV motor
Max. DC output voltage: 400V
Max. DC output current: 190A
Max. capacity: 76kW
Panel size: W1500 × H2100 × D600mm

Chiller unit
(IPU chiller unit)

Cooling water circulation (Cooling watertemperature: 65℃ or below, 8L/min ormore)

MEIDEN REVIEW Series No.172 2018 No.1

quencies can be reduced in the EV motor. By thismethod, measures have been taken against control
disorders and highly reliable measuring data havebeen collected. At the PHEV control unit, commanddispatch and data logging are carried out by using
Controller Area Network (CAN) communication in
the same manner as for the real car.

4 New Measurement Test
This system controls the EV motor mounted on
the main body of PHEV transmission and motor-powered oil pump. This is in addition to conventional
measuring items of automatic transmission. The EV
motor control unit (IPU: Integrated Power drive Unit),
the motor-powered oil pump control unit (POD:Pump On Demand), and the Transmission ControlUnit (TCU) and the measuring personal computerare controlled through the Control Area Network(CAN) based on the CAN communication protocol.
The major measurement items are as follows:( 1) EV motor control
The torque output of the EV motor is controlled
to a constant level and revolutions of the input-axis
motor are changed as a substitute of an engine. In

Table 2 List of Measuring Items
A list of measurements and operating items of this test equipment is shown.
Measuring and operating
items

Measuring range

Measuring and operating
items

Measuring range

I/O axis revolving speed

0〜6500min−1

Encoder

Turbine shaft speed

0〜6500min−1

Operation

I/O axis torque−1000〜1000N・m

Torque meter

Various CVT pressures

0〜6500kPa

Operation

Detent torque−10〜10N・m

Torque meter

CVT oil temperature

0〜100DegC

Operation

0〜75kW

Operation

Transducer

Transducer

Oil pressure at various check 0〜10MPaports

Pressure sensor Detection at various inhibitorswitches

ATF oil supply temperature

0〜100DegC

Thermocouple

Brake

Cooler inflow rate

0〜50L/min

Flow meter

Parking front/rear

I/O axis motor speed

0〜6000min−1

Encoder

Motor output

Various duties

0〜100％

Operation

Motor-powered pump speed 0〜2000min−1

Encoder

Operation

Motor-powered pump current

Current sensor

Various CVT shaft speeds−10〜6500min

3φ 380V 50Hz
IPU
: EV motor control unit
POD control unit : Motor-powered oil pump control unit
: Transmission control unit
TCU
Battery simulator+ －Chiller unit
OUTIN

PHEV control unit

+ －IPU+－+POD－ control unit

TCU

Power supply panel,
breaker panel

CB panelU V W

Test equipment
U V W
Encoder

Input axis
motor

Encoder

Outputaxis
motor 1Torquemotor

POD
AFT tank

EV motor

CVTTorquemotor

Encoder

AFT sub-tank

PalletDuty controller
Motor panel

Fig. 2

Outputaxis
motor 2

Operation and measuring panel

CAN
DC＋12V

System Diagram of Control Equipment

A system diagram of control equipment for this test equipment is shown.

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this state, the drive performance and power generating performance of the EV motor, plus the torquevalue within the transmission, are measured andevaluated.
( 2 ) Motor-powered oil pump control
The rpm value of the motor-powered oil pumpis controlled at the speciﬁed level so that themotor-powered valve mounted on the transmission
unit is regulated by current control. At that time,pressure of each valve is measured and evaluated.

5 Postscript
This paper introduced the features of the test
equipment for production line of PHEV transmission
units. Going forward, we will work on product development that can meet the changing needs of ourcustomers and will deliver products that can providethe best product experiences to them.
・All product and company names mentioned in this paper are
the trademarks and/or service marks of their respective owners.

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