Dynamics of a dual-clutch gearbox system: Analysis and experimental validation

Dynamic simulations and experimental validation tests were performed on a two-stage, two-speed gearbox. The gearbox was driven by two electromagnetic motors and had two electromagnetic, multidisk clutches to control output speed. A dynamic model of the system was created, which included a DC electric motor with proportional-integral-derivative speed control, a two-speed gearbox with dual electromagnetically actuated clutches, and an eddy current dynamometer. A six-degree-of-freedom model of the gearbox accounted for the system torsional dynamics and included gear, clutch, shaft, and load inertias as well as shaft flexibilities and a dry clutch stick-slip friction model. Experimental validation tests were performed on the gearbox in the NASA Glenn gear noise test facility. Gearbox output speed and torque as well as drive motor speed and current were compared to those from the analytical predictions. The experiments correlate very well with the predictions, thus validating the dynamic simulation methodologies.