The purpose of this project was to analyze and implement different gear shifting solutions for a 2-speed Automated Manual Transmission (AMT) equipped electric commercial delivery van to optimize shifting quality, driving comfort, performance, efficiency, and reliability. This paper investigates the design of a new transmission system without a friction synchronizer. Active speed sensing technology for the output shaft, along with the potential of speed matching using electric motors and implementation of torsional springs to dampen the possible shock that can be produced due to the speed, or the position error, eliminating the need for the friction synchronizer. An electrically controlled camshaft-type rotational actuator with a DC shift motor is implemented to the transmission system. Cascade controller is proposed to control the position of the actuator and the input voltage of the DC motor. A PWM driver is used to control the rotational speed and the direction of the DC motor by varying the duty cycle. A 1D Simscape-Simulink based gearbox and vehicle model were built up to simulate the behavior of the proposed shifting solutions. Running the Simulink model on different duty-cycles and analyzing different sets of actuators and clutches to optimize gearbox’s performance and efficiency indicated that 1 actuator with 1 dog clutch configuration provides a significant improvement in shifting quality, vehicle’s performance, and efficiency.
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