BVR PA6

ROBOTIZED GEARBOX PA6

1 PRESENTATION

1-1 General Information

It is a 6-speed gearbox "PK6"

equipped with an electro-hydraulic robot called
"Add-on". The latter allows for automation of the
clutch engagement/disengagement functions and change of
reports. He makes changes to the reports
through the selection and engagement levers of the
basic manual gearbox order.

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1-2 Gearbox

The housing of the 'classic' gearbox has been modified to accommodate the points of
fixation of the robotic module as well as a primary shaft speed sensor.

1: Anchor Points
2: Selection lever
3: Engagement lever
4: Primary speed sensor

The clutch command, as well as the

selection and the commitment of a sound report
secured by the electro-hydraulic system
Cet ensemble est géré par le calculateur d
the BVR.

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1-3 Customer services

The client has the following elements to use PA6:

the gear lever

- l’afficheur,
the "SNOW" switch,
the "CHARGE" switch,
the noisemaker (integrated into the display).

Gear lever

The gear lever allows the driver to:

request changes to reports (amounts or

descendants),
request the passage of a particular report (Neutral or Market
Back)
toggle between AUTOMATIC mode and MANUAL mode.

L+ and L–Selection of reports.

NSelection of the dead point.
RSelection of reverse gear.
A/MSelect AUTOMATIC mode/MANUAL mode.
SStable position of the lever.

Usage

Both modes allow for engine torque management, so the driver does not need to release.
the accelerator during gear changes.

The engine starts in Neutral. If a gear is engaged when attempting to start,

The "foot on the brake" pictogram is flashing on the dashboard.

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This procedure causes the gearbox to neutral and allows the engine to start.

The movement of the vehicle is achieved after selecting a gear. To do this, it is necessary
to press the brake pedal and give a forward impulse on the gear selector. The
the system is then in AUTOMATIC mode (A on the display).

When the foot is removed from the brake, the vehicle moves forward at idle speed (creeping).

The switch from AUTOMATIC mode to MANUAL mode is made by flipping the gear lever.
the left. Returning to AUTOMATIC mode is done in the same way.

However, when the system is in AUTOMATIC mode (A on the display), a forward pulse
On the gear selector causes the shift to MANUAL mode.

If the forward thrust occurs with foot on the brake, the system switches to mode
MANUEL and the second report is committed.

Note
- The engaged gear in the gearbox is visible on the dashboard display. An audible signal
warns the driver if a door is open with a gear engaged (brake released).

The calculator adapts the gear changes according to the driver's driving.
operation is called "self-adaptive". It takes into account the position of the accelerator pedal to
evaluate the gear change regimes (see chapter on shifting laws)

Board switch

The switch allows for:

activate and deactivate CHARGE mode,
turn on and off SNOW mode.

Dashboard display

The display occurs on the central part of the board.

board. It has 6 indications
useful for the driverDetail of pictograms:

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Meaning of pictograms

2 STUDY OF THE DIFFERENT COMPONENTS

The gearbox

The selection and engagement levers

The peculiarity of this gearbox is

to have a lever for engagementA)
reports and a lever for selection (B)
reports implanted in areas
distinct but close to each other.

This allowed the group to be established.

hydraulic without modification of the
internal command of the gearbox
manual.

Externally, only the engagement lever

is equipped with a finger adapted to the module of
robotization.

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The entire order of the forks

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2-2 The electro-hydraulic control module "Add On"

Details of the hydraulic group

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Hydraulic pump

The hydraulic pump generates the flow necessary to charge the accumulator. It is a pump that
gear driven by an electric motor. The latter receives its power from a relay controlled by the
calculator.

Pressure accumulator

By maintaining a quantity of liquid under pressure, the accumulator absorbs pressure variations. It
allows intermittent operation of the pump. Additionally, it enables in case of malfunction of the
pump, to be able to select the reports multiple times after the fault indicator is turned on.

Pressure sensor

This piezo-type sensor measures the pressure of the hydraulic circuit. Thanks to this information, the calculator
activates or deactivates the pump to regulate the pressure.

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Report and clutch control module

The obtaining of reports is done through:

to the selector cylinder powered by solenoid valves EV3 and EV4 and its position sensor,
to the engagement actuator powered by the solenoid valves EV1 and EV2 and its position sensor.
to the clutch actuator powered by the solenoid valve EV0 and its position sensor.

7
8

1EV1: gear engagement solenoid valve.

2EV2: engagement valve of the transmission.
3EV3: line selection solenoid valve.
4EV4: line selection solenoid valve.
5EV0: clutch solenoid.
6Selection sensor.
7Engagement sensor.
8Clutch sensor

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Fonctionnement

Selection of reports

Selection valve

This actuator allows positioning the control face in

selected report. It is
fed with oil by solenoid valves 3 and 4.

Position sensor of the selection cylinder

This potentiometer (1) measures the displacement of the cylinder selection.

It is mounted on the body of the actuator module. The
calculator uses this information to position the finger of
selection.

Selection solenoid valves

In the number of 2, they allow the feeding of the actuator. of

Selection. They are controlled by the computer.

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Engagement of reports

Engagement cylinder

Powered by the proportional solenoid valves 1 and 2, it allows

to engage the selected report.

Position sensor of the engagement cylinder

Identical to that of the selection cylinder, it measures the movement of the cylinder piston.
engagement. It is mounted on the actuator module body and allows the computer
to verify the proper engagement of the selected report.

Engagement solenoid valves

In the number of 2, they allow for the gradual feeding of the engagement cylinder.

Whatever the relationship

asked, the
solenoid valves 1 and 2 are
activated and this even if the
gearbox is located
at a standstill.

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Clutch command

In order to perform the clutching and declutching operations, the system uses:

- a clutch cylinder,
a proportional flow solenoid valve,
a position sensor,
an engagement transmitter
a hydraulic buffer.

Clutch cylinder

The clutch cylinder is powered by the proportional solenoid valve in flow. The movement of the cylinder is
proportional to the amount of oil introduced into the chamber. The cylinder, by pushing the transmitter's piston
of the clutch, moves the clutch release bearing. The oil in the hydraulic body is not compatible with it
In the clutch circuit, a membrane ensures the sealing between the actuator and the clutch master cylinder.

1Hydraulic body oil.

2Master piston.
3Clutch control oil.
4Sealing membrane.
5 Clutch release piston.
6Hydraulic stop.

Clutch stop

The hydraulic clutch stop is the same as on the box

PK6.

The clutch command bleeding is performed

manually by scrupulously applying the method of
repair. The command mode available in the tool of
diagnostic is used to refine a purge and not for a purge
complete.

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Clutch actuator position sensor

It is a potentiometer linked to the movement of the cylinder. It allows the computer to manage the position of
the clutch.

1Clutch actuator position sensor.

Clutch solenoid valve

It allows to power the cylinder

of the clutch. It is controlled in debit
by the calculator, depending on of
the information provided by the sensor
of the position of the cylinder.

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2-3 Gestion électronique de la Boîte de Vitesses Robotisée

Presentation

The calculator, 80 channels Magneti-Marelli, is connected to the system by 2 connectors.

52 and 28 tracks.

Implanted under the left eye, it manages the 3

hydraulic cylinders, with the help of different sensors
and actuators.

Moreover, it supports management of the couple

engine, during the changes of reports.

Inter-computer links

The multiplexed network is the essential communication element of the Powertrain Group. It connects the transmission
robotized speeds to other calculators present on the network.

A lot of information circulates between computers and particularly allows for management of
couple by the BVR calculator. Indeed, during a gearshift, the transmission control unit
Robotized manages the engine couple, the injection controller no longer takes into account the driver's demand.

Main CAN messages consumed by the BVR calculator:

engine mode (injection)
driver's will (injection)
water temperature (injection)
effective torque (injection),
braking information (ABS)
parking brake switch (dashboard)

Main CAN messages issued by the BVR calculator:

request for takeover (injection),
couple request (injection)
rampage (injection)
- engaged report (dashboard),
fault indicator (dashboard).

Some information is duplicated and arrives at the gearbox calculator via multiplexed connections.
and wired.
engine regime
vehicle speed,
braking information.

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CAN H/L
Topology RADIO
BUS CAN NAVIGATION
HdG vehicle speed
& ABS DIAG_K DIAG_K
BdG
Leaves
Witness
before CENTRAL UNIT
Leaves HABITACLE
back
Witness
Witness

Witness DASHBOARD R

Info
Witness handbrake
alternator Witness
Detection_info Siren piloting

ALARM
SUSPENSION DETECTOR
PNEUMATIC DIAG_K SIRENE
Contactor
STOP
DOUBLE
Info crash RING
transponder

AIRBAG
DIAG_K
INJECTION CAN H/L
EDC15
OU DIAGNOSTIC TAKING
EDC16 Info stop DIAG_K
DIAG_K
Engine regime UC BVR
R
CAN H/L DIAG_K
Tachograph
DIAG_K

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2-4 Contactors and sensors

Speed selection switches

The control of the robotic gearbox is electric. The positions of the lever
are transmitted to the computer via an electrical signal generated by the closure or
the opening of four contacts installed at the bottom of the control module.

The contactors (1, 2, 3, and 4) inform the

calculator of movements applied to
gear selector, by the driver. They are
driven in groups of 2.

Status table of the contactors following the impulse given to the lever:

This operating principle secures the information transmitted to the computer. If a

des contacts est défaillant, les signaux générés par les trois autres permettent encore de
differentiate the lever positions. After each impulse, the lever returns to its equilibrium position
in which no switch is activated.

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Detail of the gear lever

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Stop light switch

It is the same switch used by the brake lights. Its information is required by the computer.
to allow the engagement of forward gear, reverse gear, or neutral. In addition, it
intervenes in the management of certain operational strategies, such as inhibition of the
rampage function or braking assistance by downshifting.

Handbrake switch

In addition to lighting up the dashboard indicator, it inhibits the rampage function.

Primary shaft speed sensor

It is an inductive sensor.1) who measure

the rotation speed of the primary shaft.
It is implanted on the mechanism housing of box
of speeds and uses as a target the pinion of MAR
of the short secondary tree. This information
intervenes in the management of strategies of
gear shifting.

Snow Switch

The SNOW button is a momentary contact switch. Pressing this button allows the driver to
select or deselect the SNOW mode when using the vehicle on low traction surfaces
adhesion.

The main features of the SNOW mode are as follows:

The SNOW mode enforces the "AUTO" mode. If the driver presses the SNOW button then
when the MANUAL mode is selected, the automatic transmission shifts to AUTO mode and SNOW mode.

When pressing the SNOW button while the SNOW mode was activated, the SNOW mode is
deselected, but the AUTO mode remains active.

The SNOW mode is only accessible and functional when the engine is running.

There is no memory of the SNOW mode when the engine is turned off.
the driver will be required to select the mode at each start.

- While driving, in case of pulses at the lever (L+, L-), the SNOW mode will be
deselected (returned to MANUAL mode) and the request will be taken into account.

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Charge switch

When the driver retrieves their vehicle after charging it, they must select the mode "
CHARGE. Indeed, operating strategies vary depending on the onboard mass.
in the vehicle. These strategies particularly impact the clutch bonding time which
is minimized in order to preserve it as much as possible.

The CHARGE button is a momentary contact. Pressing this button allows the driver to
select or deselect the CHARGE mode and allows the calculator to apply by
anticipation the necessary corrections.

Pressing the CHARGE button will only be taken into account when the engine is running. There is no
memorization of the mode at engine shutdown, the driver will be required to select the mode
CHARGE at each startup.

Remarks:
If the CHARGE mode is activated, the charge indicator light is on. In this case, the calculator
will increase the speed shift regime compared to the regime determined by
the self-adaptive.

The conditions for exiting CHARGE mode are as follows:

engine cut-off,
turning the key to the OFF or accessory position,
press the CHARGE button.

Start authorization relay

It is controlled by the computer if the gearbox is in neutral and the user

press the brake. In the event that a gear is engaged, the system puts the gearbox in
dead point before allowing the start.

Relay of the electropump group

It is controlled by the computer when the pressure drops below a certain threshold.

Accelerator pedal

The accelerator pedal is a dual potentiometer. It is specific, as it is equipped with a

hard point to fulfill the "kick-down" function.

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Self-adaptive passage laws of the automatic mode

The computer has 7 gear shift laws. The system continuously chooses the gear.
of laws best suited to the situation.

Three laws based on the type of conduct:

1. ECO law: it corresponds to a calm drive on flat roads. (gear shifting to

weak regimes).

2. MEDIUM law: it corresponds to a slightly nervous behavior on flat road.

(transition from reports to average regimes).

3. SPORT law: it corresponds to a nervous driving style on flat roads.

reports to very high engine regimes.)

Code of conduct
Elle est sélectionnée par le calculateur à partir du comportement du conducteur.

The latter is defined by:

the average position of the accelerator pedal,
the speed of pressing the accelerator pedal,
the speed of the vehicle.

Slope law
The calculator estimates the slope and the resistance to advancement based on the following parameters
:
the position of the accelerator,
the speed of the vehicle,
the acceleration of the vehicle.

Choice of law
The system must choose between the law of conduct and the law of slope to decide on the thresholds of
gear shifting to be adopted. It should be noted that priority is given to ascending inclines.

Threshold passage correction

At the request of a report passage by the adopted passage law, a certain number of
functions can lead the calculator to temporarily modify the passing thresholds of
reports.

blocking of the engaged report, in lift-off

downshifting one or two gears based on the pedal depression
of the accelerator
activation function 'charge'.

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Full throttle function

When pressing the pedal down to the floor position (passing the hard point) there is
anticipation of downshifting, in order to obtain the necessary engine speed during a maneuver
of exceeding.

Brake assist function

This function is activated during a braking action to provide maximum braking.
engine by anticipating downshifts when the driver applies the brakes.

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2-5 Special Operations

Rampage

In 1st, 2nd, or in reverse, after releasing the handbrake and/or the brake pedal, the
vehicle moves in slow motion. This feature makes parking maneuvers easier.
is inhibited in case of clutch overheating (see clutch overheating strategy).

Starting "in stroller"

If the power supply voltage of the computers is sufficient, it is possible to start the vehicle.
by pushing it. At a speed of about 7 km/h, the noisemaker emits a signal to indicate to
the user can engage a speed.

At this stage, a push on the gear selector causes the selection of the 2nd gear and
the engine clutch with the gearbox.

Clutch overheating strategy

When the driver uses the BVR in an abnormal and abusive manner (e.g.: keeping the vehicle in
brake with the accelerator pedal instead of pressing the brake pedal), he risks damaging
the clutch.

That is why the BVR calculator continuously estimates the temperature of the clutch and
when a temperature threshold is exceeded, the BVR automatically protects itself by activating the
it makes noise and inhibits the "rampage" function. Furthermore, in order to avoid further damaging the clutch, the
BVR calculator prohibits takeoff in 2nd gear in MANUAL mode.

These specific actions are maintained as long as the temperature is above the threshold of
clutch overheating.

Emergency mode
Gear shift
In the event of loss of the lever information, pressing the brake allows the transition to auto mode.

Maintenance
A certain number of learnings or configurations must be carried out when intervening on
elements of the robotic gearbox. It is imperative to use the repair manual to
ensure the proper functioning of the BVR following the repair.

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3 SCHEMAS

3-1 Schematic diagram of principle

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3-2 Hydraulic principle diagram

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3-3 Wiring of the calculator

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3-4 Wiring of the add-On module

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