The dynamic characteristics and energy loss in a shifting control system is important and necessary in the performance improvement of an automatic transmission. The direct operating solenoid valve has been considered as a potential component applying in the shifting control system in vehicle. The previous method can solve only a specific physical field or use the test results of the magnetic force as input curve. The paper presents a numerical approach for solving the multi-domain physical problem of the valve. A precise model of the direct acting solenoid valve considering different physical field is developed. An experimental study is also performed to evaluate and confirm the simulation. Based on the model, the influences on the dynamic characteristics of the valve are analyzed by calculating forces acting on the valve. The systematic analysis of forces and energy loss characteristics are performed for three different flow conditions varying clearance height from 10 µm to 30 µm. The results demonstrate that the pressure response time can be improved with smaller clearance between the spool and the sleeve. Moreover, the leakage of the shifting control system employing the direct acting solenoid valve can be reduced by 60% compared to the conventional two-stage pilot valve in our previous product.

Clutch fill control in clutch‐to‐clutch transmissions influences shift quality considerably. An oncoming clutch should be applied synchronously with the release of an offgoing clutch to shift gear smoothly; therefore, the gap between the piston and clutch plates should be eliminated when the torque capacity is near zero at the end of the clutch fill phase. Open‐loop control is typically implemented for the clutch fill because of the cost of pressure sensor. Low control precision causes underfill or overfill to occur, deteriorating shift quality. In this paper, a mathematical model of an electrohydraulic clutch shift control system is presented. Special dynamic characteristic parameters for optimal clutch fill control are subsequently proposed. An automatic method for predicting initial fill control parameters is proposed to eliminate distinct discrepancies among transmissions caused by manufacturing or assembling errors. To prevent underfill and overfill, a fuzzy adaptive control method is proposed, in which clutch fill control parameters are adjusted self‐adaptively and continually. Road vehicle test results proved that applying the fuzzy adaptive method ensures the consistency of shift quality even after the transmission’s status is changed.