Article(id=1197492489180463385, tenantId=1146029695717560320, journalId=1189621681917173762, issueId=1197492487066530363, articleNumber=null, orderNo=null, doi=10.19620/j.cnki.1000-3703.20231062, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=null, receivedDateStr=null, revisedDate=1718899200000, revisedDateStr=2024-06-21, acceptedDate=null, acceptedDateStr=null, onlineDate=1763434057754, onlineDateStr=2025-11-18, pubDate=1742745600000, pubDateStr=2025-03-24, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1763434057754, onlineIssueDateStr=2025-11-18, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1763434057754, creator=13701087609, updateTime=1763434057754, updator=13701087609, issue=Issue{id=1197492487066530363, tenantId=1146029695717560320, journalId=1189621681917173762, year='2025', volume='', issue='3', pageStart='1', pageEnd='62', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1763434057251, creator=13701087609, updateTime=1763434367830, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1197493789779603575, tenantId=1146029695717560320, journalId=1189621681917173762, issueId=1197492487066530363, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1197493789779603576, tenantId=1146029695717560320, journalId=1189621681917173762, issueId=1197492487066530363, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=56, endPage=62, ext={EN=ArticleExt(id=1197492489369207068, articleId=1197492489180463385, tenantId=1146029695717560320, journalId=1189621681917173762, language=EN, title=Research on the Optimization of DCT Performance Based on Dual Clutch Launching, columnId=1200009531011985931, journalTitle=Automobile Technology, columnName=Special Topic on Multimodal Information Monitoring and Recognition Technologies for Human Factors in Intelligent Driving, runingTitle=null, highlight=null, articleAbstract=

In order to solve the problem of clutch overheating during the launching of a Dual Clutch Transmission (DCT) vehicle in the Drive mode of D1 gear under extreme working conditions, this paper proposes a dual-clutch launching control method to improve the climbing and escape performance of the vehicle. Based on the analysis of the hardware structural conditions, the clutch plate temperature model and the specific process of DCT launching, this paper proposes to use the D2 gear clutch to undertake the useless slipping power at the beginning of the steady speed stage of launching, and then switch back to the D1 gear clutch when the engine torque gradually increases to exceed the threshold, the paper then elaborates in detail the activation conditions and specific implementation process of the control method. Vehicle test verification shows that the dual-clutch launching has obvious advantages in clutch temperature control and driving smoothness compared with the single-clutch launching, and the vehicle climbing and escape performance has been significantly improved.

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针对某双离合变速器(DCT)车型在极限工况下前进挡(Drive)D1挡起步的离合器过热问题,提出用双离合起步的控制方法来提升车辆的爬坡和脱困性能。通过分析硬件结构条件、离合器片温度模型和DCT起步具体过程,在起步稳速阶段使用D2挡离合器来承担无用滑摩功,当发动机扭矩增加且超过阈值时,切换D1挡离合器,并详细阐述该控制方法的激活条件和具体实施过程。实车验证结果表明:双离合起步策略对于离合器温度控制、驾驶平顺性均具有明显优势,车辆爬坡和脱困性能得到显著提升。

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名称 取值 名称 取值
整车整备质量/kg 1 753 发动机排量/L 3.0
整车满载质量/kg 2 128 气缸数/个 4
轮胎滚动半径/mm 366 发动机最大扭矩/N·m 375
1挡速比 16.991 发动机最大功率/kW 175
2挡速比 10.588 机械传动效率 0.97
发动机含飞轮转动惯量
/kg·m²
0.227 5 滚动阻力系数 0.006 9
离合器输入端惯量
/kg·m²
0.008 5
), ArticleFig(id=1200009540759548579, tenantId=1146029695717560320, journalId=1189621681917173762, articleId=1197492489180463385, language=CN, label=表1, caption=

整车参数

, figureFileSmall=null, figureFileBig=null, tableContent=
名称 取值 名称 取值
整车整备质量/kg 1 753 发动机排量/L 3.0
整车满载质量/kg 2 128 气缸数/个 4
轮胎滚动半径/mm 366 发动机最大扭矩/N·m 375
1挡速比 16.991 发动机最大功率/kW 175
2挡速比 10.588 机械传动效率 0.97
发动机含飞轮转动惯量
/kg·m²
0.227 5 滚动阻力系数 0.006 9
离合器输入端惯量
/kg·m²
0.008 5
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起步次序 离合器1温度/℃ 离合器2温度/℃ 基础油温/℃
1 268 237 96
2 265 258 98
3 273 245 102
4 271 263 105
5 281 244 108
6 277 267 111
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35%满载爬坡测试结果

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起步次序 离合器1温度/℃ 离合器2温度/℃ 基础油温/℃
1 268 237 96
2 265 258 98
3 273 245 102
4 271 263 105
5 281 244 108
6 277 267 111
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基于双离合变速器的起步控制优化研究
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龚君 , 李滨 , 熊斌 , 陈裕棋
汽车技术 | 智能驾驶中人因状态多模态信息监测与识别技术专题 2025,(3): 56-62
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汽车技术 | 智能驾驶中人因状态多模态信息监测与识别技术专题 2025, (3): 56-62
基于双离合变速器的起步控制优化研究
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龚君, 李滨, 熊斌, 陈裕棋
作者信息
  • 麦格纳动力总成江西有限公司,南昌 330013
Research on the Optimization of DCT Performance Based on Dual Clutch Launching
Jun Gong, Bin Li, Bin Xiong, Yuqi Chen
Affiliations
  • Magna Powertrain Jiangxi Co., Ltd., Nanchang 330013
出版时间: 2025-03-24 doi: 10.19620/j.cnki.1000-3703.20231062
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针对某双离合变速器(DCT)车型在极限工况下前进挡(Drive)D1挡起步的离合器过热问题,提出用双离合起步的控制方法来提升车辆的爬坡和脱困性能。通过分析硬件结构条件、离合器片温度模型和DCT起步具体过程,在起步稳速阶段使用D2挡离合器来承担无用滑摩功,当发动机扭矩增加且超过阈值时,切换D1挡离合器,并详细阐述该控制方法的激活条件和具体实施过程。实车验证结果表明:双离合起步策略对于离合器温度控制、驾驶平顺性均具有明显优势,车辆爬坡和脱困性能得到显著提升。

双离合变速器  /  双离合起步  /  DCT过热

In order to solve the problem of clutch overheating during the launching of a Dual Clutch Transmission (DCT) vehicle in the Drive mode of D1 gear under extreme working conditions, this paper proposes a dual-clutch launching control method to improve the climbing and escape performance of the vehicle. Based on the analysis of the hardware structural conditions, the clutch plate temperature model and the specific process of DCT launching, this paper proposes to use the D2 gear clutch to undertake the useless slipping power at the beginning of the steady speed stage of launching, and then switch back to the D1 gear clutch when the engine torque gradually increases to exceed the threshold, the paper then elaborates in detail the activation conditions and specific implementation process of the control method. Vehicle test verification shows that the dual-clutch launching has obvious advantages in clutch temperature control and driving smoothness compared with the single-clutch launching, and the vehicle climbing and escape performance has been significantly improved.

Dual Clutch Transmission (DCT)  /  Dual Clutch Launch  /  DCT Overheating
龚君, 李滨, 熊斌, 陈裕棋. 基于双离合变速器的起步控制优化研究. 汽车技术, 2025 , (3) : 56 -62 . DOI: 10.19620/j.cnki.1000-3703.20231062
Jun Gong, Bin Li, Bin Xiong, Yuqi Chen. Research on the Optimization of DCT Performance Based on Dual Clutch Launching[J]. Automobile Technology, 2025 , (3) : 56 -62 . DOI: 10.19620/j.cnki.1000-3703.20231062
离合器过热是限制双离合变速器(Dual Clutch Transmission,DCT)性能的关键问题[1-2]。湿式离合器作为主流离合器,在日常驾驶中,能够主动控制油冷散热,明显改善离合器过热问题[3]。但在30%以上的坡道原地坡起、深坑脱困等极限工况效果不佳,导致车辆的爬坡和脱困性能不足。
由于DCT没有液力变矩器,因而起步只能依靠离合器自身的滑摩,使发动机与输入轴的转速同步。若无法驱动车辆起步,离合器会长时间处于最大滑摩状态,此时,发动机的输入扭矩逐渐增大,离合器表面的热负荷会迅速累积,导致离合器过热报警。同时,摩擦片磨损较大,缩短了离合器的使用寿命[4]
量产的DCT均采用单离合器起步,产生的热量集中在一个离合器上,极易发生离合器过热问题。为此,秦大同等[5]结合速度模糊控制的DCT起步控制策略,虽然能够反映驾驶员的起步意图,但缺少对起步滑摩阶段的优化控制。陈海军等[6]基于极小值原理,联合起步过程中发动机和双离合器转矩最优控制算法,延长了离合器的使用寿命。李震宇等[7]建立了车辆起步过程中湿式双离合器联合起步动力学模型,对静态和动态模型进行仿真对比,但未提及具体的实现过程。Zhao等[8]搭建了干式双离合器起步的仿真模型,但未对其使用条件作出明确的界定。
本文针对某车型DCT开发过程中,前进挡(Drive)D1挡起步过热导致离合器断开问题,提出使用D2挡离合器分担能量,从而降低D1挡离合器的温度,并通过实车测试证明该方案的有效性。
本文以含有2个湿式离合器的某DCT变速器为研究对象,其冷却部分硬件结构如图1所示。
冷却系统的循环主要通过一个专用的冷却泵,将冷却油从油底壳吸入,经油道分配至2个离合器(先经过内离合器,再经过外离合器),在外部油冷器中进行热交换冷却,最后流回油底壳。其中,外离合器C1控制D1、D3、D5、D7挡,内离合器C2控制D2、D4、D6和倒车挡(Reverse)R挡。
该硬件冷却结构中,内离合器的冷却效果较好,但外离合器的冷却效果较差。相较于R挡或D2挡起步,D1挡起步极易发生过热问题,因此,可使用D2挡离合器支持D1挡离合器起步。
根据离合器钢片温度与油底壳油温、离合器扭矩和转速滑差间关系建立温度模型。由于离合器的热量源于钢片与摩擦片间的摩擦,所以离合器片生成的能量等于离合器的滑摩功,部分能量通过油冷系统散发,剩余能量在离合器内部积累,使离合器钢片和摩擦片温度升高[9],则离合器的滑摩功为[10-11]
W c t = T c t × ω e t - ω n t 9.55
式中:Tc为离合器扭矩,ωe为发动机转速,ωn为离合器对应输入轴转速。
离合器的冷却油具有散热、润滑和减少磨损的作用,其内部的热量传递方式主要为热对流[12],换热方程为:
Q c t = h ( K c t - K f ( t ) )
式中:Qc为冷却油液散发的离合器热量,h为对流传导系数,KcKf分别为离合器钢片和冷却油的温度。
由于Qc为泵流量的等比例函数,取决于泵流量的分配系数,按照经验,将油底壳温度设为4 ℃,而离合器钢片的温度模型公式为:
K c t = 0 t W c t - Q c t C d t
式中:C为离合器比热容。
温度模型是DCT过热保护机制的基础,鉴于软件中温度模型技术已经成熟,而且当离合器钢片温度超过300 ℃会停止工作,所以,考虑控制离合器钢片的温度解决DCT过热问题。
经分析,可通过增大冷却流量、降低离合器滑差或降低滑摩时间3种方式降低离合器钢片的温度。其中,增大冷却流量需提高冷却泵的功率,但硬件成本也随之增加。降低离合器滑差需降低发动机的起步转速,当转速降低时,扭矩较低,但发动机起步动力性较弱;反之,起步动力性更强,但离合器磨损更大。因此,可使用双离合起步,降低单个离合器的滑摩时间。由于D1挡和D2挡传动方向相同,且离合器C2的冷却效果更佳。当使用D1挡起步时,通过D2挡离合器分担滑摩时间。
D1挡单离合起步的车辆起步过程传动系统动力学模型可表示为:
T c 1 t = T e t - J e ω ˙ e t F f = f + s i n α m g + C D A v 2 21.15 T f = F f r i 1 η
式中:Tc1为离合器1加载的扭矩,Tf为整车阻力Ff转换至离合器端的阻力矩,Te为发动机扭矩,ωe为发动机转速,Je为随发动机同转速旋转部件的转动惯量,α为坡度,f为静摩擦因数,m为整车质量,g为重力加速度,A为迎风面积,CD为风阻系数,v为车速,i为总传动比,r为轮胎半径, η为传动系统总效率。
单离合起步过程控制,如图2所示,各阶段控制为[13]
a. 提速阶段:控制发动机转速达到目标转速,此过程中,$\dot{\omega}_{\mathrm{e}}(t)>0, T_{\mathrm{c} 1}(t)<T_{\mathrm{e}}(t)$。
b. 稳速阶段:控制恒定的发动机转速,此过程中,$\dot{\omega}_{\mathrm{e}}(t)=0, T_{\mathrm{c} 1}(t)=T_{\mathrm{e}}(t)$。
c. 同步阶段:控制发动机转速与输入轴转速同步[14],此过程中,$\dot{\omega}_{\mathrm{e}}(t)>0, T_{\mathrm{c} 1}(t)<T_{\mathrm{e}}(t)$。
在提速阶段,用离合器1扭矩来控制发动机转速。发动机的动力主要用于提升发动机转速,使其尽快上升至较高水平,目的是提升发动机扭矩;在稳速阶段,离合器1扭矩与发动机扭矩相等,发动机的动力全部用于驱动车辆,提升车速;当输入轴转速接近发动机转速时,进入同步阶段,此阶段主要控制离合器扭矩使发动机转速与输入轴转速逐渐同步[15-17]
在起步过程中,离合器的扭矩会随着发动机扭矩逐渐升高而增加。当 T c 1 T f时,发动机无法驱动车辆,整车处于静止状态,此时,输入轴转速为0,滑摩功最大且全部转化为热能,部分累积导致离合器温升。结合式(1)和式(4),离合器1的滑摩功为:
W c 1 t = T c 1 t × ω e t 9.55 = T e t × ω e ( t ) 9.55 = P e
式中:Pe为发动机功率。
因此,当发动机驱动力无法克服车辆阻力时,发动机做功完全转化为热能,即为无用功。
相较于单离合起步,双离合起步是由发动机中2个离合器同时提供动力。
a. 提速阶段:D1挡起步过程中,发动机扭矩逐渐上升。当发动机扭矩无法克服阻力矩时,D2挡承担发动机的无用功。当发动机扭矩上升至足够大,再使用D1挡来驱动。
b. 稳速阶段:进行双离合起步控制, ω ˙ e t = 0,发动机扭矩完全分配给2个离合器, T e t = T c 1 t + T c 2 t,此时,双离合起步的牵引力为 F t = T c 1 t i 1 + T c 2 t i 2 η r。由于D2挡的i2<i1,双离合起步轮端的牵引力小于D1挡单离合起步。
单离合起步过程中,随着发动机扭矩逐渐增大,存在一个扭矩点,使用D1挡恰好驱动车辆,此时若使用双离合起步,无法驱动车辆。需要预估这个特殊点,使用D1挡起步 F m a x t = F f,最大牵引力为 F m a x t = T e t i 1 η r
因此,为了简化控制,仅在稳速阶段进行双离合起步控制,控制过程如图3所示,各阶段控制为:
a. 提速阶段:控制离合器1扭矩使发动机转速达到目标转速,与单离合起步相同。
b. 稳速阶段:开始时,计算 F m a x t F f,离合器1的扭矩撤回,扭矩交换主要通过离合器2支撑发动机扭矩;当 F m a x t F f,离合器2扭矩完全撤回,再扭矩交换由离合器1来输出。
c. 同步阶段:由离合器1同步,与单离合起步相同。
因此,依照扭矩分配理解双离合起步:在稳速阶段,发动机的扭矩同时分配给D1挡离合器和D2挡离合器,用于驱动车辆。由于发动机扭矩较小不能驱动车辆,发动机扭矩主要分配给D2挡离合器。随着发动机扭矩上升超过阈值时,最大牵引力克服阻力,D1、D2挡交换驱动,D2挡离合器扭矩减小,D1挡离合器扭矩提升,完成扭矩交换。奇偶离合器扭矩共进行2次扭矩交换。
依照能量分配理解双离合起步:整个过程产生的能量由D1挡离合器和D2挡离合器共同承担,当发动机扭矩较小而无法驱动车辆时,先由D2挡离合器来承担无用功;当发动机扭矩逐渐增大且能够驱动车辆时,再交换D1挡离合器,完成2个离合器的分时复用。
在双离合起步中,由于离合器频繁交替工作,其控制过程复杂,精度要求较高。为了解决DCT过热问题,缩小工况验证范围,因此,双离合起步的策略仅在稳速阶段变更,且在30%以上的坡道和堵转(Curbstone)特殊工况下激活,相应的控制策略流程如图4所示。
DCT控制软件通过控制器局域网(Controller Area Network,CAN)的车身电子稳定系统(Electronic Stability Program,ESP)提供的纵向加速度识别坡度。鉴于ESP使用三向加速度传感器,当车辆在坡道上静止时,纵向加速度不为0,可根据纵向加速度得到相应的坡度值。车辆静止在30%的坡道时,实测加速度如图5所示。
假设采集的纵向加速度为x,当前坡度为 α = a r c s i n x g,该坡道上静止阻力 F f = f + s i n α m g = f m g + x m。当 F m a x t> F f时,双离合器更换为单挡离合器进行驱动。
Curbstone工况指车辆因顶住障碍物或卡在深坑中,即使驾驶员踩全油门,仍未能脱困。该工况识别需满足以下条件:
a. 仅在4驱模式下监测。
b. 油门踏板开度高于设定阈值。
c. 制动压力低于设定阈值。
d. 发动机扭矩高于设定阈值,且一段时间内车速低于设定阈值。
由于Curbstone工况下,无法准确计算阻力矩,所以在实际应用中,整车应根据具体的脱困性能技术指标(如需翻越18 cm固定石砖),实际测量阻力,再与最大牵引力 F m a x t对比。
针对控制过程中一些关键参数进行重点说明。
a. 发动机目标转速。在稳速阶段,滑摩能量为: W c t = T e t × ω e t - ω n t / 9.55
由于起步为动态过程,发动机扭矩 T e t逐渐增大,特别针对废气涡轮增压的发动机来说,转速越高,单位时间循环的次数越多,增压能力更强,发动机扭矩上升更快,起步所用的时间更短。
但更高的发动机转速带来更高的滑摩能量,离合器片更容易过热,两种因素共同作用下,需要尝试设置不同的目标转速以达到最佳的起步效果。
b. 离合器1目标扭矩的设定。为了防止离合器2先过热,在双离合起步过程中离合器1的扭矩也不会降到0,而是保持较小的目标扭矩。根据硬件结构的分析,两个离合器的冷却能力不同,离合器1目标扭矩的设置标准需保证两个离合器温升基本一致。
c. F f的设定。 F f决定了扭矩由离合器2交换回离合器1的时刻。如果 F f设置值过小,当切回离合器1时不能保证爬坡的动力性,设置值过大会延长不必要的滑摩时间,一般设置在理论值的基础上增加一定的冗余。
本文控制策略使用Simulink编写,并集成到自动变速器控制单元(Transmission Control Unit,TCU)中进行实车测试。其中,利用电子控制单元校准应用平台INCA(Integrated Calibration and Application Platform)采集整车信号,并通过专用设备ES582连接端口同时采集。
CAN接口采集的信号主要包括ESP的纵向加速度信号、发动机管理系统(Engine Management System,EMS)中发动机真实扭矩、发动机转速和油门开度;TCU内部控制数据主要包括离合器(1和2)的模型温度、加载扭矩、实际压力、TCU控制起步目标转速、输入轴转速和挡位信号等。整车测试参数如表1所示。
在35%坡道满载原地坡起、车轮顶住18 cm高的固定石砖2种工况下,分别进行单离合、双离合起步测试。结果表明,2种工况下,单离合起步均失败,而双离合起步均能够顺利完成,且离合器未发生超温警报。鉴于2种工况数据相近,所以仅分析35%坡道起步的数据,结果如图6所示。
图6可知,发动机的目标转速越高,扭矩上升越快,但离合器滑差越大。为了避免离合器滑差过大导致离合器超温,经过标定调试,实测发动机目标转速控制在2 100 r/min时,离合器温度达到最低;双离合起步时,发动机转速基本能够跟随目标控制转速,控制精度与单离合起步相近;离合器扭矩经过2次扭矩交换,与前文设计相符;双离合起步时,离合器1扭矩交换到离合器2后,离合器1保持最小扭矩65 N·m,防止离合器2过热,同时避免离合器1的温升过快。由于 F f随坡道变化,所以35%坡道中 F f阈值应设置为13 200 N,保证发动机动力的连续性。
相同工况下,对比单离合和双离合起步,结果如图7所示。图7a中,在相同起步滑差条件下,单离合起步的离合器1扭矩远大于双离合起步时离合器1扭矩。图7b中,单离合起步时间为2.5 s,离合器1温度超过300 ℃后断开,导致起步失败;而双离合在4 s内完成起步,离合器1最高温度为272 ℃,且温升速率远低于单离合起步;离合器2最高温度为262 ℃,与离合器1基本一致,爬坡性能明显提升。图7c中,单离合起步离合器1的最大滑摩功率为65 kW,而双离合起步离合器1的最大滑摩功率为38 kW,离合器2达到56 kW。由于离合器2的散热性较高,因此,相较于单离合起步,双离合起步离合器片的温升更慢。
在实际工程中,通过加速度传感器信号的线性度和波动反映驾驶水平[18],评价标准为滤波后振幅不超过0.4 m/s2图7d中,单离合起步加速度加速响应较好,而双离合起步加速度线性更佳,平顺性更好,二者各有优势,均能满足工程开发目标。
为了验证双离合起步的可靠性,多次爬坡测试结果如表2所示,当基础油温超过90 ℃,整车满载经过6次连续爬坡测试,离合器温度均未超过300 ℃限值。
因此,在35%坡道满载原地坡起、车轮顶住18 cm高的固定石砖全油门起步2种极限工况下,单离合起步均未能完成,双离合起步均可顺利起步,改善了车辆的爬坡和脱困性能,对离合器的温度控制更佳,鲁棒性更好,但其急加速性能低于单离合起步。结果表明:可根据不同工况选择起步策略,单离合起步控制策略适用于动力加速工况,而双离合起步适用于爬坡脱困工况。
经过极限测试,当坡道达到40%或台阶超过22 cm时,双离合未能完成原地起步,已达到硬件的使用极限。
本文详细阐述了双离合变速器起步方法,经实车测试证明了该方案的有效性,在工程上具有一定的借鉴意义。双离合起步需要综合考虑工况与硬件的使用,对于其他车型的改善还需进一步深入研究。
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doi: 10.19620/j.cnki.1000-3703.20231062
  • 首发时间:2025-11-18
  • 出版时间:2025-03-24
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
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