vertical dynamic test rig realtime vehicle simulation model · pdf filedynamic tire load...

Apply & Innovate 2016

Prof. Dr. Marcus Jautze

20.09.2016

Vertical Dynamic Test Rig

for Integration in a

Realtime Vehicle

Simulation Model

Short Overview.

University of applied sciences

Landshut

Near Munich Metropolitan Region

Foundation in 1978

Total: 5480 Students in WS15/16

Faculties:

Business Administration

Computer Science

Electrical and industrial engineering

Mechanical Engineering

Interdisciplinary studies

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 1

Landshut

Munich

Business Administration

1.14121%

Social Work85516%

Electrical and Industrial

Engineering1.61630%

Mechanical Engineering

1.03219%

Computer Science77414%

WS14/15

Why vertical dynamics will have a revival.

The increasing automatisation of driving gives all the passengers the

posibility to relax or work in the car

Sensibility concerning primary and secondary ride comfort will increase

Vertical dynamics will even get more important

Thesis:

„For best benefit of fully autonomous driving controlled vertical

dynamic systems will be necessary“

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 2

Overview of controlled vertical dynamic systems.

20.09.2016 Prof. Dr. M. Jautze, University of Applied Sciences Landshut 3

Functional Aspects

Hight Control Body Movement Dynamic Tire Load

Comfort Driving SafetyComfort /

Driving Safety /

Energy

Consumption

Overview of controlled vertical dynamic systems.

20.09.2016 Prof. Dr. M. Jautze, University of Applied Sciences Landshut 4

Functional Aspects

Systems

Hight Control

Levelling Systems

Body Movement

Variable Damper,

Full Active Systems

Dynamic Tire Load

Variable Damper,

Full Active Systems

Comfort Driving SafetyComfort /

Driving Safety /

Energy

Consumption

Quarter car model

body mass

Coil spring

zat

zbt

v

Pdyn

zrt

unsprung mass

(Variable) damper or

actuator

Stiffness

of the tire

Damping of the tire

Stiffness of the top mount

Control strategy:

Double skyhook damping

aaskybbskyact zkzkF ,,

520.09.2016 Prof. Dr. M. Jautze, University of Applied Sciences Landshut

Why is a HIL test bench for vertical dynamics needed ?

Why is a HIL test bench for vertical dynamics needed ?

Damper, spring and top mount have a significant influence on comfort

Accurate Modeling of these components is quite difficult

In durability tests with realtime road profiles the component behavior

has a massive effect (‘feedback’)

Solution:

Combination of realtime simulation model with vertical dynamic test rig

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 6

HIL Test Rig: Concept.

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 7

RoadBox 4U ACDC

• F19P Core 2,

Duo Single Board Computer

• M36N-01 - Analog Inputs

• M62N - Analog Outputs

HIL

Vertical Dynamic Test Rig

• Machine Frame Schenk

PC400N

• Inova EU3000-RTC

• Hydropulse Cylinder 50 kN

• Cylinder Travel 250 mm

Car.DampFR.Frc_ext

User.DampsFR

HIL Test Rig: Concept – Variants of test samples.

Damper with rebound spring

Damper with rebound, bound spring, spring coil or air spring including

top mount

Depending on concept: Airspring Stand Alone

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 8

Hydropulse Test Rig: Component Testing.

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 9

-0,297433398

-0,19217452

-0,334933813

-0,117706354

-0,417868783

0,000328554

-0,591515936

0,06939029

-0,674734314

0,139384916

-0,762331814

0,228198276

-1,206926246

0,705985906

-1,5

-1

-0,5

0

0,5

1

-25 -20 -15 -10 -5 0 5 10 15 20 25

Kra

ft in

[N

]

Weg in [mm]

Kraft-Weg-Diagramm Dämpfertest mit 0 A Bestromung, Geschwindigkeiten:

Datenreihen1

-0,31965612

-0,172182606

-0,406601707

-0,038619429

-0,725247438

0,35784321

-1,111866531

0,769180004

-1,254493845

1,024159055

-1,371042344

1,17047145

-1,754079272

1,636333949

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-25 -20 -15 -10 -5 0 5 10 15 20 25

Kra

ft in

[N

]

Weg in [mm]

Kraft-Weg-Diagramm Dämpfertest mit 0,9 A Bestromung

Datenreihen1

-0,527320458

0,525693683

-0,865353527

1,015354335

-1,070076005

1,180005879

-1,336204225

1,41163516

-1,485305828

1,598800689

-1,619214191

1,757732544

-2,174685891

2,364837184

-2,5

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

2,5

3

-25 -20 -15 -10 -5 0 5 10 15 20 25

Kra

ft in

[N

]

Weg in [mm]

Kraft-Weg-Diagramm Dämpfertest mit 1,8 A Bestromung

Datenreihen1

Component Testing

Soft Damper Characteristic

Middle Damper Characteristic

Hard Damper Characteristic

„VDA-Testing“

Hydropulse Test Rig: Component Testing.

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 10

• VDA Test

• Dynamic behavior

„Real Part“ „Simulation Model“

Validated Simulation Model (Matlab Simulink)

for integration in CarMaker

Realtime Vehicle Simulation Model: Test Equipment.

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 11

Test car:

BMW 730d

Additional sensors:

Acceleration sensors, height sensors and sensor cluster

in the center of gravity

Measurement System:

dSpace micro autoboxMasterthesis: T. Aman, „Konzipierung und Validierung eines fahrdynamischen Messsystems durch Referenzmessung als Basis für ein

vertikaldynamisches Regelsystem und Aufbau eines Simulationsmodelles “, 2015.

Realtime Vehicle Simulation Model: Validation (1).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 12

Measurement with real car

Simulation with CarMaker

Comparision of

relevant values

Good correlation.

Realtime Vehicle Simulation Model: Validation (2).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 13

Masterthesis: H. Hornberger, „Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem“, 2016.

Beam

left

and

righ

tsid

e

Wheel travel FR

Vertical acceleration unsprung mass FR

Realtime Vehicle Simulation Model: Validation (3).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 14

Masterthesis: H. Hornberger, „Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem“, 2016.

Beam

left

and

righ

tsid

e

Wheel travel RR

Vertical acceleration unsprung mass RR

Realtime Vehicle Simulation Model: Validation (4).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 15

Masterthesis: H. Hornberger, „Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem“, 2016.

Beam

left

and

righ

tsid

e

Vertical acceleration in center of gravity

Pitch-Rate

Realtime Vehicle Simulation Model: Validation (5).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 16

Masterthesis: H. Hornberger, „Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem“, 2016.

Beam

only

right

sid

e

Vertical acceleration in center of gravity

Roll-Rate

HIL Test Rig: Beam, single sided (right).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 17

HIL Test Rig: Beam, single sided (right).

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 18

Vertical Dynamic Test Rig for Integration in a Realtime

Vehicle Simulation Model.

Conclusion.

(Advanced) Vertical Dynamics will get a revival.

Realised Concept of a vertical dynamics test rig, suitable for HIL

application and component measurement.

Good accuracy of the HIL vehicle model and measurements with

the real car concerning vertical dynamic (damper with fixed damping

curve, obstacle beam).

HIL can be used for functional development and endurance

strength.

20.09.2016 Prof. Dr. M. Jautze, Hochschule Landshut 19

Hochschule Landshut

Prof. Dr. M. Jautze

Am Lurzenhof 1 ∙ D-84036 Landshut

Tel.: +49 871 506-267

marcus.jautze@haw-landshut.de

www.haw-landshut.de