Mechanical Simulation

Advanced Vehicle Dynamics Solutionswww.carsim.com

Introduction

Mechanical Simulation Corporation develops and distributes vehicle dynamics software tools for simulating the way cars and trucks respond to driver controls under different environmental conditions. The company markets many variants of the following:

CarSim is a software tool for simulating and analyzing the way cars, light trucks and SUVs (with or without trailers) respond to steering, braking and acceleration inputs.

TruckSim extends the concept to cover heavy-duty vehicles with dual wheels, asymmetric steering systems, multiple axles and single or multiple trailers.

BikeSim is a software tool for simulating and analyzing the way motorcycles and scooters repond to steering, braking and acceleration inputs.

CarSim,TruckSim and BikeSim provide the most accurate and realistic predictions that are possible, in a form that can be easily used by most engineers and technical staff. Each package includes our Simulation Graphical User Interface (SGUI), graphical database manager, plotter, animator, on-line help and solver programs with and without a built-in Simulink interface.

Mechanical Simulation supplies the same vehicle math models for real-time (RT) solutions used in many applications including, hardware-in-the-loop (HIL) and high-fidelity driving simulators.

We also provide related services such as custom vehicle models and shapes, training, user conferences, web seminars and engineering consulting services.

Mechanical Simulation Corporation was founded in 1996 to continue development of analysis and simulation technology originally started over 30 years ago. The company has significantly advanced the state-of-the-art in simulation of vehicle dynamics and has extended the capabilities of the models into many more vehicle types.

Vehicle DynamicsStarting in the late 1960's, the University of Michigan Transportation Research Institute (UMTRI) was a pioneer in developing knowledge about vehicle dynamic behavior and modeling. Knowledge about vehicle dynamics came from three activities:

The early research projects included many experimental tests, where modeling assumptions were validated by direct comparison with test data.

The modeling concepts and assumptions developed at UMTRI form the basis for the CarSim, TruckSim and BikeSim models. In addition to emphasizing the correctness of the math, we apply the research results to include vehicle properties that are both significant and measurable.

AutoSim and our Math ModelsIn the late 1980's, one of the UMTRI scientists (Dr. Michael Sayers, a founder of Mechanical Simulation) developed the world's most advanced automated code generation capability for vehicles and other multibody systems. The code generator – AutoSim – was used at UMTRI to create new vehicle models and is now used by Mechanical Simulation for all multibody modeling. The error-free code generated by AutoSim can support highly detailed math models with unparalleled computational efficiency.

AutoSim technology supports several unique characteristics of our software development:

History

We can create new models and extend existing models quickly.

Our models run fast, as required to support real-time and optimization applications.

We can support new interface and operating-system requirements rapidly by updating AutoSim to generate new code.

Experimental testing and analysis of results.

Development of models and algorithms which duplicate the observed behavior.

Special laboratory tests and measurements to obtain the vehicle and tire properties needed to complete simulation and analysis models.

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CarSim 6 is a software tool used globally by OEMs, suppliers, racing teams, universities and students to simulate the dynamic behavior of four-and three-wheeled vehicles including cars, race cars, light trucks, light utility vehicles and SUVs.

CarSim 6 Trailer is an extension used for simulating the dynamic behavior of vehicles including cars, light trucks, light utility vehicles and SUVs towing one-and two-axle trailers.

CarSim 6 and CarSim 6 Trailer are extensible and compatible with a wide range of software products and most real-time (RT), hardware-in-the-loop (HIL) and software-in-the-loop (SIL) systems.

CarSim 6 is used in all types of vehicle simulators, from tabletop systems to sophisticated moving base motion platforms. These applications allow researchers, engineers and developers to study a very wide range of subjects from driver behavior and accident avoidance, to vehicle calibration and tuning using simulators equipped with real world vehicle dynamics in a controlled, repeatable laboratory environment.

Products

CarSim

TruckSim

BikeSim

TruckSim 6 is a software tool for simulating and analyzing the dynamic behavior of trucks, buses and articulated vehicles in response to steering, braking and acceleration inputs.

TruckSim 6 uses the same technology as CarSim 6, but involves models with dual tires, asymmetric steering and arbitrary combinations of trailers and axles.

BikeSim 1 is a software tool for simulating and analyzing the dynamic behavior of motorcycles and scooters.

BikeSim uses the same technology as CarSim 6 with the modifications necessary to model motorcycles and scooters. Driver/Rider behavior during cornering, acceleration and braking is also modeled in BikeSim.

Mechanical Simulation produces and distributes software tools for simulating and analyzing the dynamic behavior of motor vehicles in response to steering, braking, and acceleration inputs. These software tools are extensively validated and correlated to real world results as measured and observed by many automotive OEMs around the world.

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Reduce time and cost using accurate, repeatable and correlated simulations of Cars, Trucks and Motorcycles

CarSimCarSim 6 is a software tool specifically designed and developed to simulate the dynamic vehicle behavior of cars, light trucks and utility vehicles. CarSim animates simulated tests and generates over 500 output variables that can be plotted and analyzed with other software such as MATLAB , Excel , design-of-experiments (DOE) and optimization tools. The software has extensive features, a few areillustrated below:

Analysis of “What If?” ScenariosCarSim 6 is used by engineers in design, development, testing and planning. If you make decisions that involve vehicle dynamics, then CarSim helps make better decisions quicker. CarSim is used for applications ranging from initial proof-of-concept, through productdevelopment, to advanced analysis of existing vehicles.

Easy to UseA modern graphical user interface controls all aspects of the software. Users run a simulated test by clicking the “Run Math Model” button. Results of the simulated test are observed by clicking the “Animate” button. Engineering plots are viewed by clicking the “Plot” button. You will be making new runs and viewing results within an hour of installing CarSim 6. All properties that you set or adjust are represented in the graphical interface. Over 140 graphic screens are organized to allow easy access to all properties of the vehicle, control inputs, road geometry, plot settings and animation settings. The CarSim 6 database minimizes the time needed to build a vehicle description and set up run conditions. The database comes with an extensive array of examples and allows you to set up libraries of components, vehicles and test results. This feature allows users to rapidly go back and forth between different runs to compare results and make changes. Overlay plots and animations quickly to identify the results of your changes.

The vehicle and its properties are defined by parameters and tables that are measurable and available from a variety of sources, including tests or suspension design software. CarSim 6 sets a new standard for minimizing the time needed to assemble a complete vehicle description.

Reporting and PresentationsCarSim 6 output plots and data are exportable and easily inserted into reports, Excel worksheets and PowerPoint presentations. Animations can also be exported to a wide variety of report software.

Force arrows indicate direction and relative magnitude.

Example CarSim 6 Simulation Graphical User Interface (SGUI).

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More than 500 different variables can be automatically plotted.

CarSim accurately predicts NHTSA “Fish-hook” results.

Built-in modules that come

with CarSim

MATLAB/Simulink S-function

plug-in Modules

Library files with extendible C

code for stand-alone EXE files

FastCarSim 6 combines a complete vehicle math model with high computational speed. Vehicle models run up to ten times faster than real time on a 3 GHz PC. Speed enables CarSim 6 to easily support real-time (RT) testing with hardware-in-the-loop (HIL) or software-in-the-loop (SIL). CarSim 6 supports real-time systems from Applied Dynamics International (ADI), A&D, dSPACE, ETAS, Opal-RT and many other RT suppliers. This speed also helps with software that requires many repetitions (optimization, design-of-experiments).

Accurate and ValidatedCarSim 6 is built on decades of research spentcharacterizing vehicles and reproducing their behavior with mathematical models. Validation testing continues as new features are added. Users from OEMs and suppliers consistently report close agreement between CarSim 6 predictions and actual test results.

Standard and ExtensibleCarSim 6 runs on ordinary Windows desktop and laptop PCs. CarSim also runs on computers used in real-time systems. The equations of motion in the math models are “well-behaved” and can be extended to work with custom models of controllers, instrumentation and subsystems. These models can be provided in three forms listed below:

Tires, suspensions, brakes and steering systems all use intuitive input screens.

Cost Effective, Stable, ReliableCarSim 6 includes everything needed to simulate vehicle tests and view the results. Mechanical Simulation uses advanced automated code generation to produce stable and reliable simulation programs much faster than is possible with traditional “hand-coded” software development.

Software Packages CarSim 6 features the database and graphical interface, motor-vehicle models, plotter, animator, spectrum analyzer and supporting utility programs.

CarSim 6 Trailer is an extension that features extra models and programs for the CarSim 6 motor vehicles towing single or tandem axle trailers.

CarSim 6 Source Code is available for most of the math model equations, for advanced projects such as driving simulators.

CarSim 6 RT (Real-Time) and CarSim 6 Trailer RT are available for a wide range of HIL system providers.

CarSim 6 for Simulators is available for complex motion base simulators.

Custom Versions of CarSim 6 and unique vehicle shapes can be created to match your requirements.

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Effects of stability control systems can be animated and plotted.

TruckSim 6 is a software tool for simulating and analyzing the dynamic behavior of medium to heavy trucks, buses and articulated vehicles. It operates just like CarSim with a few important differences.

Truck ModelsTrucks and buses use a different steering system than cars. They can also have dual tires, multiple axle configurations and a wide range of tractor-trailer combinations. TruckSim 6 includes 24 example trucks and buses with all of their key chassis components to cover most of the vehicles found around the world. Examples come from North America, Europe and Japan. Users can even request custom models at a reasonable price if needed.

ResultsTruckSim is built on decades of research in characterizing vehicles and reproducing their behavior with mathematical models.

Graphical DatabaseData screens are intuitive and serve as your primary interface to TruckSim. These contain all of the vehicle model parameters, driver and controls inputs and road surfaces. The data screens are part of an extensive database that maintains libraries of linked data sets.

TruckSim RT and Source versionsTruckSim 6 RT (Real-Time) extends TruckSim to work with HIL, SIL and Driving Simulator applications. This provides an extensible common modeling environment, making it easy to move component designs between Simulink early concept SIL simulations and later HIL testing. TruckSim 6 Source version includes the TruckSim software plus source code describing the equations in C (for the stand-alone EXE programs) and CMEX (for the DLL plug-in modules).

Driver view and steering input can be visually monitored.

TruckSim®

Worldwide truck and trailer

examples

Complete truck simulation

software

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BikeSim includes easy to understand data input screens.

BikeSim is a new software tool specifically designed to simulate the dynamic behavior of motorcycles and scooters. It analyzes the response to the rider's inputs – steering torque, brake, shift and throttle. Environmental inputs are included – aerodynamics, road geometry and friction. The motorcycle dynamics model is made using the same technology as CarSim and TruckSim.

Traditionally, motorcycle dynamics have been studied by universities and laboratories using pen and paper analysis and simple kinematics programs. BikeSim was created to meet the strong demand among motorcycle and scooter manufacturers and their suppliers for an easy to use, accurate simulation package.

Easy, Turn-Key SolutionsBikeSim includes the software configurations and SGUI found in CarSim and TruckSim. It allows users to easily setup the bike properties, roads and control inputs and quickly see the animations and graphical results. The bike and its properties are defined by parameters and tables that are measurable by tests or available from design software. Users run any simulated road test by just clicking a button. Our fast computational speed is completed in about 1/10 of real time. Many design variations could be tested and automatically optimized using DOE software.

Complete Bike ModelBikeSim is delivered with a complete bike model, which has 20 degrees-of-freedom (DOF). The suspension model (front fork and rear swing arm) and non-linear tire model calculate accurate bike dynamics. The model includes a brake system and powertrain that can be easily modified. The user can select either open loop turns or a closed loop path follower. Road generation tools allow users to create 3D roads such as banked curves, hills and race tracks with a range of simulated friction coefficients. Aerodynamic data inputs are also available. All of these capabilities are demonstrated in a series of test examples.

ExtensibleBikeSim runs on Windows desktop or laptop PCs. BikeSim can run with MATLAB/Simulink by providing an S-Function model for importing/exporting all key variables. Users can easily include controller and actuator blocks for ABS, TCS or any new type of sub-system. BikeSim is available in real-time systems to test HIL or SIL for ECU development.

Any road course or skid pad event can be run in BikeSim.

BikeSim®

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Your vehicle can be tested with actual racetrack data.

Develop Your InsightHundreds of outputs are calculated at each time step, so you can study trade-offs and develop deep insight into a vehicle’s performance. Racing teams can easily identify the contributions of suspension settings to aerodynamic gains, optimize gear ratio and brake settings, select springs, dampers and sway bar settings. Other uses include studying wedge and stagger, locking differentials and weight distribution effects. Make the improvements you need to get to the front and stay there.

Extend to Meet Any ChallengeCarSim models cover a vast range of vehicles and components “as is,” but you don’t need to stop there. You can easily extend the models for features like monoshock and third spring suspensions, or advanced electronic control systems. You can even simulate the performance of a 7-post rig, or use CarSim Real-Time to control dynamometers and other test systems.

Ideal for MotorsportsCarSim 6 software includes everything needed to develop open wheel or closed wheel cars for racing on road circuits and oval tracks. CarSim even includes example race tracks, vehicles, chassis components and development tests. Results are easy to understand.

Users can select from independent or solid axle suspensions, and may add any required amount of detail, including full aerodynamic maps, symmetric or asymmetric suspensions and any drivetrain. Race teams can easily create road courses or test surfaces and evaluate limitless combinations of chassis settings. Testing in CarSim eliminates the driver and weather variables, and the cost of travel, tires, engines, crew and all other track testing expenses. CarSim results have correlated with OEM proving ground tests for over 10 years.

Ideal at Any LevelWhether you need a low cost, self-contained analysis package to learn and understand the fundamentals; or a high-end, sophisticated tool to support your unique methods and real-time testing, CarSim is the best tool to help win races.

Extreme handling maneuvers can be safely tested in CarSim.

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Mini-Baja and Formula SAE events can be easily simulated using CarSim.

Academic

Classroom UseCarSim, TruckSim and BikeSim are being used at universities around the world to teach the fundamentals of vehicle dynamics. Since our software is easy to learn and use, students can solve real-life automotive chassis problems after a single class. CarSim is available as "CarSim in the Classroom." This is a program where any college or university can lease CarSim for classroom usage. Free training, online help, example homework problems and example vehicle data are included. This program is designed to support professors teaching vehicle dynamics, chassis development or electronic controls classes.

Academic Race Teams CarSim is now available in a special, low-cost program that gives student teams an edge in SAE competitions like "Formula" and "Mini Baja." Teams can use CarSim to design and develop their vehicles. CarSim can help in many competition areas to develop lap-time simulations, chassis development, tuning and the required presentations. Academic Research

CarSim, TruckSim and BikeSim are offered at a substantial discount for college and university researchers involved in academic projects. Over 50 universities in 10 countries are using our software for a wide variety of research programs.

Commercial University ResearchCarSim and TruckSim have also been used for government or commercially funded projects at colleges and universities around the world.

CarSim includes off-road testing examples.

CarSim for SAE student

competitions

Over 50 universities in 10

countries currently use our

software tools

CarSim in the Classroom

University research projects

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Animations and plots help Simulink designers “see” their results.

ExtensibleMATLAB/SimulinkCarSim, TruckSim and BikeSim allow users to apply external model vehicle dynamic control systems (i.e. ABS, TCS, ESC, 4WS, Yaw Control Differential) through MATLAB/Simulink. Additionally, the sub-components of any vehicle model (e.g. Driver, Powertrain, Spring/Damper) can be replaced with Simulink blocks, which can represent very sophisticated, complex external models. Multiple vehicle simulations can be shown using duplicate vehicle blocks running simultaneously.

Over 500 variables are available for importing and exporting with external software models and are easily specified in the SGUI. The Simulink model is also fully integrated into our software packages for animation and plotting. Mechanical engineers can use CarSim, TruckSim or BikeSim with Simulink running in the background, or controls engineers can stay in the Simulink design environment and see results ontheir screen.

Design of ExperimentsCarSim, TruckSim and BikeSim can interface with most of the design, development and analysis software used by engineers. CarSim users have interfaced with AMESim from Imagine Software to develop new stability controllers. Design-of-experiments for optimizing chassis systems and components may be done using HyperStudy , iSIGHT , OPTIMUS or any other DOE package. Since our products run much faster than real time, these optimization programs can be completed in record time. OEMs and Suppliers can greatly speed up their development process using other software tools with CarSim, TruckSim or BikeSim.

Optimizations using hundreds of test runs can be performed in hours with any DOE software.

S-Functions can run in parallel

Compatible with most

DOE/Optimization software

All software is fully extensible

Mechanical Simulation has

demonstrated compatibility

with over 25 software partners

around the world

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Reduce development time

Test earlier in the product

development process with...

Physical testing and simulated testing join in real-time when some of the system exists in hardware and some are simulated with math models.

HIL and SILFrom the simulation point of view, the ECU is hardware-in-the-loop (HIL). Simulation results depend on real-time interactions between the math model and the physical hardware. Hardware can also include brake or steering systems, suspension corners, or a complete vehicle-in-the-loop. Software-in-the-loop (SIL) is used to test simulated ECUs early in the design process before they are burned.

Join the Real-Time RevolutionWhen hardware and software are combined, the system can be tested earlier in the product development cycle. Many iterations can be tested rapidly and with greater control. Engineers can proceed from component models to the real thing, while using the advantages of a virtual vehicle to run more tests. New configurations that might not exist yet can be run under conditions that are dangerous or expensive in real-life testing.

Buying a Complete HIL System

Our Real-Time models are shipped ready to run with systems from our real-time partners Applied Dynamics International, A&D, dSPACE, ETAS, NationalInstruments, Opal-RT and many others. Real-Time tools are also used with custom systems involving target machines with the QNX and RT-Linux operating systems.

How It WorksCarSim, TruckSim and BikeSim models run on computers much faster than real time, meaning a simulation of a 30-second test is normally complete in less than 5 seconds. Our models support the MATLAB/Simulink block control interface. This not only gives compatibility with Simulink, but also provides a standard method for working with any real-time testing software that uses the same interface. To run in real time, the model is given measurements from the hardware. At the same time, the hardware is given calculated vehicle and road variables from the model. To obtain real-time operation, the software obtains calculations from the math model, waits for the clock to catch up, exchanges information with the hardware and then repeats at the next step.

A host computer with Windows runs the CarSim, TruckSim or BikeSim graphical database, animator, plotter and supporting software. A target computer with a real-time operating system runs the math models together with data acquisition software.

Real-Time

CarSim is used on the most advanced driving simulators.

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Main Office Europe Asia

Mechanical Simulation912 North Main Suite 210Ann Arbor, MI 48104USAPhone: 734-668-2930Fax: 734-668-2877info@carsim.comwww.carsim.com

add2 LimitedHawkesyard HallArmitageWS15 1PU StaffordshireUnited KingdomPhone: 44-1-889-574400Fax: 44-1-889 576779www.add2.co.uk

Virtual Mechanics Corporation1-40, Hagiyama-cho, Mizuho-ku Nagoya-shi, Aichi-ken 467-0011 JapanPhone: 81-052-853-7309Fax: 81-052-853-7261www.virtualmechanics.co.jp

MAGNUMBunsenstraBe 22D-64293 DarmstadtGermanyPhone: 49-6151-802-500Fax: 49-6151-802-600www.magnum.de

AMET S.r.l.Via San Luigi, 2010043 Orbassano (TO)ItalyPhone: 39-011-9007743Fax: 39-011-9007740www.amet.it

Shinho Systems Co., Ltd.B-702 Ssangyong IT Twin Tower 442-5 Sangdaewon-dong, Jungwon-gu, Seongnam-si, Gyeonggi-doKorea 462-723Phone: 82-31-608-0434Fax: 82-31- 608-0439www.shinho-systems.co.kr

TeraSoft Inc.15-1 Fl, 161 Sungteh RoadTaipei 110,Taiwan, R.O.C.Phone: 886-2-2346-5598Fax: 886-2-2346-5758www.terasoft.com.tw

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