mastering unexpected situations safely · simplified 7 dof stand-alone model air spring model...
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Mastering Unexpected Situations Safely
Chassis & Safety | Vehicle Dynamics
Chassis & Safety | Vehicle Dynamics
CarMaker @ Electronic Suspension Systems IPG Apply & Innovate 2016/09/20 Dipl.-Ing. Stefan Mölle
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Agenda
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ESS: Organization and products 1
Model Implementation, Parameter Identification and Validation 2
CarMaker@ESS: Fields of Application 3
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Electronic Suspension Systems within the Automotive Group
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Division Chassis & Safety
Automotive Group
Division Interior Division Powertrain
Vehicle Dynamics Hydraulic Brake
Systems
Advanced Driver
Assistance Systems
Passive Safety &
Sensorics
Electronic Suspension
Systems Chassis Electronics Electronic Brake Systems
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Electronic Suspension Systems Footprint
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Headquarters (232 people, 16/09/01)
Production
Engineering
Joint Venture
Headquarters Hanover
Gifhorn
Sibiu, Romania Yokohama, Japan Auburn Hills
Morganton
Seoul, Korea
Service Truck
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Business Unit Vehicle Dynamics (VED) ESS is a Global Player! Customer overview
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Electronic Suspension Systems Product Portfolio
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Chassis Control Unit
(incl. acc. Sensor)
Solenoid
valve block
Reservoir
Strut with guided air spring,
switchable volume,
comfort bellow
4 level sensors
(for height control)
2-3 body
acceleration sensors
Free standing
guided air spring and
switchable volume
Compressor &
Dryer
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Electronic Suspension Systems Air Suspension Benefits
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Lowering vehicle’s CoG
Lowered spring rate
Reduction of Body Motion
~constant Eigenfrequency
Reduction of unsprung mass
Dynamics Comfort Safety levelling Emissions Fuel
Dynamics & Comfort Safety ECO Load independent ride height
Full range of dynamic spring travel
available
Optimal tire traction
Improved terrain ability (Variable
ground clearance)
Load detection
Reduction of fuel
consumption & CO2
emissions
(Aero Mode on highways)
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Electronic Suspension Systems Air Suspension Benefits
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Switching spring volume: adapting base stiffness
Realization of up to 4 natural air springs in one
(multi-chamber design)
Taking advantage of air
damping effects
Optimal Piston Contour
Wide tuning range for optimal progression /
degression
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Electronic Suspension Systems Requirements for ESS Simulation Environment
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Interface for Air Spring System Model
One SW Environment for X-iL
Full vehicle simulation, realtime and faster
Possibility to enhance the simulation environment and .exe application
Model Exchange with Customers, securing intell.-property
Parameter studies, tests triggered by automated routine
Good tool handling: realization of complex testruns, visual feedback
+
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Electronic Suspension Systems
Implementation via Simulink Interface
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Used Interface:
“External
Suspension Forces”
Co-Simulation with Simulink or
integration
into CarMaker.exe via wrapper from CM
in-house developed Matlab/Simulink
component and (sub-)system Library
used high Modularity
Tube &
connector
Models
Reservoir
Model
Valve &
Compressor
Models
Air Spring/ Damper
Models
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Electronic Suspension Systems Identification & Data Acquisition for Validation…
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VEHICLE
SYSTEM
COMPONENT
SUBCOMPONENT
MODULE
Subst. kinematics
bench
Kinematics rig
4-Poster test rig
Road test
e.g. Contidrom
Module test rig
Component test rig
+ Customer
Data
Variable chassis
frame
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Electronic Suspension Systems …Validation Using CarMaker
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Model of 4-poster
test rig inside
CarMaker
Open loop
Maneuvers with
Carmaker
Simplified 7 DoF
stand-alone model
Air Spring Model Matlab/
Simulink only
SYSTEM
COMPONENT
SUBCOMPONENT
MODULE
VEHICLE
Open loop road validation
Input:
“Speed Profile Mode” and measured data as
input file for open loop road validation
Stand-Still: levelling performance,
load distribution
On module level, only
Matlab/Simulink
serves as Simulation
Platform
Enhanced simulation environment:
Modules for excitating wheel /4Poster)
And chassis (kinematics test bench)
Input: Measured input signals (stroke)
Model of kinematics
test Bench inside
CarMaker
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Electronic Suspension Systems Simulation ready for Application
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Base Set of Parameters
For each level:
Validity check of
data set
Loop identification if
necessary
System
Component
Subcomponent
Module
Weight distribution; CoG
matching Tire model (!)
Base geometry (wheel base, width)
Steering definition, Brake & PWT
Air spring & buffer parameters
Kinematics (camber/toe and leverage
spring to wheel)
Damper characteristics
Parasitic & Stabilizer stiffness
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Electronic Suspension Systems Fields of Application: “Base studies”
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RTI = Ramp Travel Index
RTI = distance
travelled on ramp /
wheelbase x 1000
(Ramp angle 20°)
Switching logic
Additional
volumes
switching
strategy
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pneumatic
air spring
model*
CarMaker vehicle simulation
with Customer vehicle data
set + tire model
Air spring+vehicle model (CM)
Pneumatic Layout*
Valves, reservoir,
tubes, …
Compressor
model*
Air supply model
Electronic Suspension Systems Fields of Application: HiL
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*for customer: Provided as .mex or .fmu
Air spring pressure
Pre-/Counter-
pressure
Chassis-Heights, Air spring + Reservoir pressure, air mass, Restbus (vehicle speed,…)
air mass-flow
Pressure (force)
Air mass flow
displacement,
forces
Actuator signals
(Valve+Compr.)
Carmaker X-
Pack4
Online
manipulation
(script, DVA, … )
real HW
ctrl. model
Level
Ctrl.
(LC)*
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Module
from
Application
Software
(ASW)
Electronic Suspension Systems Fields of Application: Function Test
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Actuator
signals
e.g.
detection
signal
Height signals, accelerations, …
Simplified
controller /
Manipulator
Monitor
Example: testing a curve detection function
CarMaker-
Test-Manager,
Maneuver-catalogue
& Python (planned)
Ext.
Forces
Autom. Testrun + Evaluation
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for your attention! Thank you
9 August 2016
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