Vertical Dynamic Test Rig for Integration in a Realtime Vehicle Simulation Model. Apply & Innovate 2016 Prof. Dr. Marcus Jautze

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1 Vertical Dynamic Test Rig for Integration in a Realtime Vehicle Simulation Model Apply & Innovate 2016 Prof. Dr. Marcus Jautze

Metropolitan Region Foundation in 1978 Munich Total: 5480

032 19% Computer Science 774 14% Business Administration 1.

industrial engineering Mechanical Engineering Interdisciplinary

2 Short Overview. University of applied sciences Landshut Landshut Near Munich Metropolitan Region Foundation in 1978 Munich Total: 5480 Students in WS15/16 Faculties: Mechanical Engineering % Computer Science % Business Administration % Business Administration Computer Science Electrical and industrial engineering Mechanical Engineering Interdisciplinary studies Electrical and Industrial Engineering % Prof. Dr. M. Jautze, Hochschule Landshut 1 Social Work % WS14/15

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

4 Overview of controlled vertical dynamic systems. Functional Aspects Hight Control Body Movement Dynamic Tire Load Comfort / Driving Safety / Energy Consumption Comfort Driving Safety Prof. Dr. M. Jautze, University ofapplied Sciences Landshut 3

Damper, Full Active Systems Dynamic Tire Load Variable Damper, Full Active Systems

5 Overview of controlled vertical dynamic systems. Functional Aspects Systems Hight Control Levelling Systems Body Movement Variable Damper, Full Active Systems Dynamic Tire Load Variable Damper, Full Active Systems Comfort / Driving Safety / Energy Consumption Comfort Driving Safety Prof. Dr. M. Jautze, University ofapplied Sciences Landshut 4

6 Why is a HIL test bench for vertical dynamics needed? Quarter car model Coil spring Stiffness of the tire body mass unsprung mass z b Stiffness of the top mount (Variable) damper or actuator z a Damping of the tire Control strategy: Double skyhook damping F act k sky, b zb k sky, a v t t z a P dyn z r t Prof. Dr. M. Jautze, University ofapplied Sciences Landshut 5

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

8 HIL Test Rig: Concept. HIL User.DampsFR Car.DampFR.Frc_ext RoadBox 4U ACDC F19P Core 2, Duo Single Board Computer M36N-01 - Analog Inputs M62N - Analog Outputs Vertical Dynamic Test Rig Machine Frame Schenk PC400N Inova EU3000-RTC Hydropulse Cylinder 50 kn Cylinder Travel 250 mm Prof. Dr. M. Jautze, Hochschule Landshut 7

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

10 Kraft in [N] Kraft in [N] Kraft in [N] Hydropulse Test Rig: Component Testing. Soft Damper Characteristic Kraft-Weg-Diagramm Dämpfertest mit 0 A Bestromung, Geschwindigkeiten: 1 0, VDA-Testing 0,5 0, , , , Kraft-Weg-Diagramm Dämpfertest mit 0,9 20 A Bestromung 25-0, , , Datenreihen1 Middle-0, Damper Characteristic -0, , ,5 1,5-0, , , , , , , ,5 Component Testing -1,5 0, Weg in [mm] , , , , ,5 Datenreihen1-0, Kraft-Weg-Diagramm Dämpfertest mit 1,8 A Bestromung , Hard Damper Characteristic -1, ,5 2, , ,5 2-2 Weg in [mm] -1, , , ,5 1, , , ,5 0, Datenreihen ,5-0, , , ,5-1, , , , ,5 Weg in [mm] Prof. Dr. M. Jautze, Hochschule Landshut 9

11 Hydropulse Test Rig: Component Testing. VDA Test Dynamic behavior Real Part Simulation Model Validated Simulation Model (Matlab Simulink) for integration in CarMaker Prof. Dr. M. Jautze, Hochschule Landshut 10

gravity Measurement System: dspace micro autobox Masterthesis: T.

12 Realtime Vehicle Simulation Model: Test Equipment. Test car: BMW 730d Additional sensors: Acceleration sensors, height sensors and sensor cluster in the center of gravity Measurement System: dspace micro autobox Masterthesis: T. Aman, Konzipierung und Validierung eines fahrdynamischen Messsystems durch Referenzmessung als Basis für ein vertikaldynamisches Regelsystem und Aufbau eines Simulationsmodelles, Prof. Dr. M. Jautze, Hochschule Landshut 11

13 Realtime Vehicle Simulation Model: Validation (1). Measurement with real car Comparision of relevant values Good correlation. Simulation with CarMaker Prof. Dr. M. Jautze, Hochschule Landshut 12

Beam left and right side Realtime Vehicle Simulation Model: Validation (2). Wheel travel FR Vertical acceleration unsprung mass FR Masterthesis: H.

14 Beam left and right side Realtime Vehicle Simulation Model: Validation (2). Wheel travel FR Vertical acceleration unsprung mass FR Masterthesis: H. Hornberger, Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem, Prof. Dr. M. Jautze, Hochschule Landshut 13

Beam left and right side Realtime Vehicle Simulation Model: Validation (3). Wheel travel RR Vertical acceleration unsprung mass RR Masterthesis: H.

15 Beam left and right side Realtime Vehicle Simulation Model: Validation (3). Wheel travel RR Vertical acceleration unsprung mass RR Masterthesis: H. Hornberger, Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem, Prof. Dr. M. Jautze, Hochschule Landshut 14

Beam left and right side Realtime Vehicle Simulation Model: Validation (4). Vertical acceleration in center of gravity Pitch-Rate Masterthesis: H.

16 Beam left and right side Realtime Vehicle Simulation Model: Validation (4). Vertical acceleration in center of gravity Pitch-Rate Masterthesis: H. Hornberger, Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem, Prof. Dr. M. Jautze, Hochschule Landshut 15

17 Beam only right side Realtime Vehicle Simulation Model: Validation (5). Vertical acceleration in center of gravity Roll-Rate Masterthesis: H. Hornberger, Konzipierung, Umsetzung und Validierung der Funktionslogik eines vertikaldynamischen Fahrwerksystem, Prof. Dr. M. Jautze, Hochschule Landshut 16

18 HIL Test Rig: Beam, single sided (right) Prof. Dr. M. Jautze, Hochschule Landshut 17

19 HIL Test Rig: Beam, single sided (right) Prof. Dr. M. Jautze, Hochschule Landshut 18

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

21 Hochschule Landshut Prof. Dr. M. Jautze Am Lurzenhof 1 D Landshut Tel.: marcus.jautze@haw-landshut.de

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