Real Time Driving Dynamics Simulation in Heavy Commercial Vehicles

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1 Real Time Driving Dynamics Simulation in Heavy Commercial Vehicles Dr. Jan Fleischhacker Dr. Philipp Wagner Edin Topcagic Patrick Rund apply & innovate 2012 IPG Technology Conference Karlsruhe, < 1 >

2 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 2 >

3 Variety in Commercial Vehicle Suspension Heavy, medium and light trucks, off-highway, special-purpose vehicle City-bus, intercity-bus, coach Up to 5 axles, variety in configuration and wheel base Up to 3 steered axles (mechanically, hydraulic, electrically) Suspension: Leaf spring, air spring, coil spring, hydropneumatic Powertrain: Configurations (up to 8x8), gearboxes, diff. gear units, tires, retarders Wide range between empty and laden vehicle Variety in platforms (tractor, body, flatbed, tipper, swap body, tanker, mixer, fire truck, urban) < 3 >

4 Real Time Driving Dynamics Simulation Motivation Virtual development of varieties Reliable modeling of variants in simulation Real time capability Detailed consideration of components relevant for driving dynamics (here) IPG-TruckMaker benchmark < 4 >

5 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 5 >

6 Scope of Work TruckMaker as a real-time simulation environment Integration of sophisticated subsystem models (compare the MODELON presentation) Management of variants Integrative real-time capable vehicle Driver, road, environment Vehicle variants (truck / bus) Ridable basic vehicle Modules in different LOD* ZF AS-Tronic * Level of Detail < 6 >

7 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 7 >

8 SIMPACK MBS-Model Reference vehicle Vehicle data MAN TGX 4x2 BL Tractor Additional load on fifth wheel 10,5 t Front axle with leaf spring Rear axle with air spring and 4 point steering rod Model properties Modeling in SIMPACK Elastic parts: frame, axle parts, 4 point steering rod Steering controller Drive controller Tire model TMEasy < 8 >

9 SIMPACK MBS-Model Reference suspension Rear axle kinematics 4 air springs 2 dampers 2 lower steering rods 4 point steering rod x Front axle kinematics 2 leaf springs 2 dampers stabilizer bar steering system (not shown) x < 9 >

10 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 10 >

11 Real time model in TruckMaker Properties Model variants: Chassis / Suspension Linear kinematics IPG Kinematics analysis K&C analysis (SIMPACK) Other model properties IPG Driver Pneumatic brake system Elastic cabin mount Elastic body Test runs with and without trailer < 11 >

12 Real Time Driving Dynamics Simulation IPG Kinematics vs. MBS Required effects (e.g. for chassis controller development) Elasto-kinematics (e.g. bending of axle body) Axle buffer and S-Schlag buffer Compliance in steering rods 3D-nonlinear bushing characteristics 3D-nonlinear leaf spring behavior Today, requirements can only be fulfilled with a MBS analysis < 12 >

13 Real Time Suspension Model Workflow Kinematics and Compliance Analysis* Automated integration of axle model in K&C test rig Generation of test procedure in K&C Manager for SIMPACK (.if2) Simulation and result data export (.sbr) through scripted post processing Generation of SKC file according to TruckMaker specifications Axle model (.spck) MBS SIMPACK K&C test rig (.if2) (.sbr) K&C Manager SKC-File * P. Rund, Aufbau eines virtuellen K&C-Prüfstands mit Datenverarbeitungsroutine zur Parametrierung kennlinienbasierter echtzeitfähiger Fahrdynamikmodelle. Master Thesis, Uni BW München, MAN Truck & Bus AG, < 13 >

14 SIMPACK K&C Analysis Front suspension, leaf spring Interface to TruckMaker: Segment shaft angle (steering gear) Equals the steering rack travel < 14 >

15 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 15 >

16 Results (first attempt) Steady-state run comparison MAN TGX 4x2 BL Tractor Comparison of results Steady-state circular test with 47m radius, constant velocity 15 m/s IPG Driver and SIMPACK driver tests (similar behavior in steady state) Different Level of Detail in modeling IPG Kinematics K&C analysis with SIMPACK < 16 >

17 Results Roll angle comparison MAN TGX 4x2 BL Tractor Roll behavior of rigid axles in steady-state circular test (accelerated) Kinematic coupling of left and right wheel (bending and torsional stiffness) Kinematic constraints due to leaf spring and 4 point steering rod Stabilizing mechanism is considered by kinematic constraints in K&C No additional force element required in TruckMaker < 17 >

18 Results ISO Lane Change comparison MAN TGX 4x2 BL Tractor Behavior of rigid axles in ISO lane change test Comparison of different driver models (SIMPACK vs. IPG Driver) Equal trajectory Slight differences in steering behavior => differences in vehicle reaction Correlation for identical steering input (IPG Driver in SIMPACK) < 18 >

19 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 19 >

20 Integration into MAN development framework Workflow Simulation of Variants SPM* - system for automated export functionalities K&C results can be exported from database Direct export of vehicle data (based on parts and modules) into TruckMaker model file Part / Assembly SPM Export filter (ascii) TruckMaker Model file * Simulation Parameter Management < 20 >

21 Example Damper Today Manual export of parts and subsystems Direct export to TruckMaker ASCII-file < 21 >

22 Example Damper Today Manual export of parts and subsystems Direct export to TruckMaker ASCII-file < 22 >

23 Real Time Driving Dynamics Simulation Contents 1 Motivation 2 Scope of work 3 MBS model (reference vehicle) 4 TruckMaker model with different suspension modeling 5 Results: First benchmark 6 Integration into MAN development framework 7 Conclusion and outlook < 23 >

24 Conclusion and Outlook Conclusion Good results in vehicle dynamics on the first try Suspension have to be considered with K&C-analysis to correlate MBS Constraints between right and left wheel (rigid axle) lead to new approaches TruckMaker vehicle models can be generated by database Outlook Integration of MBS-Suspension (C-Code export) Establish a SPM model base Automated generation of enquiry vehicle model variants < 24 >

25 Dipl.-Ing. Dr. techn. Jan Fleischhacker MAN Truck & Bus AG Engineering Research Vehicle Dynamics and Simulation Methods (Abt. ERVD) Dachauer Straße 667 D München Telefon: < 25 >

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