Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel

Transkript

1 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel Institute of Machine Design and Automotive Engineering University of Karlsruhe, Germany o. Prof. Dr.-Ing. Dr. h.c. Albert Albers Dipl.-Ing. Marc Albrecht Dipl.-Ing. Arne Krüger Dr.-Ing. Ralph Lux testing

2 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 2

3 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 3

4 Drive Test Customer requirements, comfort, life E x p e r i m e n t Roller Test Stand (scheduled) Power Train Test-Bench Complete power trains, components Sub-system Transmissions, rolling- and sliding bearings S i m u l a t i o n Element Frictional function systems, EHD-systems Methodology Integration of Experiment and Simulation 4

5 Customer Subjective Impression Assessment Modified Simulation Data Correlation Simulation Data Modification of Simulation Model Measurement in the Vehicle Objective Data Modelling Simulation Test-Bench Examination Methodology 5

6 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 6

7 Driving Unit Retardants - Excitation frequencies up to 250 Hz - Torque of driving unit in continuous operation up to 260 Nm - Speed of driving unit up to 6900 rpm - Simulation of vehicle mass done electrically by retardants - Torque of driven machines up to 1500 Nm The Universal Power Train Test Bench 7

8 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 8

9 Powertrain with Conventional Clutch Engine Gearbox Engine + Flywheel CD Gearbox Vehicle Powertrain with Dual Mass Flywheel Engine Gearbox Engine + DMF CD Vehicle Gearbox Function of the Dual Mass Flywheel 9

10 Speed [rpm] 1150 Speed Primary Side Speed Secondary Side Engine + DMF 1100 CD Mechanical low-pass filter 25 Hz Time [s] Function of the Dual Mass Flywheel 10

11 Primary side Primary side of a DMF: Stop at primary side Spring channel Carrier Arc spring Secondary side Supporting shell Design of the Dual Mass Flywheel 11

12 Forces between arc spring and support channel depend on angle of distorsion and rotary speed. Forces in the Dual Mass Flywheel 12

13 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 13

14 rpm Torque [Nm] rpm 1000 rpm 100 rpm Twist angle [ ] Load Cycle Hysteresis Curves 14

15 Mean speed: 1000 rpm Amplitude: 40 rpm Torque [Nm] Twist angle [ ] Partial Hysteresis Loops 15

16 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 16

17 Multi-body Simulation Model of one Arc Spring Flection friction1 Flection friction2 Flection friction3 Flection friction4 Flection friction5 Friction contact1 Friction contact2 Friction contact3 Friction contact4 Friction contact5 Centrifugal force C Springend1 + + Springend2 C2 Rotary speed Primary mass J1 Spring J2 Spring J3 Spring J4 Spring J5 section1 section2 section3 section4 Torsion angle Compression condition1 Compression condition2 Torsion angle Simulation Model 17

18 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 18

19 Load Cycle Hysteresis Curves at 200 rpm: Torque [Nm] Twist angle [ ] (Simulation) Twist angle [ ] (Measurement) Validation 19

20 Load Cycle Hysteresis Curves at 2200 rpm: Torque [Nm] Twist angle [ ] (Simulation) Twist angle [ ] (Measurement) Validation 20

21 Partial Hysteresis Loops at 200 rpm and 80 Nm: Torque [Nm] Measurement Simulation Twist angle [ ] Validation 21

22 Nm rpm km/h Drive shaft torque 44 Simulation Measurement Crank shaft speed Gearshaft speed Driving speed Time [s] Validation 22

23 Integration of Simulation and Testing in Power Train Engineering Based on the Example of the Dual Mass Flywheel - Introduction and Methodology - The Universal Power Train Test-Bench - The Dual Mass Flywheel - Function and Design - The Dual Mass Flywheel on the Test-Bench - Simulation Model of the Dual Mass Flywheel - Validation - Summary and Conclusions Table of Contents 23

24 Intergral development environment for power trains Integral action shown exemplarily with the DMF Practicality proven by corresponding results of - measurement on the car, - measurement on the test-bench, - numerical simulation = Increase of system comprehension = Improved design of power train components and entire power trains Summary and Conclusions 24

25 Contact: Dipl.-Ing. Marc Albrecht Institute of Machine Design and Automotive Engineering Kaiserstraße 12 Postfach Karlsruhe Germany testing