Mastering Unexpected Situations Safely · Simplified 7 DoF stand-alone model Air Spring Model...

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

Public

Agenda

9 August 2016

3 Stefan Mölle, ESS (VED) © Continental AG

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

9 August 2016


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

9 August 2016


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

9 August 2016


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Electronic Suspension Systems Product Portfolio

9 August 2016


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

9 August 2016


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

9 August 2016


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

air_suspension_pasm_e_AirSpring.mpg

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Electronic Suspension Systems Requirements for ESS Simulation Environment

9 August 2016


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

9 August 2016


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…

9 August 2016


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

9 August 2016


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

9 August 2016


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”

9 August 2016


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

9 August 2016


*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

9 August 2016


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

Confidential

Space for Sender Information

for your attention! Thank you

9 August 2016


Confidential

Space for Sender Information 9 August 2016


Mastering Unexpected Situations Safely · Simplified 7 DoF stand-alone model Air Spring Model...

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