LMS Imagine.Lab. Driving Dynamics Suspension & Damper Solution. Restricted LMS International 2013 All rights reserved.

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1 LMS Imagine.Lab Driving Dynamics Suspension & Damper Solution

2 Application #1 Standard dampers Goal: Assess the damper characteristics and performances early in the design phases Takes the advantages of a state-of-the-art software in Hydraulics combined with its Pneumatic libraries to analyses any technologies of dampers (mono tube or twin tube) from system to detailed approaches or from performances to noise. Page 2

3 Application #2 advanced frequency dependent dampers Goal: Design right the first time your advanced dampers. Take the advantage of the modularity of the Hydraulic Component Design library to capture variability and tradeoff in the design of advanced passive damper systems. Minimize the development risk of innovative suspensions by assessing the damper characteristics in early phases of the design even when no prototypes are available. Gain insights in designing perspectives. Page 3

4 Application #3 Adjustable dampers for race car Goal: Assess dynamics and design problems for racing. Assess the static and dynamic characteristics of the damper function of the possible valve tuning required for a particular race. Be valid up to 20 Hz by taking care of friction hysteresis and internal dynamics of the damper. Page 4

5 Application #4 Semi active and active dampers Design Goal: Assess the coupling between the actuation and the damper characteristics. Address damper design, valve actuation and control law verification for semi active and active suspensions thanks to the Hydraulic Component Design and Electro Mechanical libraries. Magneto rheological damper is also feasible but on demand. Page 5

6 Application #4 Semi active and active dampers Power efficient system Goal: Reduce the power consumption of the actuation system while maintaining comfort performances by optimization Evaluate the power consumption to actuate the pump on typical inputs dedicated to comfort analyses and optimize some design parameters versus performance criterion and power consumption thanks to interfaces with optimization tools like OPTIMUS. Occurrencies of Power Values (in%) Page Optimized parameters: Rod and piston diameters Valves characteristics Pump flow Input currents (at discretized time steps)

7 EXTRA Air Spring: Air bladder volume First of all, a specific model with an effective piston area as input, A combination of components and signal to represent a first view of the air volume. Air Volume Outer Guide Upper Housing Gas Cushion air spring stiffness through its equivalent area Roll Piston Air Spring (Flexible Air Bladder) Page 7 Oil reservoir Twin Tube Shock Absorber

8 EXTRA Air Spring: Final view A combination of mathematics for effective contribution of the piston sections and overlaps... Gas Cushion Computation of overlapping length Overlapping potential contribution of the bag Air Spring Gas Cushion Page 8

9 EXTRA Anti roll systems: parts and components Focus on component and circuit design: Pressure valves stability and priority valve testing, Couplings between the steering and the anti roll bar circuits NVH aspects due to cavitation in cylinder Tilting systems for trains or special vehicles Real time application for ECU testing displacement pressure Page 9

10 EXTRA Active anti roll bar: modularity Functional modeling of the anti roll bar. Possibility to use the Hydraulic library to make the anti roll bar active (linear or rotary cylinder). Evaluation of the suspension system performances/design on the entire virtual vehicle model. Page 10

11 EXTRA Active anti roll bar: Couplings with the vehicle Combining the vehicle and the active anti roll system to test its contribution inside the vehicle performances (handling and comfort). Page 11

12 Application #6 Active roll bar Goal: Assess the trade-off between the different technologies. Due to growing demand on EPS, even the active anti roll bar is electrified. Take the benefit of a multi disciplinary tool to tackle different technologies. Page 12

13 EXTRA Comfort analyses using the AMESim Fourier analyzer Page 13 Frequency analyses (Bode Diagram/Transfer Function) by numerical linearization and a Fourier Transform analyzer for very non linear systems.

14 Application #7 Comfort bench Mechanical views Goal: Give a multi attributes balance regarding comfort, handling and fuel eco using a multi-disciplinary software. Thanks to the connection to the Vehicle Dynamics library and its features, the direct contributions of the suspension design can be explored within the vehicle (or comfort bench) targeting multi attributes like comfort and handling but also fuel eco. Page 14

15 LMS In-House Testing Facility Damper HiL Bench Built during a national project for a damper manufacturer. Control logic designed in Scicos HiL bench management by NI tools The vehicle model is empowered by AMESim Page 15

16 EXTRA Multiple X-in-the-Loop for control design process Hydro pneumatic semi-active suspension with ECU: Shorten conception cycle (< 1 year!) Main tool for designers (end user) Frontloading controls development process Multiple environments: Model-in-the-Loop (MiL) with Simulink model of the controller Software-in-the-Loop (SiL) with the controller in C-code combined with the vehicle and its hydraulic suspension Hardware-in-the-Loop (HiL), Real Time target dspace ds1006 QuadCore Driver-in-the-Loop (DiL) with the SHERPA driving simulator to evaluate the control law upfront with a driver Solution: Application of AMESim/AMESim co-simulation with a CoSim with Simulink running real time on 2 or 4 CPUs Total of 25 manoeuvers to automatize testing Full technology transfer knowledge on Hydraulic modeling for suspension and model simplification Page 16

17 EXTRA Multiple X-in-the-Loop for control design process Taking care of Variants: Five different architectures of the hydraulic circuit modeled Each architecture has its complex model for suspension design and its simplified version for control law design and validation Page 17

18 EXTRA Multiple X-in-the-Loop for control design process Software & Hardware in-the-loop: dspace RT-Platform for ECU testing dspace 1006 QuadCore Front CPU 3=Front Suspension Suspension CPU 1=ElectroPump + Controller CPU 4=Rear Suspension CPU 2=Vehicle Page 18

19 EXTRA Multiple X-in-the-Loop for control design process VIDEO Page 19

20 EXTRA Control logic: AMESim as the plant model for more Physics Complete chain: System to Control Actuator Controller Control Loop Synthesis ECU Control Law CoSim Architecture Signal Vehicle Power subsystem AMESim the tool for Plant Modeling inside the Control Design Process Page 20

21 Success Story : IAV Automated calibration on an unique concept car requires Hardware in the Loop simulation, in order not to endanger the vehicle. The fundamental requirement is a real-time hydraulic simulation with real physics, no characteristics-based hydraulics. The process is to use the real-time features of AMESim with its model reduction tools. Agreement is good between the AMESim realtime model and the complex model. Modeling of real physics is done easily using AMESim analyses tools to transform the complex hydraulic model to a real-time system. Dr.-Ing. Hendrik GERTH IAV GmbH 2006 AMESim European Users conference Page 21

22 References Published papers and presentations Alirand M., Study and analysis of an active self leveling suspension, IEEE International Conference on Systems, Man and Cybernetics, Le Touquet, France, October 1993, pp Alirand M., Botelle E., Sau J., Modeling a force control actuator for semi active car dampers - Basics, 16 th IAVSD Symposium on Dynamics of Vehicles on Roads and Tracks, Pretoria, South Africa, September 1999, pp 1-4 Ney Y., Design methodology for automotive suspension systems - Fluid power software applications, SIA conference on Fluid Power and Transportation, Roanne, France, May 1999, pp 1-2 BotelléE., Alirand M., Sau J., Modeling a force control actuator for semi active car damper: Flow valve analysis, 5 th Int. Symposium on Advanced Vehicle Control, AVEC 2000, Detroit, MI, 2000, pp 1-8 Alirand M., Urvoy E., BoteléE., Modeling a force control actuator for semi active suspension: Application, SIA Congress on Vehicle Dynamics, Lyon, France, June 2001, pp 1-6 Alirand M., Botelle E., J. Sau, Modeling a force control actuator for semi-active car damper : Pressure controlled valve analysis, Scandinavian Int. Conference on Fluid Power, Linkoping, Sweden, June 2001, pp 1-6 Lee C.T.., Moon B.Y., Study of the simulation model of a displacement sensitive shock absorber of a vehicle by considering the fluid force, Proc of the IMechE, Part D, Journal of Automobile Engineering, vol 219, 2005, pp Cimba D., Wagner J., Baviskar A. Investigation of active torsion bar actuator configuration to reduce vehicle body roll, Vehicle System Dynamics, vol 44, n 9, September 2006, pp Gerth H., Resch R., Freimann R., Automated controller design for an anti-roll system, European AMESim User Conference, Strasbourg, France, March 2006, pp 1-9 Lino P., Maione B., Near optimum control of a full car active suspension system, LMS Engineering Simulation Conf Europe 2008, Paris, France, October 2008, Falfari S., Brusiani F., Pelloni P., Coupling Between 1D-3D Simulation Results to Predict Cavitation in Motorcycle Forks, SAE paper n 09FFL-0117, 2009, pp 1-13 Falfari S., Brusiani F., Cazzoli G., Setup of a 1D model for simulating dynamic behaviour of motorcycle forks, SAE paper n , 2009, pp 1-14 Page 22

23 References Published papers and presentations Gubitosa M., Anthonis J., Albarello N., Desmet W., A Computer Aided Engineering Approach For the Optimal Design of An Active Suspension System, Proc ASME 2009 Int. Design Engineering Technical Conf., San Diego, CA, 2009, pp 1-11 Lindvai-Soos D., Functional development process of the electric anti-roll stabilizer ears, Vehicle Dynamics Expo, Stuttgart, Germany, 2010, De Bruyne S., Anthonis J., Gubitosa M., Van der Auweraer H., Model Based Actuator Management for a Hydraulic Active Suspension System Improving Comfort Performance by Advanced Control, Proc of the ASME 2011 Int Mechanical Engineering Congress & Exposition, Denver, CO, November 2011, pp 1-9 Kim H.., Lee H., Study Model-based fault-tolerant control for an automotive air suspension control system, Proc of the IMechE, Part D, Journal of Automobile Engineering, vol 225, 2011, pp Moshchuk N., Li Y., Opiteck S. Air suspension system model and optimization, SAE Paper N , 2011, pp 1-14 De Bruyne S., Anthonis J., Gubitosa M., Van der Auweraer H, Modeling Model Based Design of a Hydraulic Active Suspension System, Int. Symposium on Advanced Vehicle Control, AVEC 2012, Seoul, Korea, 2012, pp 1-9 Manlong P., Feng L., Wenkui F., Yunqing Z., Multi-domain modeling and robust design of hydraulic shock absorber, 2 nd Int. Conf on Computer Application and System Modelling, paris, France, June 2012, pp Sadeghi Reineh M., Pelosi M., Physical Modeling and Simulation Analysis of an Advanced Automotive Racing Shock Absorber using the 1D Simulation Tool AMESim, SAE Paper n , 2013, pp 1-11 Pelosi M., Subramanya K., Lantz J., Investigation on the Dynamic Behavior of a Solenoid Hydraulic Valve for Automotive Semi-Active Suspensions Coupling 3D and 1D Modeling, 13 th Scandinavian Int. Conference on Fluid Power, Linkoping, Sweden, June 2013, pp 1-10 Barale S., Plisson A., Guillet J., Lagnier J., Alirand M., Improved Functional Modelling in Comfort Analyses for Hydraulic Suspension Testing, Chassis Tech Int. Conference, Munich, Germany, June 2013, pp 1-11 Page 23

24 Product Line - Solution 6 Conclusion Page 24 20XX-XX-XX

25 Conclusions Use the recognized state-of-the-art software for Fluid Power (Hydraulics & Pneumatics) for designing your damper components and air springs. Use a best-in-class multidisciplinary software to tackle the new challenges of chassis electrification. Thanks to the AMESim modularity, insure scalability of your models from functional perspectives like model exchanges to detailed analyses like NVH. Ensure continuity between the design process of your active suspension components and the control design process by having scalable models of the plant for MiL, SiL and HiL thanks to a unique AMESim capability for model simplification. Page 25

26 Thank you Driving Dynamics - Suspension & Damper Solution