Active Suspension System. Josh Rose, Xander Serrurier, Rhydon Vassay, Chase Ramseyer Advisor: Steven Gutschlag 11/30/2016

Transcription

1 Active Suspension System Josh Rose, Xander Serrurier, Rhydon Vassay, Chase Ramseyer Advisor: Steven Gutschlag 11/30/2016

2 Suspension Systems Purpose The set of devices used to support the chassis of a vehicle on its axles Used to prevent chassis movements caused by road imperfections to the car s passengers Primary types Passive Active Hybrid (Semi-active) 2

3 Passive Suspension System Mass, spring, damper (shock absorber) Gain constants dictate system response No electronics No power required Cheaper to manufacture Source: [2] Q. Zhou. Research and Simulation on New Active Suspension Control System. Lehigh University, PA,

4 Active Suspension System Electronic actuator performs as dynamic damper Actuator applies force directly to chassis Greater performance We will use a simplified version of this model Source: [2] Q. Zhou. Research and Simulation on New Active Suspension Control System. Lehigh University, PA,

5 Suspension Systems Suspension system type Passive suspension system Semi-active suspension system Active suspension system Regulatory element General shock absorber Adjustable damper Hydraulic system or Servo motor system Action principle Damping constant Damping continuously adjust Adjust the force between wheel and vehicle body Control method No Automatic hydraulic Electronics or magnetic or fluid control Bandwidth Unknown Up to 20Hz > 15Hz Energy consumption Zero Minimal Significant Lateral dynamics control No Middle Good Vertical dynamics control No Middle Good Cost Lowest Middle Highest Source: [2] Q. Zhou. Research and Simulation on New Active Suspension Control System. Lehigh University, PA,

6 Present and Future Most vehicles are currently equipped with passive suspension systems Active suspension systems are a popular research subject In the future, more vehicles will likely be equipped with active suspension systems In general Active better performance Passive lower cost 6

7 ACTSS General Overview Minimize vertical displacement Real-time disturbance minimization Applications Cars, tractors, off-road Chassis suspension Cab/seat suspension 7

8 Previous Work Developed power electronics H-bridge Snubber circuit Isolation circuit Developed proportional control system Disturbance cancelled: 75% with load 87.5% without load 8

9 Hardware Specifications EMAC Micropac MHz on-board crystal Separate LCD/keypad interfaces 8 10-bit ADC channels 24 digital IO 3 RS232 serial ports Programmed in Assembly 9

10 Hardware Specs (cont d) MSK4227 H-Bridge 200V, 20A rating 20µA logic input current 1µs minimum dead time (switching) Direct heatsinking with forced convection 10

11 Hardware Specs (cont d) 4N25 Optical Isolator 5V supply voltage 10mA enable current Max 70V output 50mA output current 2µs switching speed 5000V isolation voltage 11

12 Hardware Specs (cont d) IDC EC2-H Electric Cylinder 160V DC, 12A 3600N max thrust 930mm/sec max no load speed 1 in/ 27.2ms 5.0N-m max torque 12

13 Hardware Specs (cont d) Position Sensors (P1613) Light duty potentiometer 2 in bidirectional travel 10K Ohms 3-Phase Motor (4Z394) Camshaft (VPLE-212) 1in displacement 13

14 Modified Hardware List Atmel ATmega 128 Microcontroller Personal extensive experience Code development in embedded C 16MHz on-board crystal 8 10-bit ADC channels 53 digital IO channels 2 serial ports 14

15 Modified Hardware (cont d) 6N137 Optical Isolator 5V supply voltage 15mA enable current Logic-level output 50mA output current 10MBd switching speed 5300V isolation voltage 15

16 System Overview 16

17 Subsystem Overview Keypad PWM Upper Position Sensor ADC Lower Position Sensor Actuator Position Sensor PWM Actuator On/Off Motor Linear Actuator Microcontroller Power Electronics Em_Stop Upper Platform 17

18 Conceptual Flowchart 18

19 Isolator Overview 19

20 Work Completed 20

21 H-Bridge Overview 21

22 Work Completed 22

23 Work Completed 23

24 H-Bridge Testing Results H-bridge output (e.g. A0) Optical Isolator output Switching Signal (From Function Generator) 24

25 H-Bridge with Isolation 25

26 Parts List Part Description Quantity Cost ($) Supplier Purchased Microcontroller and Development Board Waveshare Y Keypad Vetco Y LCD Display Ebay Y Atmega128 Programmer Mouser Y H-Bridge 1 Unavailable MSK N 6N137 Optical Isolator Mouser N IDC Electric Cylinder EC2H Linear Actuator Amazon N Maurey Linear Motion Sensor P1613 Position Sensor Process Industrial Surplus Corp N Maxi-Torq 4z394 3-Phase Motor Amazon N Camshaft Motion Industries N Accelerometer Under Investigation N Atmega128A Dev Kit Keypad LCD (HD44780) AVR Dragon MSK4227 VPLE-212 Under Investigation 26

27 Completion Timeline 27

28 Tasks Research Referenced previous projects Industry papers Code Wrote test cases for optical isolators Wrote test cases for H-bridges Testing Test actuator Test 3 phase motor Test position sensors 28

29 Tasks (cont d) Control system Develop control system Convert system to an algorithm Simulations Simulink for control algorithm PSpice for power electronics Assembly Assemble system Run test conditions on system 29

30 Division of Labor Task Worked on by Completed Research All Yes Write Testing Code Chase, Xander Yes Test Actuator Rhydon, Josh No Test H-Bridge All Underway Test Position Sensors Josh, Rhydon No Test Motor Rhydon, Josh No PSpice Simulations Rhydon, Josh No Develop Control System Xander, Chase Underway Simulink Model Xander, Chase No Convert Control System to a DT algorithm Chase, Xander No Assemble System All Underway Run Test Cases on System All No Documentation All Underway Deliverables All Underway 30

31 References Previous Senior Projects: Patrice Jackson and Shawn Downey (2003) Blake Boe and Tyson Richards (2006) Research Papers [1] W.K.N. Anakwa. Development and Control of a Prototype Pneumatic Active Suspension System. Bradley University, IL, Oct [2] Q. Zhou. Research and Simulation on New Active Suspension Control System. Lehigh University, PA,