Proper Modeling of Integrated Vehicle Systems

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1 Proper Modeling of Integrated Vehicle Systems Geoff Rideout Graduate Student Research Assistant Automated Modeling Laboratory University of Michigan Modeling of Integrated Vehicle Powertrain Systems 1

2 Modeling of Vehicle Driveline Systems for an Integrated Environment Project team - Driveline Systems: Jeff Stein, Professor UM Geoff Rideout, Graduate Student UM Loucas Louca, Research Fellow UM Dan Grohnke, Senior Development Engineer NAVISTAR Polat Sendur, Graduate Student UM Modeling of Integrated Vehicle Powertrain Systems 2

3 Outline Motivation for integrated simulation tool - VESIM Integrated simulation environment Subsystem model implementation tools Description of powertrain module models Simulation results Future work Modeling of Integrated Vehicle Powertrain Systems 3

4 Motivation Integrated Ground Vehicle Simulation: - Facilitates concurrent engineering of military, passenger and commercial vehicles - Enables rapid study of alternate vehicle configurations È system design and optimization studies driveability, fuel economy, emissions, etc. Modular environment ensures long-term relevance of simulation tool Modeling of Integrated Vehicle Powertrain Systems 4

5 Goal: Integration of Variable Complexity Models ENGINE VEHICLE DYNAMICS EMPIRICAL t SIMPLIFIED POINT-MASS RPM THERMODYNAMIC Air COMPRESSOR TURBINE MULTI-BODY INTER- COOLER INTAKE MANIFOLD FUEL SYSTEM Fuel MULTI-CYLINDER DIESEL ENGINE Exhaust gas EXHAUST MANIFOLD WASTEGATE HIGH-FIDELITY Ẇ Modeling of Integrated Vehicle Powertrain Systems 5

6 Background and Current State-of-the-Art Integrated simulation packages have been developed to: - Study transient operation of engines and vehicles - Predict dynamic response - Assess alternate system configurations Existing software packages allow building-block model construction Models have been developed for each subsystem, but integration effort is fairly new We have yet to fully tap the potential of such a tool. Modeling of Integrated Vehicle Powertrain Systems 6

7 Integrated Modeling Tools MATLAB-SIMULINK Block diagram graphical user interface - Simulink block libraries - Matlab programming language - C or Fortran source code Common solver used for engine, driveline, vehicle Modeling of Integrated Vehicle Powertrain Systems 7

8 Integrated Modeling Tools 20SIM Bond graph model graphical user interface Common formalism for different energy domains - Systematic generation of state equations Bond graph and block diagram elements can be integrated Generates source code for Matlab C-MEX files Modeling of Integrated Vehicle Powertrain Systems 8

9 Driveline System Schematic MODULAR STRUCTURE flexibility in choosing vehicle configuration T C D-F Trns IA-D Tr-C D-FR D-R Modeling of Integrated Vehicle Powertrain Systems 9

10 Torque Converter IMPELLER PUMP DRIVE HUB IMPELLER ROTATION DIRECTION TURBINE STATOR CONCAVE SIDE STATOR CONVEX SIDE (J.C. WHITE/FORD MOTOR CO.) 3 element torque converter (pump, turbine & stator) Static or dynamic model? Modeling of Integrated Vehicle Powertrain Systems 10

11 Torque Converter Model Static Model Methodology (e.g., Salaani and Heydinger, 1998) Turbine Speed Engine Speed Speed Ratio Turbine Torque (to trans.) Torque Ratio Engine Speed 2 Pump Torque (to engine) Capacity Factor Capacity Factor Implementation - 20SIM -> C code -> Matlab/Simulink - Direct block diagram entry to Matlab/Simulink Modeling of Integrated Vehicle Powertrain Systems 11

12 Automatic Transmission Modeling Strategies - Input-output model based on experimental data - Physical component-level model TURBINE SPEED TORQUE TO TRANS. INPUT TORQUE TURBINE SPEED TORQUE CONVERTER OUTPUT SHAFT SPEED TORQUE TO DIFFERENTIAL INPUT TORQUE INPUT SHAFT SPEED TRANSMISSION DIFFERENTIAL Modeling of Integrated Vehicle Powertrain Systems 12

13 Input-Output Transmission Model Based on experimental measurement of input and output effective inertias, stiffnesses, and damping Implemented as discrete components (e.g. Bond Graph) - 20SIM -> C-MEX files -> Matlab/Simulink Incorporates losses - Gear inefficiency - Fluid pumping INPUT INERTIA OUTPUT INERTIA GEAR REDUCTION Modeling of Integrated Vehicle Powertrain Systems 13

14 Input-Output Transmission Model Empirical blending functions are used for shifting. Speed Ratio Torque Ratio Shift Duration Time Modeling of Integrated Vehicle Powertrain Systems 14

15 Alternative Transmission Model Physical-Based Model (Cho and Hedrick, 1989) TO 1-2 BAND Model considers inertias of gears and compliances of shafts Clutches engage/ disengage during shift event - Torque phase - Speed phase Model can switch between bond graphs for different phases TO SECOND CLUTCH TO FIRST CLUTCH TO SECOND CLUTCH TO 1-2 BAND TO FINAL DRIVE Modeling of Integrated Vehicle Powertrain Systems 15

16 Shift Logic Decision to shift based on - Transmission output shaft speed - Throttle position Implementation - C-MEX function È Accepts inputs from transmission and driver È Outputs gear number, torque multiplication and speed reduction ratios Throttle Position [0-1] Output Shaft Speed [rad/s] Modeling of Integrated Vehicle Powertrain Systems 16

17 Differential/Driveshaft Models Differentials - Bond graph representations È Conventional bevel-gear È Worm-gear Propshafts and Driveshafts - Compliance, inertia, damping - Axle cooler churning losses Implementation - 20SIM -> C-MEX files AUTOMATIC TRANS. WHEEL DIFFERENTIAL WHEEL Modeling of Integrated Vehicle Powertrain Systems 17

18 Vehicle Specifications Engine Vehicle/Driveline V8 DI Diesel Turbocharged, Intercooled Rated Power: 210 rpm GVWR: 7950 Kg 4 Speed Automatic Transmission Rear Wheel Drive - 4x2 NAVISTAR 4700 Series Modeling of Integrated Vehicle Powertrain Systems 18

19 Validation and Parametric Study Vehicle launch performance validation - Ò0-60 mphó full throttle acceleration from idle - Engine and vehicle speed compared to experimental data Torque converter stall test validation - Compare torque converter stall speed with test data Shift quality parametric study - Shift duration nominally 0.8 seconds - Vary duration +/- 0.4 seconds - Compare vehicle forward jerk Modeling of Integrated Vehicle Powertrain Systems 19

20 Model Validation (0-60 MPH) ENGINE SPEED [RPM] st 2nd 3rd 4th Gear Test VESIM VEHICLE SPEED [MPH] TIME [SEC] Test VESIM Modeling of Integrated Vehicle Powertrain Systems 20

21 Torque Converter Stall Test Test VESIM ENG. SPEED [RPM] TIME [SEC] Modeling of Integrated Vehicle Powertrain Systems 21

22 Shift Quality - Vehicle Jerk 8 Consider trade-off between ride quality and - Acceleration - Clutch wear FORWARD JERK [M/S^3] sec shift 0.8 sec shift 1.2 sec shift NORMALIZED TIME [SEC] Modeling of Integrated Vehicle Powertrain Systems 23

23 Summary An inventory of models for different powertrain components has been implemented Driveline models have been integrated with engine and vehicle (VESIM) Models have been partially validated with test data Potential utility of simulation tool has been explored through example design studies Modeling of Integrated Vehicle Powertrain Systems 24

24 Conclusions Vehicle/engine integration of varying fidelity is possible Engine/vehicle interactions appear to be important to vehicle mobility design and evaluation Additional work on driveline models is necessary Modeling of Integrated Vehicle Powertrain Systems 25

25 Future Work Extend usefulness of VESIM as predictive design tool by expanding component model inventory Continue data collection effort for validation Modeling of Integrated Vehicle Powertrain Systems 26

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