Testing Facilities Institute of Vehicle System Technology FAST

Transcription

1 Testing Facilities FAST Karlsruhe, September 218 KIT University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association

2 Contents Structure Facilities of FAST Flat Track / External Drum Test Bench Technical Data Rolling Resistance Measurements Internal Drum Test Bench Technical Data Overview of Measurements & Tracks Longitudinal Force Measurements Flat Track / External Drum Measurements on Wet Track Surface Measurements on Snow and Ice Surfaces Measurements with the TIME Procedure Measurements for Tire Comfort Models Determination of the Magic Formula Coefficients Equipment for Determination of Tire Envelopes Setup for Acoustic Test Tire contact force sensor Grip- and Abrasion Test stand (GAT) Facilities of FAST at Campus Ost Internal Drum Test Bench Buildings 7.21 & 7.22 Vehicle-In-the-Loop Test Rig (VEL) in Building 7.21 Acoustic 4WD Chassis Dynamometer Noise, Vibration and Harshness Tests Test vehicles Contact 2 Testing Facilities of the, Acoustic 4WD Chassis Dynamometer Vehicle-In-the-Loop Test Rig

3 - FAST Structure Vehicle System Technology Chair of Vehicle Technology Passenger Cars & Trucks LFF Prof. Dr. rer.nat. Frank Gauterin Safety Energy Efficiency Drivability Cost Mobile Machines MOBIMA Prof. Dr.-Ing. Marcus Geimer Rail Vehicle Systems BST Prof. Dr.-Ing. Peter Gratzfeld Light Weight Technology LB Prof. Dr.-Ing. Frank Henning 3 Testing Facilities of the,

4 Facilities of FAST Campus Süd Campus Ost 4 Testing Facilities of the,

5 Flat Track / External Drum Test Bench Technical Data Measurement of Rolling Resistance Outside diameter of the drums 2, m 1,71 m Top speed - on the drums 3 km/h - on the flat surface 25 km/h Camber angle Slip angle Measuring system for rolling resistance 6 component measuring system: Max. vertical force Max. lateral force, longitudinal force Max. overturning torque Max. aligning torque Max. driving torque 1. N 1. N 1.2 Nm 3 Nm 3 Nm 5 Testing Facilities of the,

6 Flat Track / External Drum Test Bench Rolling Resistance Measurements Measurement of rolling resistance versus time, variation of velocity 6 5 Reifen-Nr. : 1 Reifengröße : 195/65 R 15 Luftdruck : 2,9 bar Radlast 8 % ETRTO Umgebungstemp. : 25 C Longitudinal Force / N Umfangskraft / N km/h 9 km/h 12 km/h 15 km/h 18 km/h Time/ Zeit Minutes / min 6 Testing Facilities of the,

7 Flat Track / External Drum Test Bench Rolling Resistance Measurements Measurement of rolling resistance on different curved track surfaces on a combined flat track external drum test bench. Longitudinal force / N % ETRTO 8 % ETRTO Tire load 4 % ETRTO 1,71 m drum 2, m drum Flat track Aerodynamic Resistance Tire No. Tire Size Track Infl. Pressure : 5 : 225/45 R 17 : 1,71 m, 2, m, Flat : 2,2 bar Velocity / km/h Influence of driving velocity on the rolling resistance for different track surface curvatures. 7 Testing Facilities of the,

8 Internal Drum Test Bench Technical Data Inside diameter of the drum Track surfaces 3,8 m Safety Walk Diverse concrete surfaces Diverse asphalt surfaces Top speed - on Safety Walk 2 km/h - on asphalt / concrete 15 km/h Water film depth... 4 mm Ambient temperature C Slip angle Camber angle ( ) Max. Tyre Radius: Max. Tyre Width (Contact-Width): 48 mm 33 (27) mm Measuring system for frictional force behaviour: Rotating 6 component measuring system: Max. vertical force, lateral force, longitudinal force Max. driving torque, overturning torque Max. aligning torque 15 kn 5.5 Nm 1.5 Nm 8 Testing Facilities of the,

9 Internal Drum Test Bench Overview of Measurements Test Methods Longitudinal force versus slip Lateral force and aligning moment versus slip angle TIME procedure tire comfort measurements (rolling over cleats) Variation of ambient conditions Different track surfaces (safety walk, asphalt, concrete) Dry, wet, snow and ice surfaces Variation of ambient temperature Different types of cleats 9 Testing Facilities of the,

10 Internal Drum Test Bench Installable Tracks SRT 39 SRT 44 SRT 51 SRT 53 Analysis of the influence of different composites of the track different textures of track surface for example: Safety-Walk asphalt concrete on the frictional behavior of tires on wet and dry roadway. Umfangskraft [ kn ] Reifen: Geschwindigkeit: Radlast: Wasserhöhe: Profiltiefe: Sommerreifen B 8 km/h 4 N,1 mm 2 mm Schlupf [ % ] Variation of skid resistance, tests on humid track surface 1 Testing Facilities of the,

11 Internal Drum Test Bench Longitudinal Force Measurements N 15 N 3 N 4 N 48 N Slip Angle: Longitudinal force / N Lateral force / N Longitudinal slip / % Longitudinal force / N Manufacturer Tyre size Rim size : : : 5,5 x 15 Velocity Inflation pressure Slip angle Waterfilm depth Vertical force : 1 km/h : 2,1 bar : : mm : var. Manufacturer Tyre size Rim size : : 7,5 x 16 Velocity Inflation pressure Camber angle Waterfilm depth Vertical force : 4 km/h : 2,2 bar : : mm : 48 N 11 Testing Facilities of the,

12 Internal Drum Test Bench Measurements on Wet Track Surface 6 5 Vertical force: 6 N, waterfilm depth: mm 6 N, waterfilm depth:.2 mm 6 N, waterfilm depth: 2 mm Longitudinal force / N Longitudinal slip / % Manufacturer Tyre size Rim size : : 6, x 15 Velocity Inflation pressure Slip angle Waterfilm depth Vertical force : 8 km/h : 2,6 bar : : /.2 / 2 mm : var. 12 Testing Facilities of the,

13 Internal Drum Test Bench Measurements on Snow and Ice Surfaces 13 Testing Facilities of the,

14 Internal Drum Test Bench Measurements on Snow and Ice Surfaces Test Procedures - Lateral Traction on Snow ± α Lateral traction determined in 2 cycles by varying the slip angle. 14 Testing Facilities of the,

15 Internal Drum Test Bench Measurements on Snow and Ice Surfaces Test Procedures - Longitudinal Traction on Hard Packed Snow s = % Longitudinal traction performance is determined within one drum turn to avoid rolling over of iced surfaces. 15 Testing Facilities of the,

16 Internal Drum Test Bench Measurements on Snow and Ice Surfaces Influence of Track Hardness on Winter Roads Medium packed snow CTI 82 Hard packed snow CTI 9 Ice On tracks with low hardness, high traction forces can be transmitted under high slip. Distinctive force maximum on hard packed snow and ice. 16 Testing Facilities of the,

17 Internal Drum Test Bench Measurements on Snow and Ice Surfaces -3-2 Slip angle N 3 N 45 N 6 N 78 N Longitudinal force / N -1-5 Lateral force [N] Longitudinal slip / % Longitudinal slip [ % ] Manufacturer Tyre size Rim size Inflation pressure : : : 6,5 x 15 : 2,4 bar Velocity Slip angle Track surface Ambient temperature Vertical force : 8 km/h : : Ice : -1 C : variabel Manufacturer Tyre size Rim size Inflation pressure : : : 6,5 x 15 : 2,4 bar Velocity Slip angle Track surface Ambient temperature Vertical force : 8 km/h : variabel : ice : -1 C : 6 N 17 Testing Facilities of the,

18 Internal Drum Test Bench Measurements with the TIME Procedure Measurement Target value 8 7 H-Axis-System Slip angle / Lateral force / N Measurement point / - Adjustment of certain parameter combinations (constant for 3 sec) Manufacturer Identity Tyre size Rim size : : : : 7 x 16 Velocity Inflation pressure Inclination angle Waterfilm depth Vertical force : 4 km/h : 2,4 bar : var. : mm : var Measurement point/ - Measurement of tire forces at adjusted parameter combinations Manufacturer Identity Tyre size Rim size : : : 7 x 16 Velocity Inflation pressure Inclination angle Waterfilm depth Vertical force : 4 km/h : 2,4 bar : var. : mm : var. 18 Testing Facilities of the,

19 Internal Drum Test Bench Measurements for Tire Comfort Models Rolling over Cleats Changeable Pavement and changeable cleats 19 Testing Facilities of the,

20 Internal Drum Test Bench Measurements for Tire Comfort Models Measurement of Forces and Moments 2 16 F [N] F [N] y x Power spectrum Power spectrum F [N²s] F [N²s] y x F z [N] Power spectrum F z [N²s] M [Nm] M [Nm] z x Power spectrum Power spectrum M [N²m²s] M [N²m²s] z x Time [s] Frequenz [Hz] Manufacturer Tyre size Form of cleat : : : Batten Vertical force Velocity Inflation pressure Slip angle : 4. N : 1 km/h : 2.2 bar : 2 Testing Facilities of the,

21 Inner Drum Test Rig Determination of the Magic Formula Coefficients Lateral force versus slip angle Longitudinal force versus longitudinal slip 21 Testing Facilities of the,

22 Inner Drum Test Rig Equipment for Determination of Tire Envelopes Measurement under Real Driving Conditions at Internal Drum Test Bench 22 Testing Facilities of the,

23 Inner Drum Test Rig Equipment for Determination of Tire Envelopes wheel suspension cameras and laser for tread gear wheel stepper motor 15kN measuring hub camera and laser for sidewall/ mirror balance weight tire 23 Testing Facilities of the,

24 Inner Drum Test Rig Equipment for Determination of Tire Envelopes Light Section Triangulation Method laser detector / camera profile contour β b α device under test x known 24 Testing Facilities of the,

25 Inner Drum Test Rig Equipment for Determination of Tire Envelopes Measurement under Real Driving Conditions at Internal Drum Test Bench Non-contact measurement of tire contour under real (even extreme) driving conditions on real track surfaces with measurement of tire forces and moments at the same time. Measured tire contour for several load and slip angle conditions 25 Testing Facilities of the,

26 Inner Drum Test Rig Setup for Acoustic Test Drive shaft is decoupled mechanically by elastic flexible disc. 2. Acoustic dividing wall: Subdivision of the test rig into a measuring cabin and a cabin for the power unit. 3. Solid-borne sound reduction: wheelhouse with the hydraulic motor is placed onto dampening mounting feet 4. Applying the wheel force through an electrically driven ball screw 5. Absorption modules ensuring a semi-anechoic space 26 Testing Facilities of the, 3 Sound Reduction [db] sound reduction index Result: Reduced sound generation caused by the power unit Frequency [Hz]

27 Inner Drum Test Rig Analysis of Tires Contact Forces with Triaxial Force Sensor Telemetry Contact Triaxial Force Sensor Top View 27 Testing Facilities of the,

28 Test Equipment of FAST Visualization of the tire tread deformation mobile under-floor laboratory [2] DE [2] DE mobile under-floor laboratory installed into a common drain on the street easy integration illumination with > 14. Lumen recording of tire crossing > 2,3 fps simple handling 28 Testing Facilities of the,

29 Test Equipment of FAST Visualization of the tire tread deformation mobile under-floor laboratory start-up carpet avoids collecting stones and dust particles by the tire during drive up b light barrier (a) activates pre-defined torque at electric vehicle automatically reproducible tangential forces can be applied a light barrier (b) activates camera recording fully automated 29 Testing Facilities of the,

30 Grip- and Abrasion Test stand (GAT) loading unit watering unit drive unit water supply water drain 3 Testing Facilities of the,

31 Grip- and Abrasion Test stand (GAT) pneumatic cylinder shock absorber load cell rubber sample fixation surface sample cast watering unit 31 Testing Facilities of the,

32 Grip- and Abrasion Test stand (GAT) sliding body rubber wheel 32 Testing Facilities of the,

33 Facilities of FAST at Campus Ost Buildings 7.21 & 7.22 Acoustic 4WD Chassis Dynamometer 7.22 Vibration Test Room Vehicle-In-the-Loop Test Rig 7.21 Assembly area passenger cars Exterior Front View Mechanical Workshop 33 Testing Facilities of the,

34 Facilities of FAST at Campus Ost Building 7.21 Truck lift Assembly area passenger cars Exterior view Building Testing Facilities of the,

35 Facilities of FAST at Campus Ost Vehicle-In-the-Loop Test Rig (VEL) Vehicle-In-the-Loop Test Rig Main applications: 4 Technical Data: Max. vehicle mass: Max. wheel load: Wheel base: Direct, dynamic street load simulation with robots (pedals and steering wheel) for power & consumption measurement, Powertrain characteristic at certain speeds, Influence of tires force characteristic, 12, kg 3, kg m Track width: m 2. min-1 Max. Speed (1) 3 ( km/h) 5 Max. Torque (1) 2.5 Nm 2 1 Power (1) 29 kw Max. Slip angle front (2) +/- 2 Max. Aligning Torque (2) 1. Nm Max. wind speed (4) 135 km/h Room temperature C Vehicles wheel hubs directly connected to the dynamic operating load engines. Torques are measured close to wheel (3). 35 Testing Facilities of the,

36 Facilities of FAST at Campus Ost Acoustic 4WD Chassis Dynamometer (AARP) Max. vehicle mass: Max. wheel load: Wheel base: Track width (rollers inner & outer edges): Max. Vehicle Dimensions: 56, kg 14, kg m m 18 m x 4 m x 4,5 m (LxWxH) Nom. I max. traction force: 24 kn I 44 kn Max. air flow rate m x 3 m Max. speed 16 km/h Acoustic insulation hemi-anechoic room (ISO 3745) Simulator for sun and heat influence. 36 Testing Facilities of the, Cross Section of Test rig implemented in Building 7.22 (Source: Dömges Architekten, Dreher)

37 Facilities of FAST at Campus Ost Test Setup for Analysis of Acclimatization at AARP Pos. Specification Value 1 Temperature Range +2 C to +5 C 2 Speed of air: 1,5 m/s bis 49,5 m/s 3 Size of area for air intake of condenser / motor cooler: 1,2 m x,8 m 4 Size of area for air intake of vehicle acclimatization system:,5 m x,1 m 4 Humidity of air for acclimatization system: max. 68 kg/h 5 Radiation power of solar simulators (6x, each 2 W, HQI) 37 W/m 2 bis 15 W/m 2 5 Size of area, which can be radiated by solar simulators: 2,5 m x 1, m 6 Radiation power of infrared radiators (12x, each 2 W): 148 W/m 2 bis 11 W/m 2 6 Size of area, which can be radiated by infrared radiators: 2,5 m x 2,3 m 37 Testing Facilities of the,

38 Facilities of FAST at Campus Ost Climate chamber for small vehicles Specification Temperature Inner dimensions (L*W*H) Max. Vehicle dimensions (L*W*H) Value -25 C to +25 C 5,48m*2,28m*2,25m 3,8m*2,m*1,65m 38 Testing Facilities of the,

39 Facilities of FAST Noise, Vibration & Harshness Tests Analysis of 1. Seismic mass (3t) 2. Shaker 3. Power cable 4. Sensor 5. Adapter 6. Acoustic torus measurement device Car vibration Tire vibration Car noise Tire noise 39 Testing Facilities of the,

40 Test Equipment of FAST Noise Generation : Pass-By Measurements Experimental Setup a c b d a: light barrier activates pre-defined torque automatically reproducible tangential forces can be applied b: experimental right front; slick left side c: microphone & artificial head: 4m distance, 1.2m height d: very dense surface, no ISO-surface 4 Testing Facilities of the,

41 Test Equipment of FAST Noise & Vibration analyzed with Elastic Wheel Hub Noise and vibrations measured by multiple triaxial accelerator sensors, microphones and 3D-Scanningvibrometer (see complete list next slide). 41 Testing Facilities of the,

42 Test Equipment of FAST NVH Equipment Sensors Amount Type Brand 6 Freefield and Diffuse Microphone 1/2 B&K 12 Freefield Microphone 1/4 G.R.A.S. 4 Microphone pressure type bis 18dB PCB 1 Acoustic Head Measurement System Head Acoustics 16 Triaxial Accelerometer B&K 1 3D-Scanningvibrometer Polytec Data Acquisition No. of input channels Performance Brand 96 f Mess 25,6 khz; 16bit B&K Pulse 24 f Mess 51,2 khz; 24bit; ICP NI PXI 8 (drahtlos) f Mess 25,6 khz; 24bit; ICP NI WLS 42 Testing Facilities of the,

43 Test Equipment of FAST Test Vehicles smart fortwo cdi Mercedes-Benz C 2 cdi Mercedes-Benz E 22d Mercedes-Benz S 5 as Acoustic Test Vehicle Mercedes-Benz A-Class converted to a Battery Electric Vehicle Mercedes-Benz Atego 815 Mercedes-Benz Actros 1845 LS 4x2 43 Testing Facilities of the,

44 Test Equipment of FAST Test Vehicles: Battery Electric Vehicle Nominal power (max.) Operating distance* (NEFZ) Max. speed* Charging time Type of battery Number of modules (of cells) Capacity Battery nom. power (Max.) Technical and calculated* data 45 kw (65 kw) 15 km (9% SOC) 154 km/h 1 h LiFeMgPO4 21 (5p x 6s = 3) 27,8 kwh 48,4 kw (8,6 kw) 44 Testing Facilities of the,

45 Test Equipment of FAST Test Vehicles: Battery Electric Vehicle 45 Testing Facilities of the,

46 Test Equipment of FAST Test Vehicles: Battery Electric Vehicle Modeling and Simulation Velocity / m/s Load profile during regenerative braking 1 2 speed 8 current 15 Torque Torque / Nm Current / A Model of electric powertrain Time / s Simulation of battery electric drive Development of vehicle control software e.g.: software sequence for regenerative braking Hardware modification for regenerative braking 46 Testing Facilities of the,

47 Contact Please feel free to contact us: Further information's can be found at: 47 Testing Facilities of the,