Using Adams as master model for ECU system simulation
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1 Using Adams as master model for ECU system simulation Dipl.-Ing. Simon Schmeiler Technische Universität München Fakultät für Maschinenwesen Lehrstuhl für Fahrzeugtechnik (FTM) Dipl.-Ing. Karl-Eric Köstlin TESIS DYNAware Technische Simulation Dynamischer Systeme GmbH
2 Agenda Agenda Outline of Visio.M project Design goals and process of Visio.M Deriving a DYNA4 RT Model from ADAMS Results Benefits & Outlook 2
3 Visio.m joint research project Premise of Vehicle Concept: Inexpensive. - Total vehicle costs equivalent to conventional compact cars. Efficient. - Highly efficient overall concept as a basis for cost reduction. Safe. - Vehicle safety equivalent to conventional compact cars. Consortium: Sponsors: 3
4 Technical Data Visio.M Concept Occupants Trunk Space Range Costs Market Top Speed Power Weight Battery electric car 2 persons 2 pieces of luggage, 500 l 166 km (NEDC) equal to conventional compact cars Europe 120 km/h 15 kw 450 kg (without traction battery) 4
5 Development Process Multi-Body-Simulation First test vehicle Measurement of operational loads Optimization of weight and durability Controller development for active chassis components Driving tests 5
6 Relevant Dimensions and Weight Distribution 55 % 45 % 2100 mm 470 mm 1400 mm 1450 mm 6
7 Tires Dimension: 115/70 R16 66T Compact class Subcompact Visio.M 7
8 Passive driving dynamics Development goals for active drivetrain components Better Dynamics in normal driving conditions More stable in critical conditions 8
9 Drivetrain Rear-wheel drive Torque Vectoring (active differential) electric drive machine axle gear actuator superimposing gear differential 9
10 Torque Vectoring Controller Controller Model based desired value generation Tuning by small number of parameters Control of yaw-rate Actuation through Torque Vectoring Drive 10
11 DYNA4 parameterisation from ADAMS DYNA4 was introduced for its real-time simulation capability and to perform DOEs for controller development Conversion from ADAMS to DYNA4 performed in following steps: 1. Axle component generation & validation - K&C test rig I. Kinematics II. Compliance 2. Full vehicle validation Steady state maneuvers e.g. Circular driving 3. Full vehicle validation Dynamic maneuvers e.g. Steer step 11
12 DYNA4 axle generation from ADAMS Import filter Including: Spring Rebound/Jounce Anti-roll bar Steering ADAMS K&C Measurements DYNA4 Suspension Generator Tabled kinematic and compliance axles Simulation inputs Axle component validation DYNA4 Suspension test rig 12
13 Visio.M axle validation - Kinematics Extract from automated report results: Front axle, Right wheel Steering sweep Curb load Characteristics: Perfect correlation Wave effect due to steering column universal joints is reproduced 13
14 Visio.M axle validation - Compliance Extract from automated report results: Front axle, Left wheel Lateral force sweep at contact patch Performed at Curb load Characteristics: Perfect component validation with ADAMS used as reference 14
15 Visio.M full vehicle validation - Steady state circular driving Steady state validation (passive): Steady state circular driving 100m radius Lateral acceleration up to 7m/s 2 Asymmetrical vehicle loading 15
16 Visio.M full vehicle validation - Steady state circular driving 16
17 Visio.M full vehicle validation - Dynamic steer step Dynamic validation (passive): 20 steering wheel step in 0,5s 60km/h Asymmetrical vehicle loading 17
18 Visio.M full vehicle validation - Dynamic steer step 18
19 Visio.M in DYNA4 environment 19
20 Preliminary results Constant radius cornering Step steer Radius: r = 55 m Improvement: a y +0,36 m/s² 20
21 Benefits & Outlook Wide coverage of development process tasks with ADAMS and DYNA4 ADAMS provided a high resolution multi-body model for the development of the Visio.M chassis and its components Closed framework for controller development with DYNA4 and Simulink In the next step we wish to work on fault detection and functional safety In the medium term: HiL tests for real ECU testing and extreme condition simulation Simulating F-Tire in the DYNA4 vehicle if tire temperature, pressure and tread are to be investigated More information and videos: 21
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