I/We* have read this thesis and from my/our* opinion this thesis is sufficient in aspects of scope and quality for awarding Bachelor of Mechanical Engineering (Automotive) Signature :. Name of Supervisor : Mohd Hanif bin Harun Date : 13 May 2010 *Line which is irrelevant
i SIMULATION STUDY ON ACTIVE SEAT SUSPENSION FOR A PASSENGER CAR MUHAMAD SUFFIAN EFFENDI BIN MD YUSUF This report is presented as a requirement for a degree undergraduate in Bachelor of Mechanical Engineering (Automotive) Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka APRIL 2010
ii I declare this report is on my own work except for summary and quotes that I have mentioned its sources Signature Name of Author :.. : Muhamad Suffian Effendi Md Yusuf Date : 20/05/2010
iii To my family for their love
iv ACKNOWLEDGEMENTS Praise is to Allah S.W.T to Whom seek help and guidance and under His benevolence we exist and without his help this project could not have been accomplish. I would like to take this opportunity to express my gratitude to my supervisor En. Mohd Hanif bin Harun his constant guidance and encouragement during the past fourteen weeks. He always appreciates whatever little progress I have achieved, and continuously gives me much inspiration by sharing his precious knowledge and experience. I shall always remember the fun we have had together. Finally, but most importantly of all, my parents Tifah bte Masran and should receive my greatest appreciation for their enormous love. They always respect what I want to do and give me their full support. The support from my siblings is also highly appreciated. Muhamad Suffian Effendi Md Yusuf UTeM April 2010
v ABSTRACT The goal of this project is to propose control mechanism of the active seat suspension for a passenger car in order to improve riding comfort of the vehicle. This analysis incriminates Newton Second Law Theory for vertical force, pitching moment and also rolling moment. For study for this model it only have ride model. This ride model after that will be tested by using software MATLAB Simulink for simulation test. For this model its only 10 DOF needed. The data after that will compare from active suspension and passive suspension between their performance and motion from the simulation and authentic with data from the true source.
vi ABSTRAK Matlamat projek ini ialah untuk mencadangkan pemasangan mekanisma kawalan terhadap sistem gantungan aktif terhadap bangku kenderaan penumpang dengan tujuan untuk penambahbaikkan dalam pemanduan kenderaan. Analisa ini melibatkan teori Newton kedua terhadap daya menegak sistem gantungan dan juga tapak cagak momen terhadap kecuraman dan momen golekkan. Untuk mempelajari model ini hanya medel tunggangan diperlukan. Model tunggangan ini kemudian akan diuji menggunakan perisian komputer MATLAB Simulink untuk diuji di bawah keadaan yang hampir nyata dengan keadaan sebenar dan prestasinya disiasat. Dalam model ini 10 darjah kebebasan diperlukan. Data yang diperoleh daripada ujian dibandingkan perlaksanaan dan pergerakkannya dalam simulasi dan disahkan dengan data yang diperoleh daripada pelbagai sumber, antaranya daripada sumber ilmiah dan industri.
vii TABLE OF CONTENT CHAPTER TITLE PAGE PREFACE DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF TABLE LIST OF FIGURE LIST OF SYMBOL NOMENCLATURE ii iii iv v vi vii ix x xii xvii 1 INTRODUCTION 1.1 Background 1 1.2 Objective 2 1.3 Scope 2 1.4 Problem statement 3 1.5 Thesis Outline 4 1.5.1 Chapter summary 6 2 LITERATURE REVIEW 2.1 Introduction 7 2.2 Theory of seat suspension 8
viii 2.3 Passive suspension 9 2.4 Semi-active suspension 11 2.4.1 Electroreheological 12 2.5 Active suspension 14 2.5.1 Electric Servo-Motor Actuator 15 2.6 Active Vs. Passive suspension 16 3 METHODOLOGY 3.1 Introduction 20 3.2 Seat Suspension Model 22 3.2.1 Model Seat Ride Model Parameter 23 3.3 Full Model of Suspension Ride Model 24 3.4 Free body diagram 26 3.5 Mathematical Model 27 3.6 Controller 32 3.6.1 Actuator Control (Decoupling Transformation) 34 3.7 MATLAB Simulink Model 36 4 RESULTS AND DISCUSSION 4.1 MATLAB Simulink Result and Discussion 44 4.2 Result validation 52 5 CONCLUSION AND RECOMMENDATION 5.1 Conclusion 57 5.2 Recommendation 58 REFERENCE 59 BIBLIOGRAPHY 60 APPENDIX 61
ix LIST OF TABLE TABLE TITLE PAGE 1.5.1 Gantt chart Of Project Outline for PSM 1 4 1.5.2 Gantt chart Of Project Outline for PSM 2 5 2.6 Comparison between Active and Passive Suspension 17 3.1 Gantt chart of Project Research 21 3.2.1 Parameter for Ride Model 23 4.1.1 Reduction of magnitude for acceleration 47 4.1.2 Reduction of Magnitude for Speed 50 4.1.3 Reduction of Magnitude for Displacement and Angle 52
x LIST OF FIGURE FIGURE TITLE PAGE 2.1 Motion of seat with safety 8 2.3.1 Seat model of passive suspension system 10 2.3.2 FBD Seat model of passive suspension system 10 2.3.3 Result of transmissibility of different foam 11 2.4.1 ER Seat Suspension System 12 2.4.2 Experimental Apparatus for ER Seat Suspension System 13 2.4.3 Frequency Response ER seat suspension System 13 2.5.1 Active suspension seat develop by Georgia Institute of technology 15 2.5.2 Analysis model of servo-motor seat suspension 16 2.5.3 Control system of servo-motor seat suspension 16 2.6 Time response between used and unused controller in suspension system 18 3.1 Project Flow Chart 20 3.2 Seat Model 22 3.3.1 Seat ride model for passive system 25 3.3.2 Seat Model for Active System with Vehicle Suspension 25 3.4.1 FBD for seat ride model for passive system 26 3.4.2 Rolling Moment 30 3.4.3 Pitching Moment 31 3.5 Active Vibration Control 33 3.7.1 MATLAB Simulink model for the system 36
xi 3.7.2 Function Block Parameter for PID Controller 37 3.7.3 Decoupling Transformation Subsystem 37 3.7.4 Subsystem for Active Seat Suspension 38 3.7.5 Subsystem For Passive Seat Suspension 39 3.7.6 Subsystem for Seat Pitchd & Rolld 39 3.7.7 Subsystem for Seat Pitch & Roll 40 3.7.8 Subsystem for Seat Damper 40 3.7.9 Subsystem for Seat Spring 41 3.7.10 Sample Subsystem for Seat Mounting 41 3.7.11 Subsystem for Seat Vertical Motion 42 3.7.12 Subsystem for Seat Pitching Moment 42 3.7.13 Subsystem for Seat Rolling Moment 43 4.1.1 Disturbance Input (Road Bump) 45 4.1.2 Seat Vertical Acceleration vs. Time 45 4.1.3 Seat Pitch Acceleration vs. Time 46 4.1.4 Seat Roll Acceleration vs. Time 46 4.1.5 Seat Vertical Speeds vs. Time 48 4.1.6 Seat Pitch Rate vs. Time 48 4.1.7 Seat Roll Rate vs. Time 49 4.1.8 Seat Vertical Displacement vs. Time 50 4.1.9 Seat Pitch Angle vs. Time 51 4.1.10 Seat Roll Angle vs. Time 51 4.2.1 Graph of Displacement and Acceleration vs. Time for Passive and Active Suspension from Theory 53 4.2.2 Graph of Displacement and Acceleration vs. Time for Passive and Active Suspension from Simulation Data 54 4.2.3 Graph Seat Vertical Displacement vs. Time 55 4.2.4 Graph Seat Vertical Displacement vs. Time from Simulation 56
xii LIST OF SYMBOLS SYMBOL TITLE UNIT Seat Rolling Angle rad Seat Roll Rate At Body Centre Of Gravity rads -1 Seat Roll Acceleration At Body Centre Of Gravity rads -2 Vehicle Rolling Angle rad Vehicle Roll Rate At Body Centre Of Gravity rads -1 Vehicle Roll Acceleration At Body Centre Of Gravity rads -2 Seat Pitching Angle rad Seat Pitch Rate At Body Centre Of Gravity rads -1 Seat Pitch Acceleration At Body Centre Of Gravity rads -2 Vehicle Pitching Angle rad Vehicle Pitch Rate At Body Centre Of Gravity rads -1 Vehicle Pitch Acceleration At Body Centre Of Gravity rads -2 C fl Vehicle Front Left Damper Coefficient Nsm -1 C fr Vehicle Front Right Damper Coefficient Nsm -1 C rl Vehicle Rear Left Damper Coefficient Nsm -1 C rr Vehicle Rear Right Damper Coefficient Nsm -1 Cs fl Seat Front Left Damper Coefficient Nsm -1 Cs fr Seat Front Right Damper Coefficient Nsm -1 Cs rl Seat Rear Left Damper Coefficient Nsm -1 Cs rr Seat Rear Right Damper Coefficient Nsm -1 Disturbance Force At Front-Left Unsprung Mass N Disturbance Force At Front-Right Unsprung Mass N
xiii Disturbance Force At Rear-Left Unsprung Mass N Disturbance Force At Rear-Right Unsprung Mass N F Force N Fdsfl Seat Front-Left Damper Force N Fdsfr Seat Front-Right Damper Force N Fdsrl Seat Rear-Left Damper Force N Fdsrr Seat Rear-Right Damper Force N Fdcfl Vehicle Front-Left Damper Force N Fdcfr Vehicle Front-Right Damper Force N Fdcrl Vehicle Rear-Left Damper Force N Fdcrr Vehicle Rear-Right Damper Force N Fssfl Seat Front-Left Spring Force N Fssfr Seat Front-Right Spring Force N Fssrl Seat Rear-Left Spring Force N Fssrr Seat Rear-Right Spring Force N Fscfl Vehicle Front-Left Spring Force N Fscfr Vehicle Front-Right Spring Force N Fscrl Vehicle Rear-Left Spring Force N Fscrr Vehicle Rear-Right Spring Force N Fv Vertical Force N I ps Seat Sprung Mass Pitch Inertia kgm -2 I rs Seat Sprung Mass Roll Inertia kgm -2 I pc Vehicle Sprung Mass Pitch Inertia kgm -2 I rc Vehicle Sprung Mass Roll Inertia kgm -2 K fl Vehicle Front-Left Spring Coefficient Nm -1 K fr Vehicle Front-Right Spring Coefficient Nm -1 K rl Vehicle Rear-Left Spring Coefficient Nm -1 K rr Vehicle Rear-Right Spring Coefficient Nm -1 Ks fl Seat Front-Left Spring Coefficient Nm -1 Ks fr Seat Front-Right Spring Coefficient Nm -1 Ks rl Seat Rear-Left Spring Coefficient Nm -1 Ks rr Seat Rear-Right Spring Coefficient Nm -1 Kt fl Tire Front-Left Spring Coefficient Nm -1
xiv Kt fr Tire Front-Right Spring Coefficient Nm -1 Kt rl Tire Rear-Left Spring Coefficient Nm -1 Kt rr Tire Rear-Right Spring Coefficient Nm -1 Kp Proportional Gains Respectively Ki Integral Gains Respectively Kd Derivative Gains Respectively m s Seat Mass kg m c Vehicle Mass kg m w Wheel Mass kg Mp Pitch Moment Nm Mr Roll Moment Nm Ts Seat Width m Tc Vehicle Track Width m Wsd Seat Body Length From CG to Front Mounting m Wsb Seat Body Length From CG to Rear Mounting m Wcd Seat Body Length From CG to Front Tire m Wcb Seat Body Length From CG to Rear Tire m Zc Sprung Mass Displacement At Vehicle Body CG m Sprung Mass Velocity At Vehicle Body CG ms -1 Sprung Mass Acceleration At Vehicle Body CG ms -1 Zcfl Front-Left Vehicle Displacement m Zcfr Front-Right Vehicle Displacement m Zcrl Rear-Left Vehicle Displacement m Zcrr Rear-Right Vehicle Displacement m Vehicle Velocity At Front-Left Corner ms -1 Vehicle Velocity At Front-Right Corner ms -1 Vehicle Velocity At Rear-Left Corner ms -1 Vehicle Velocity At Rear-Right Corner ms -1 Vehicle Acceleration At Front-Left Corner ms -2 Vehicle Acceleration At Front-Right Corner ms -2 Vehicle Acceleration At Rear-Left Corner ms -2 Vehicle Acceleration At Rear-Right Corner ms -2 Zs Sprung Mass Displacement At Seat Body CG m
xv Sprung Mass Velocity At Seat Body CG ms -1 Sprung Mass Acceleration At Seat Body CG ms -1 Zsfl Front-Left Seat Displacement m Zsfr Front-Right Seat Displacement m Zsrl Rear-Left Seat Displacement m Zsrr Rear-Right Seat Displacement m Seat Velocity At Front-Left Corner ms -1 Seat Velocity At Front-Right Corner ms -1 Seat Velocity At Rear-Left Corner ms -1 Seat Velocity At Rear-Right Corner ms -1 Seat Acceleration At Front-Left Corner ms -2 Seat Acceleration At Front-Right Corner ms -2 Seat Acceleration At Rear-Left Corner ms -2 Seat Acceleration At Rear-Right Corner ms -2 Zmfl Sprung Mass Displacement At Front-Left Seat Mounting m Zmfr Sprung Mass Displacement At Front-Right Seat Mounting m Zmrl Sprung Mass Displacement At Rear-Left Seat Mounting m Zmrr Sprung Mass Displacement At Rear-Right Seat Mounting m Sprung Mass Velocity At Front-Left Seat Mounting ms 1 Sprung Mass Velocity At Front-Right Seat Mounting ms 1 Sprung Mass Velocity At Rear-Left Seat Mounting ms 1 Sprung Mass Velocity At Rear-Right Seat Mounting ms 1 Sprung Mass Acceleration At Front-Left Seat Mounting ms -2 Sprung Mass Acceleration At Front-Right Seat Mounting ms -2 Sprung Mass Acceleration At Rear-Left Seat Mounting ms -2 Sprung Mass Acceleration At Rear-Right Seat Mounting ms -2 Zwfl Sprung Mass Displacement At Front-Left Tire m Zwfr Sprung Mass Displacement At Front-Right Tire m Zwrl Sprung Mass Displacement At Rear-Left Tire m Zwrr Sprung Mass Displacement At Rear-Right Tire m Sprung Mass Velocity At Front-Left Tire ms 1 Sprung Mass Velocity At Front-Right Tire ms 1
xvi Sprung Mass Velocity At Rear-Left Tire ms 1 Sprung Mass Velocity At Rear-Right Tire ms 1 Sprung Mass Acceleration At Front-Left Tire ms -2 Sprung Mass Acceleration At Front-Right Tire ms -2 Sprung Mass Acceleration At Rear-Left Tire ms -2 Sprung Mass Acceleration At Rear-Right Tire ms -2
xvii NOMENCLATURE DOF FBD PID CG Degree of Freedom Free Body Diagram Proportional-Integral-Derivative Centre of Gravity
1 CHAPTER 1 INTRODUCTION 1.1 Background Suspension is a system encircles spring and shock absorber to absorb any vibration from road roughness and on-board source. It is for giving comfortable to the driver and passenger. The suspension systems support the vehicle body, decrease the road surface induced vehicle vibrations, help to improve ride comfort and road holding. Springs and dampers are main components of the suspensions that are parallel to each other and placed between the vehicle body and axles. The optimum design of these elements is the main goal of the manufacturers. Two important factors of ride comfort and road holding which are conflicting each other have to be compromised. Hard springs result in better road holding whereas ride comfort gets worse. On the other hand, resonance of the linear and angular motions of the vehicle body is another source of the uncomfortable ride. Addition of active systems has the potential of improving ride comfort. A good vehicle suspension system has to reduce the sprung mass displacement together with acceleration and provide adequate suspension deflection to maintain tires on contact. This helps to improve ride comfort and vehicle maneuverability. Thus, the improvement of the active vehicle suspensions systems has attracted more interest and been the
2 subject of the research and development in last decades. The reason is commercial as well as being scientific. The main aim of the commercial activity is the desire of the automotive manufacturers to improve the performance and quality of their products. On the other hand, researchers and control system designers have claimed that the active control of the vehicle suspension system is possible when the developments in actuators, sensors and electronics have been considered. In the last twenty years, many studies have been published on active and semi-active suspension systems. 1.2 Objective The objectives of this project are to propose control mechanism of the active seat suspension for a ground vehicle in order to improve riding comfort of the vehicle. 1.3 Scope MATLAB Simulink Software will be chosen as a computer design tools used to simulate the dynamics behavior and evaluate the performance of the control structure. The research methodology implemented in this project take the following steps of works: literature review on related fields, study some previous works and the latest development on active seat suspension, development of equation of motion, simulation and comparison with the passive system.
3 1.4 Problem Statement Normally in a vehicle have a vibration. Source of vehicle vibration is generally is divided into two classes: Road roughness On-board source G.M Alan etc. (2005) said effect from the vibration can transfer from vehicle seat to human body. Its affect not only comfort, working efficiency and performance but can affect at health and safety when driving. Injury statistics from the Mine Safety and Health Administration (MSHA) showed incidences of exposure to whole-body vibration (WBV) and it also support by S.J Kooster (2004). Operators of mine vehicles are in particular subject to high levels of vibrations under very constraining conditions. The vehicle operator often is more confined to a less space than in normal cars or vehicles and the seats are not equipped with a suspension system. In the vehicles, an effective vehicle handling requires a significant torque on the front an axle which creates vibrations in the driver s seat. Improving the ergonomics of the seat can lessen the adverse effects of vehicle vibration. Adding a secondary suspension mechanism to the driver s seat of vehicles is another solution that was found to reduce the vibration induced by the seat.
4 1.5 Thesis Outline Table 1.5.1: Gantt chart of Project Outline for PSM 1 NO ITEM WEEK(S) 1 Project Title Discussion 1 JULY '09 AUG '09 SEPT '09 OCT '09 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 Introduction 2 3 Literature Review 3 4 Research Methodology 4 5 Report Writing 3 6 Report Submission 1 Target Actual
5 Table 1.5.2: Gantt chart of Project Outline for PSM 2 NO ITEM WEEK(S) 1 PSM 2 Discussion 1 2 Build Simulation (using MATLAB) 3 Simulation (MATLAB) 3 4 JAN '10 FEB '10 MAR '10 APR '09 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 4 Result Discussion 2 5 Report Writing 4 6 Report Submission 1 Target Actual
6 1.5.1 Chapter Summary Chapter 1: Chapter 2: Chapter 3: Chapter 4: Chapter 5: This chapter explains about the objective and scope of this project. In this chapter also have the problem about the conventional and newer system. This chapter describes about the previous study about the seat suspension system. This chapter shows the system in mathematical modeling 10DOF full ride model. Result and discussion is briefly explained in this chapter Conclusion.