Magneto-rheological suspensions for improving ground vehicle’s ride comfort,stability, and handling

ABSTRACT

A state-of-the-art discussion on the applications of magneto-rheological (MR) suspensions for improving ride comfort, handling, and stability in ground vehicles is discussed for both road and rail applications. A historical perspective on the discovery and engineering development of MR fluids is presented, followed by some of the common methods for modelling their non-Newtonian behaviour. The common modes of the MR fluids are discussed, along with the application of the fluid in valve mode for ground vehicles’ dampers (or shock absorbers). The applications span across nearly all road vehicles, including automobiles, trains, semi-trucks, motorcycles, and even bicycles. For each type of vehicle, the results of some of the past studies is presented briefly, with reference to the originating study. It is discussed that Past experimental and modelling studies have indicated that MR suspensions provide clear advantages for ground vehicles that far surpasses the performance of passive suspension. For rail vehicles, the primary advantage is in terms of increasing the speed at which the onset of hunting occurs, whereas for road vehicles – mainly automobiles – the performance improvements are in terms of a better balance between vehicle ride, handling, and stability. To further elaborate on this point, a single-suspension model is used to develop an index-based approach for studying the compromise that is offered by vehicle suspensions, using the H₂ optimisation approach. Evaluating three indices based on the sprung-mass acceleration, suspension rattlespace, and tyre deflection, it is clearly demonstrated that MR suspensions significantly improve road vehicle’s ride comfort, stability, and handling in comparison with passive suspensions. For rail vehicles, the simulation results indicate that using MR suspensions with an on-off switching control can increase the speed at which the on-set of hunting occurs by as much as 50% to more than 300%.     

A signal-based fault detection and classification method for heavy haul wagons

This paper proposes a signal-based fault detection and isolation (FDI) system for heavy haul wagons considering the special requirements of low cost and robustness. The sensor network of the proposed system consists of just two accelerometers mounted on the front left and rear right of the carbody. Seven fault indicators (FIs) are proposed based on the cross-correlation analyses of the sensor-collected acceleration signals. Bolster spring fault conditions are focused on in this paper, including two different levels (small faults and moderate faults) and two locations (faults in the left and right bolster springs of the first bogie). A fully detailed dynamic model of a typical 40t axle load heavy haul wagon is developed to evaluate the deterioration of dynamic behaviour under proposed fault conditions and demonstrate the detectability of the proposed FDI method. Even though the fault conditions considered in this paper did not deteriorate the wagon dynamic behaviour dramatically, the proposed FIs show great sensitivity to the bolster spring faults. The most effective and efficient FIs are chosen for fault detection and classification. Analysis results indicate that it is possible to detect changes in bolster stiffness of ±25% and identify the fault location.     

State estimation in roll dynamics for commercial vehicles

Accurate lateral load transfer estimation plays an important role in improving the performance of the active rollover prevention system equipped in commercial vehicles. This estimation depends on the accurate prediction of roll angles for both the sprung and the unsprung subsystems. This paper proposes a novel computational method for roll-angle estimation in commercial vehicles employing sensors which are already used in a vehicle dynamic control system without additional expensive measurement units. The estimation strategy integrates two blocks. The first block contains a sliding-mode observer which is responsible for calculating the lateral tyre forces, while in the second block, the Kalman filter estimates the roll angles of the sprung mass and those of axles in the truck. The validation is conducted through MATLAB/TruckSim co-simulation. Based on the comparison between the estimated results and the simulation results from TruckSim, it can be concluded that the proposed estimation method has a promising tracking performance with low computational cost and high convergence speed. This approach enables a low-cost solution for the rollover prevention in commercial vehicles.     

Vehicle lift-off modelling and a new rollover detection criterion

The modelling and development of a general criterion for the prediction of rollover threshold is the main purpose of this work. Vehicle dynamics models after the wheels lift-off and when the vehicle moves on the two wheels are derived and the governing equations are used to develop the rollover threshold. These models include the properties of the suspension and steering systems. In order to study the stability of motion, the steady-state solutions of the equations of motion are carried out. Based on the stability analyses, a new relation is obtained for the rollover threshold in terms of measurable response parameters. The presented criterion predicts the best time for the prevention of the vehicle rollover by applying a correcting moment. It is shown that the introduced threshold of vehicle rollover is a proper state of vehicle motion that is best for stabilising the vehicle with a low energy requirement.     

Insights into vehicle trajectories at the handling limits: analysing open data from race car drivers

Race car drivers can offer insights into vehicle control during extreme manoeuvres; however, little data from race teams is publicly available for analysis. The Revs Program at Stanford has built a collection of vehicle dynamics data acquired from vintage race cars during live racing events with the intent of making this database publicly available for future analysis. This paper discusses the data acquisition, post-processing, and storage methods used to generate the database. An analysis of available data quantifies the repeatability of professional race car driver performance by examining the statistical dispersion of their driven paths. Certain map features, such as sections with high path curvature, consistently corresponded to local minima in path dispersion, quantifying the qualitative concept that drivers anchor their racing lines at specific locations around the track. A case study explores how two professional drivers employ distinct driving styles to achieve similar lap times, supporting the idea that driving at the limits allows a family of solutions in terms of paths and speed that can be adapted based on specific spatial, temporal, or other constraints and objectives.     

Design of tyre force excitation for tyre–road friction estimation

Knowledge of the current tyre–road friction coefficient is essential for future autonomous vehicles. The environmental conditions, and the tyre–road friction in particular, determine both the braking distance and the maximum cornering velocity and thus set the boundaries for the vehicle. Tyre–road friction is difficult to estimate during normal driving due to low levels of tyre force excitation. This problem can be solved by using active tyre force excitation. A torque is added to one or several wheels in the purpose of estimating the tyre–road friction coefficient. Active tyre force excitation provides the opportunity to design the tyre force excitation freely. This study investigates how the tyre force should be applied to minimise the error of the tyre–road friction estimate. The performance of different excitation strategies was found to be dependent on both tyre model choice and noise level. Furthermore, the advantage with using tyre models with more parameters decreased when noise was added to the force and slip ratio.     

The Kalker book of tables for non-Hertzian contact of wheel and rail

A new regularisation of non-elliptical contact patches has been introduced, which enables building the look-up table called by us the Kalker book of tables for non-Hertzian contact (KBTNH), which is a fast creep force generator that can be used by multibody dynamics system simulation programs. The non-elliptical contact patch is regularised by a simple double-elliptical contact region (SDEC). The SDEC region is especially suitable for regularisation of contact patches obtained with approximate non-Hertzian methods for solving the normal contact problem of wheel and rail. The new regularisation is suitable for wheels and rails with any profiles, including worn profiles.

The paper describes the new procedure of regularisation of the non-elliptical contact patch, the structure of the Kalker book of tables, and parameterisation of the independent variables of the tables and creep forces.

A moderate volume Kalker book of tables for SDEC region suitable for simulation of modern running gears has been computed in co-simulation of Matlab and program CONTACT.

To access the creep forces of the Kalker book of tables, the linear interpolation has been applied.

The creep forces obtained from KBTNH have been compared to those obtained by program CONTACT and FASTSIM algorithm. FASTSIM has been applied on both the contact ellipse and the SDEC contact patch. The comparison shows that KBTNH is in good agreement with CONTACT for a wide range of creepage condition and shapes of the contact patch, whereas the use of FASTSIM on the elliptical patch and SDEC may lead to significant deviations from the reference CONTACT solutions.

The computational cost of calling creep forces from KBTNH has been estimated by comparing CPU time of FASTSIM and KBTNH. The KBTNH is 7.8–51 times faster than FASTSIM working on 36–256 discretisation elements, respectively.

In the example of application, the KBTNH has been applied for curving simulations and results compared with those obtained with the creep force generator employing the elliptical regularisation. The results significantly differ, especially in predicted creepages, because the elliptical regularisation neglects generation of the longitudinal creep force by spin creepage.     

Influence of AC system design on the realisation of tractive efforts by high adhesion locomotives

The main task for heavy haul railway operators is to reduce the cost of exported minerals and enhance the long-term viability of rail transport operations through increasing productivity by running longer and heavier trains. The common opinion is that this is achievable by means of implementation of high adhesion locomotives with advanced AC traction technologies. Modern AC high adhesion locomotives are very complex mechatronic systems and can be designed with two alternative traction topologies of either bogie or individual axle controls. This paper describes a modelling approach for these two types of AC traction systems with the application of an advanced co-simulation methodology, where an electrical system and a traction algorithm are modelled in Matlab/Simulink, and a mechanical system is modelled in a multibody software package. Although the paper concentrates on the analysis of the functioning for these two types of traction control systems, the choice of reference slip values also has an influence on the performance of both systems. All these design variations and issues have been simulated for various adhesion conditions at the wheel–rail interface and their influence on the high traction performance of a locomotive equipped with two three-axle bogies has been discussed.     

基于小波和粒子群算法的HEV行驶状况辨识方法研究

针对混合动力汽车(HEV)行驶状况(道路坡度和整车载荷)变化难以有效识别,导致驱动系统控制策略不能有效满足驾驶员意图问题,以混联式HEV为研究对象,提出了基于小波滤波和粒子群算法的HEV行驶状况辨识方法。首先建立了汽车行驶状况辨识模型,采用最小二乘法确立了优化目标函数,其次研究了基于小波滤波和粒子群算法的HEV行驶状况辨识原理,最后进行了行驶状况粒子群智能算法辨识试验。在采集实车数据的基础上,对实车数据进行小波滤波,并运用行驶状况辨识方法对道路坡度和整车载荷进行了辨识,并对辨识结果进行小波滤波,结果表明,试验工况下整车载荷辨识的相对误差绝对平均值为2.71%,道路坡度辨识的相对误差绝对平均值为3.85%,验证了所提出方法的有效性。     

轻型汽油车N_2O排放特性研究

选择1辆满足国Ⅴ排放标准的轻型汽油车作为试验样车,应用全流稀释排放测试系统在FTP75和US06测试循环下,对车辆在不同测试工况下的N_2O排放水平、车辆N_2O排放的影响因素以及N_2O排放随着车辆里程增加的劣化情况进行了研究。研究结果表明:FTP75循环下的N_2O排放结果高于US06循环,前者是后者的4倍左右;在冷起动阶段,由于催化剂没有达到正常的工作温度,车辆会产生较多的N_2O排放,且随着燃油硫含量的增加,车辆的N_2O排放呈现上升的趋势;随着车辆里程的不断增加,车辆的N_2O排放存在一定程度的劣化。