Virtual durability test rigs for automotive engineering

In recent years so-called ‘virtual test rigs’ have become more and more important in the development process of cars and trucks. Originally, the idea was to substitute expensive durability tests with computer simulation. Meanwhile, the focus has changed towards a more cooperative usage of numerical and laboratory rig simulation. For many safety critical issues laboratory tests remain indispensable. In early development stages, when no physical prototypes are available yet, numerical simulation is used to analyse and optimise the design. In this paper, we show how to build numerical simulation models of complex servo-hydraulic test systems and their test specimen using multi-body simulation for the mechanics in combination with simulation models for the hydraulics and controls. We illustrate this at two industrial application examples: a spindle-coupled passenger car suspension rig and a tyre-coupled full vehicle rig. We show how the simulation models are used to design and optimise better test rigs and to support the test rig operation by preparing the physical tests with new specimen, i.e. by performing numerical simulations including numerical drive file iteration before the physical tests start.     

Roll- and pitch-plane-coupled hydro-pneumatic suspension. Part 2: dynamic response analyses

In the first part of this study, the potential performance benefits of fluidically coupled passive suspensions were demonstrated through analyses of suspension properties, design flexibility and feasibility. In this second part of the study, the dynamic responses of a vehicle equipped with different configurations of fluidically coupled hydro-pneumatic suspension systems are investigated for more comprehensive assessments of the coupled suspension concepts. A generalised 14 degree-of-freedom nonlinear vehicle model is developed and validated to evaluate vehicle ride and handling dynamic responses and suspension anti-roll and anti-pitch characteristics under various road excitations and steering/braking manoeuvres. The dynamic responses of the vehicle model with the coupled suspension are compared with those of the unconnected suspensions to demonstrate the performance potential of the fluidic couplings. The dynamic responses together with the suspension properties suggest that the full-vehicle-coupled hydro-pneumatic suspension could offer considerable potential in realising enhanced ride and handling performance, as well as improved anti-roll and anti-pitch properties in a very flexible and energy-saving manner.     

Optimal selection of suspension parameters in large scale vehicle models

Optimum values are selected for the suspension damping and stiffness parameters of complex car models, subjected to road excitation, by applying suitable numerical methodologies. These models result from a detailed finite-element discretisation and possess a relatively large number of degrees of freedom. They also involve strongly nonlinear characteristics, due mostly to large rigid body rotation of some of their components and the properties of the connection elements. First, attention is focused on gaining some insight into the dynamics of the mechanical models examined, resulting when the vehicle passes over roads involving typical geometric profiles. Then, the emphasis is shifted to presenting results obtained by applying appropriate optimisation methodologies. For this purpose, three classes of design criteria are first set up, referring to passenger ride comfort, suspension travel and car road holding and yielding the most important suspension stiffness and damping parameters. Originally, the optimisation is performed by forming a composite cost function and employing a single-objective optimisation method. Since the design criteria are conflicting, a multi-objective optimisation methodology is also set up and applied subsequently.     

A model-based traction control strategy non-reliant on wheel slip information

A traction control system (TCS) for two-wheel-drive vehicles can conveniently be realised by means of slip control. Such a TCS is modified in this paper in order to be applicable to four-wheel-drive vehicles and anti-lock braking systems, where slip information is not readily available. A reference vehicle model is used to estimate the vehicle velocity. The reference model is excited by a saw-tooth signal in order to adapt the slip for maximum tyre traction performance. The model-based TCS is made robust to vehicle modelling errors by extending it with (i) a superimposed loop of tyre static curve gradient control or (ii) a robust switching controller based on a bi-directional saw-tooth excitation signal. The proposed traction control strategies are verified by experiments and computer simulations.     

Dynamic model for ride comfort evaluations of the rubber-tired light rail vehicle

The dynamic model was developed to evaluate vibration accelerations and ride comforts during the running of the Korean-standardised rubber-tired light rail vehicle. Ride comfort indexes were analysed and tested in accordance with UIC 513R by using the dynamic model and the actual vehicle in the test track. Based on the comparisons between analysis results and test results, the validity of the developed dynamic model was evaluated. It was verified whether or not the developed Korean-standardised rubber-tired light rail vehicle met the specified target specification on ride comfort. In addition, the influence of the wearing of guide wheels on ride comfort was estimated.     

A nonlinear virtual rider for motorcycles

This work presents a virtual rider for the guidance of a nonlinear motorcycle model. The target motion is defined in terms of roll angle and speed. The virtual rider inputs are the steering torque, the rear-wheel driving/braking torque and front-wheel braking torque. The virtual rider capability is assessed by guiding the nonlinear motorcycle model in demanding manoeuvres with roll angles of 50° and longitudinal accelerations up to 0.8 g. Considerations on the effective preview distance used by the virtual rider are included.     

On the equivalent wheelbase of a three-axle vehicle

The steady-state handling properties of a rigid vehicle with a tandem rear axle configuration are developed. This work uses conventions resulting in a parsimonious characterisation of steady-state handling of such three-axle vehicles that is shown to be a simple extension of the well-known two-axle bicycle model. Specifically the concepts of understeer and wheelbase are developed for a three-axle vehicle, and shown to play the same role in characterising vehicle handling as they do in the well-known two-axle vehicle model. An equivalent wheelbase of a three-axle vehicle is expressed in terms of vehicle geometry and cornering stiffness of each axle. The model developed in this work is reconciled with previous models that make use of simplifying assumptions found in the literature.     

Influence of some vehicle and track parameters on the environmental vibrations induced by railway traffic

A study is performed on the influence of some typical railway vehicle and track parameters on the level of ground vibrations induced in the neighbourhood. The results are obtained from a previously validated simulation framework considering in a first step the vehicle/track subsystem and, in a second step, the response of the soil to the forces resulting from the first analysis. The vehicle is reduced to a simple vertical 3-dof model, corresponding to the superposition of the wheelset, the bogie and the car body. The rail is modelled as a succession of beam elements elastically supported by the sleepers, lying themselves on a flexible foundation representing the ballast and the subgrade. The connection between the wheels and the rails is realised through a non-linear Hertzian contact. The soil motion is obtained from a finite/infinite element model. The investigated vehicle parameters are its type (urban, high speed, freight, etc.) and its speed. For the track, the rail flexural stiffness, the railpad stiffness, the spacing between sleepers and the rail and sleeper masses are considered. In all cases, the parameter value range is defined from a bibliographic browsing. At the end, the paper proposes a table summarising the influence of each studied parameter on three indicators: the vehicle acceleration, the rail velocity and the soil velocity. It namely turns out that the vehicle has a serious influence on the vibration level and should be considered in prediction models.     

Multivariable speed synchronisation for a parallel hybrid electric vehicle drivetrain

In this article, a new drivetrain configuration of a parallel hybrid electric vehicle is considered and a novel model-based control design strategy is given. In particular, the control design covers the speed synchronisation task during a restart of the internal combustion engine. The proposed multivariable synchronisation strategy is based on feedforward and decoupled feedback controllers. The performance and the robustness properties of the closed-loop system are illustrated by nonlinear simulation results.     

Investigating the influence of soil properties on railway traffic vibration using a numerical model

This paper presents the influence of dynamic and geometrical soil parameters on the propagation of ground vibrations induced by external loads. The proposed approach is based on a three-dimensional model, focusing on realistic excitation sources like impulse loads and moving railway vehicles. For the latter, a complete vehicle/track model is developed. The simulation is performed in time domain, offering an interesting approach, compared with classic cyclic analyses. The ground is modelled initially as an elastic homogeneous half-space and additionally as a layered half-space. First, the effect of homogeneous soil properties on ground vibration is analysed. Soil stratification is then taken into account, using various configurations. Analysis reveals that as receiver distance increases ground wave reflection in a layered ground plays an important role in the reduction of ground surface motion. This effect is magnified when the phase velocity wavelength becomes large compared with the depth of the surface layer.