Real Time Driving Dynamics Simulation in Heavy Commercial Vehicles
Dr. Jan FleischhackerDr. Philipp WagnerEdin TopcagicPatrick Rund
„apply & innovate 2012“ IPG Technology Conference
1< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Karlsruhe, 18.09.2012
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
2< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
Variety in Commercial VehicleSuspension
� Heavy, medium and light trucks, off-highway, special-purpose vehicle
� City-bus, intercity-bus, coach
� Up to 5 axles, variety in configuration and wheel base
� Up to 3 steered axles (mechanically, hydraulic, electrically)
� Suspension: Leaf spring, air spring, coil spring, hydropneumatic
� Powertrain: Configurations (up to 8x8), gearboxes, diff. gear units, tires, retarders
� Wide range between empty and laden vehicle
3< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
� Variety in platforms (tractor, body, flatbed, tipper, swap body, tanker, mixer, fire truck, urban)
Virtual development of varieties � Reliable modeling of variants in simulation� Real time capability� Detailed consideration of components relevant for driving dynamics (here)� IPG-TruckMaker benchmark
Real Time Driving Dynamics Simulation Motivation
4< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
5< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
� TruckMaker as a real-time simulation environment� Integration of sophisticated subsystem models (compare the MODELON presentation)
� Management of variants
Scope of Work
Integrative real-time capable vehicleDriver, road, environment
6< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Driver, road, environmentVehicle variants (truck / bus)Ridable basic vehicleModules in different LOD*
ZF AS-Tronic
* Level of Detail
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
7< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
Vehicle data� MAN TGX 4x2 BL Tractor� Additional load on fifth wheel 10,5 t� Front axle with leaf spring� Rear axle with air spring and
4 point steering rod
SIMPACK MBS- Model Reference vehicle
8< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Model properties� Modeling in SIMPACK� Elastic parts:
frame, axle parts, 4 point steering rod
� Steering controller� Drive controller� Tire model TMEasy
SIMPACK MBS-Model Reference suspension
xRear axle kinematics� 4 air springs� 2 dampers � 2 lower steering rods� 4 point steering rod
9< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Front axle kinematics� 2 leaf springs� 2 dampers� stabilizer bar� steering system (not shown)
x
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
10< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
Model variants: Chassis / Suspension� Linear kinematics� IPG Kinematics analysis� K&C analysis (SIMPACK)
Other model properties
Real time model in TruckMakerProperties
11< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
� IPG Driver� Pneumatic brake system� Elastic cabin mount� Elastic body� Test runs with and without trailer
Required effects (e.g. for chassis controller development)� Elasto-kinematics (e.g. bending of axle body)� Axle buffer and “S-Schlag” buffer� Compliance in steering rods� 3D-nonlinear bushing characteristics� 3D-nonlinear leaf spring behavior
Real Time Driving Dynamics Simulation IPG Kinematics vs. MBS
12< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Today, requirements can only be fulfilled with a MBS analysis
Kinematics and Compliance Analysis*� Automated integration of axle model in K&C test rig� Generation of test procedure in K&C Manager for SIMPACK (.if2)� Simulation and result data export (.sbr) through scripted post processing� Generation of SKC file according to TruckMaker specifications
Real Time Suspension ModelWorkflow
13< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
* P. Rund, Aufbau eines virtuellen K&C-Prüfstands mit Datenverarbeitungsroutine zur Parametrierung kennlinienbasierter echtzeitfähiger Fahrdynamikmodelle. Master Thesis, Uni BW München, MAN Truck & Bus AG, 2011.
MBS SIMPACKK&C test rig
K&C Manager
(.if2)
(.sbr)
SKC-FileAxle model(.spck)
SIMPACK K&C AnalysisFront suspension, leaf spring
� Interface to TruckMaker: Segment shaft angle (steering gear)� Equals the steering rack travel
14< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
15< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
Comparison of results� Steady-state circular test with 47m radius, constant velocity 15 m/s� IPG Driver and SIMPACK driver tests (similar behavior in steady state)� Different “Level of Detail” in modeling� IPG Kinematics � K&C analysis with SIMPACK
Results (first attempt)Steady-state run comparison MAN TGX 4x2 BL Tractor
16< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Roll behavior of rigid axles in steady-state circular test (accelerated) � Kinematic coupling of left and right wheel (bending and torsional stiffness)� Kinematic constraints due to leaf spring and 4 point steering rod� Stabilizing mechanism is considered by kinematic constraints in K&C� No additional force element required in TruckMaker
ResultsRoll angle comparison MAN TGX 4x2 BL Tractor
17< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Behavior of rigid axles in ISO lane change test� Comparison of different driver models (SIMPACK vs. IPG Driver)� Equal trajectory� Slight differences in steering behavior => differences in vehicle reaction� Correlation for identical steering input (IPG Driver in SIMPACK)
ResultsISO Lane Change comparison MAN TGX 4x2 BL Tractor
18< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
19< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
Simulation of Variants� SPM* - system for automated export functionalities� K&C results can be exported from database� Direct export of vehicle data (based on parts and modules) into
TruckMaker model file
Integration into MAN development framework Workflow
20< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
SPM Export filter
(ascii)Part /
AssemblyTruckMaker Model file
* Simulation Parameter Management
Today� Manual export of parts and subsystems� Direct export to TruckMaker ASCII-file
ExampleDamper
21< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Today� Manual export of parts and subsystems� Direct export to TruckMaker ASCII-file
ExampleDamper
22< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Real Time Driving Dynamics Simulation Contents
1 Motivation
2 Scope of work
3 MBS model (reference vehicle)
23< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
4 TruckMaker model with different suspension modeling
5 Results: First benchmark
6 Integration into MAN development framework
7 Conclusion and outlook
Conclusion� Good results in vehicle dynamics on the first try� Suspension have to be considered with K&C-analysis to correlate MBS� Constraints between right and left wheel (rigid axle) lead to new approaches� TruckMaker vehicle models can be generated by database
Conclusion and Outlook
24< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
Outlook� Integration of MBS-Suspension (C-Code export)� Establish a SPM model base� Automated generation of enquiry vehicle model variants
Dipl.-Ing. Dr. techn. Jan Fleischhacker
MAN Truck & Bus AGEngineering Research
Vehicle Dynamics and Simulation Methods(Abt. ERVD)
25< >MAN Truck & Bus AG Dr. Fleischhacker, Dr. Wagner, Topcagic, Rund Fahrdynamische Echtzeitsimulation im schweren Nutzfahrzeug 18.09.2012
(Abt. ERVD)
Dachauer Straße 667 D-80995 München
Telefon: +49 89 1580 3649
[email protected] http://www.mantruckandbus.com