The modern automotive market is highly competitive and becoming ever more challenging, while at the same time the number of requirements for the vehicle development process is continuously increasing. The demand for innovations is high, while, at the same time, vehicle development time needs to be decreased in order to achieve a shorter time to market. The overall chassis development process as well as the V-model methodology has been presented. The development tool presented in this paper needs to fit into the overall vehicle development process and it should be able to support system design and integration in the V-model methodology. In an early stage of development, e.g., the design phase, the tool will be able to test different vehicle setups and to support the completion of the list of objectives. Even in the pre-production phase, the tool will be able to reduce costs and time by narrowing down the most suitable vertical dynamics characteristics to a small set. The development tool aims to minimize disassembling and mounting time during prototype testing as multiple setups can be simulated online with one integrated system. Moreover, the required number of prototypes is decreased and thus prototype costs are saved. An overview of the development tool and its components has been presented while design decisions, such as the electric motor selection, have been explained. A tubular linear permanent magnet motor has the advantages of a simple layout, low weight and inertia, small elasticity and large accelerations. The permanent magnets made from NdFeB reduce the required space by a maximum of 75% percent compared to an electric motor with excitation field windings. Furthermore energetic losses are reduced. An overview of the electric motor and its controller has also been presented. In addition to component design, the target vehicle was examined using test facilities at the Institut für Kraftfahrzeuge, RWTH Aachen, such as the K&C test rig and the ika-proving ground. FTire models were prepared in order to improve simulation quality with respect to vehicle comfort. A Matlab/Simulink vehicle control system was prepared, which used the developed electric motor design and control system to apply supplementary vehicle damper forces. The approach was to add electric motor force to a fixed damper characteristic in order to create a new one. A comparison between the passive damper characteristic and the tuned damper characteristic was conducted bysimulating driving over an obstacle using ADAMS/Car. A real obstacle from the proving ground was digitalized in .crg-format. The simulations show that the development tool has a very good performance at low as well as high frequency excitation.
Development tool for the optimization of vertical dynamics in chassis development
2012
22 Seiten, 14 Bilder, 1 Tabelle, 19 Quellen
Conference paper
Storage medium
English
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