BME GJT competence v10 · Design of active suspension using: The latest results of robust control theorem ... – Design of brake system components Chassis and electronics Development

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R&D activities

Budapest University of Technology and Economics

Department of Automobiles and Vehicle Manufacturing

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Contents

• Research fields

• Vehicle Technology

• Vehicle Manufacturing

• Laboratories

• BOSCH-EJJT Mechantonic laboratory

• Material and Manufacturing test laboratory

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Research activities

Vehicle technology Vehicle manufacturing

Engineand

driveline

Chassis and

electronics

Vehicle operation

Material science and tests

Manufacturing processes

Manufacturingsystems

Measuringand

processdiagnostics

Research fields

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Vehicle Technology

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Vehicle technology research areas

Engine and driveline research area• Comprehensive simulational and computational experiences• Engine and component analysis• Powertrain simulation• Transmission analysis• Alternative fuels: CNG, hydrogen, biofuels

Chassis and electronics research area• System overview• Active and semi-active suspensions• Development of brake systems• Steering system design• Brake system based vehicle dynamical controller

Vehicle operation research area• Developments related to vehicle recycling• Irregular vehicle operation – accident analysis• Monitoring vehicle operation – FMS development• Reliability analysis and system redundancy

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Engine and driveline research area

Comprehensive simulational and computational experiences

• Engine thermodynamics (e.g. GT-Power/GT-Suite)

• Burn theorem, and reaction kinetics

• Charge exhange and supercharging

• Cooling system analysis

• Lubication system analysis

• Structural dynamics and fatigue

• Multi-phisical analysis (e.g. thermoshock)

• 144 core supercomputer

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Engine and component analysis

• Engine test benches (150 kW/300 Nm, 270 kW/720 Nm, 350 kW/1400 Nm)

• External driven testbench for analysing thefriction

• Exhaust gas analysis

– CO, CO2, NO, NOx, HC

• Simulation and analysis of crankshaft fatigue

– Resonant bending test bench

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Powertrain simualtion


XZΓ

Fttra

c

A B

a bL D

H

hN

Fre

s

• Developing dynamic models

– Driveline

– Implementing in vehicle models

• Full driveline simulation

– Functional analysis

– Function development(transmission, clutch actuation)

– Comfort analysis

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CAN

Supply

Communication

Supply


Transmission analysis

• Transmission test bench

– Both for passenger carand trucks

– Input/output acceleration till 30001/min

– Closed-loop drivelinesimulation

• Tools for fast prototyping

– SIL and HIL simulations

– Function development

– Communication tests

• Examination of vehicledynamical sensors

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Alternative fuels: CNG, hydrogen, biofuels

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� Design of controlled vehicledynamical control systems incl.:

� Brake system (Electronic brake)

� Steering system

� Stability control system

� Suspension (Priomary and secondary)

� Driveline dynamics

� Road surface estimation

� Testing these systems on test benches

� Road tests with sensors

Chassis and electronics

System overview

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� Design of active suspension using:

� The latest results of robust controltheorem

� Test bench for identification and controller design

� Semi-active primary and secondarysuspension

� Suspension for passanger cars and trucks

� Driver seat suspension – with more patented methods

� Operable prototyp in trucks, therelease of the product is underprogress

� Partners:

� Knorr Bremse

� IMAG (Ülésgyártó)

� MTA SZTAKI

ACTIVEFORCE

[N]

RELATIVE VELOCITY [m/s] RELATIVE VELOCITY [m/s]

ACTIVE

FORCE[N]

VSC - VELOCITY FEEDBACK SEMI-ACTIVE DAMPER

TIME [sec]

SLIDINGSURFACE

EQUATION[-]

System is in slidingmode (equation =0)

Input: body and wheel

accelerations

Control output No.1:

pressure input to actuator

Control output No.2:

displacement input to the actuator

producing road excitation

CONTR.DAT.AQ.

PC

TireBody mass


Active and semi-active suspensions

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Common projects with industrial partners:

– Design of software modules of electronic brake systems

– Analysis of electronic brake system of a trailer

– Measuring caliper vibrations

– Control algorithm electro-mechanical self amplifying brake system

– Design and verification of brake systems

– Design of brake system components


Development of brake systems

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• Design of electronic steering algorithms forstability controller and steer-by-wire trucksincl.:

– Steering algorithm

– Connection to other systems, like brakesystem, engine management

• Control algorithm for an x-by-wire vehicle

• EU5 project: PEIT

Powertrain Equipped with Intelligence Technologies

Partners:

– DaimlerChrysler

– Continental

– Thyssen Krupp

– TÜVs

– Knorr Bremse

– Több egyetem


Steering system design

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• Theoretical analysis

– Defining the logics for increasing the vehicle’s stability

– Selecting the control philosophy

– Efficiency of possible actuators (brake, steering, suspension)

– Identification of reference models

– Vehicle stability in the plane of the motion (yaw) and in otherplanes (roll, pitch)

• The first controlled, brake system based vehicle dynamicalsystem was developed in 1991 in cooperation of our Department.

• The extension of the ENSZ-EGB 13 with the ESC was regulatedby our Department in 2004

TTTT1111

TTTT 2222

Original forcevector

M odified force vector bytyre slip manipulaton

Difference

Limit force vector

VEHICLE

Virtual model

KV

KU

-KC

State observer

F

Brake and Steering Contr.

Torque and add. Steering

Driver's steering effort

Without DSCrolling over

Lateral acceleration

High C.G.

Reduction in the tire lateralforce component

With DSC a slightlateral sliding

Longitudinal slip

Longitudinal tireforce

Lateral tireforce

Tends to zero by roll-over

Vertical tire load a. b.

Reduction of the lateralforce component on thefront outer wheel (highslip value)

Brakeapplication onthe outer rear

wheel, high slip)

Trailer brake application

reducing trailer push orcausing trailer pull

Increasing the slipon the outer rearwheel

Reduction of the lateralforce component on the

outer front wheel (let thewheel roll with high slip)

Releasing the inner rearwheel to reduce thelateral force componentand gaining reference

speed

Overbraking the trailer

if necessary or possible


Brake system based vehicle dynamical controller

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• The effects of controlled vehicle dynamical systems basedon electronical steering intervention:

– The intervention of the driver decreases – theelectronic steering intervenes much faster

– The brake distance decreases significantly on „µ-split” or on chess-like surfaces

– The brake intervention can be carried out later

• The autonomous steering makes other functions possible aswell:

– Avoiding leaving the lane

– Compensation of road roughness

• Partners in PEIT project:

– DaimlerChrysler

– Thyssen Krupp

– Knorr-Bremse

0 2 4 6 8 10 12 14

Time [s]

-140

-120

-100

-80

-60

-40

-20

0

20

40

M3_D

esir

ed

_S

teri

ng

_A

ng

le_C

AN

_B

[d

eg

]

0 2 4 6 8 10 12

Time [s]

-140

-120

-100

-80

-60

-40

-20

0

20

40

M3

_D

es

ire

d_

Ste

rin

g_

An

gle

_C

AN

_B

[d

eg

]


Development of electronic stability control system

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• Demonstrations vehicle: The electronic system is able todrive the vehicle on two wheels despite the disturbancesand it is able to compensate these disturbances withautonomous steering – Autonomous vehicle drive demonstration

• Video based lane leaving detection and interventionsystem


Driver aid and autonomous systems

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� Clarifying technical questions:

� Efficient removal of operation fluids

� Pre-dismantling of resalable parts

� Efficient storing of dismantling parts

� Grinding of vehicle chassis

� Separation of different materials

� Initiating changes in legislatives and directives, determination of regulationenvironment

� Identifying stakeholders

Vehicle operation

Developments related to vehicle recycling

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• Active accident analysis and reconstructionalactivity

• The largest accident database in Middle-Europe• Accident recunstruction using complex vehicle

simulation• The work-out of an accident is made using

photogrammetical methods to ensure input datafor the analytical software

• Beside the computational simulation practical test are carried out as well

Vehicle operation

Irregular vehicle operation – accident analysis

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20 TEBS4 with TRSP

Accelerationsensors

CO2 sensor

Braketemperature

sensorEBS 2

Bluetooth

Driver information unit

FMS ECU

Vehicle operation

Monitoring vehicle operation – FMS development

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• The mechanical and pneumatical back-up stages aresubstituted by electronical redundant systems

• The requirements of system reliability/availability arehigher

• Analytical reliability tests on component-level and onsystem level as well

• Development, analaysis, SIL and HIL simulation of redundant system architectures

Meghibásodási

ráta

Idő

Működési tartomány (csak véletlen hibák) ElöregedésBeégetés

Mechanikus komponensek

Elektromos komponensek

Ezt kell garantálni a fejlesztés alatt

Meghibásodási

ráta

Idő

Működési tartomány (csak véletlen hibák) ElöregedésBeégetés

Mechanikus komponensek

Elektromos komponensek

Ezt kell garantálni a fejlesztés alatt

Vehicle operation

Reliability analysis and system redundancy

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Vehicle Manufacturing

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Vehicle manufacturing research areas

Material science and tests research area

• Analysis of material properties• Material failure analysis

Manufacturing processes research area

• Mechanical technologies• Cutting process• Laser material processing• Assembly processes

Manufacturing systems research area

• Optimization of production lines• Automation

Measuring and process diagnostics research area

• Geometrical measurement• Process diagnostics

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• Mechanical properties– Hardness (microhardness distribution)– Tensile test– Impact test

• Adhesion properties (Scratch test)– Analysis of coatings

• Magnetic properties– Magnetic transformation– Influencing factors

• Solid, liquid and gas phase reactions– Hydrogen storage in metals– Wetting properties of metals


Analysis of material properties

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• Analysis of material failures

• Analysis of circumstances

• Determination of root causes

• Decrease or eliminate failures


Material failure analysis

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• Heat treatments

• Welding technologies

• Resistant welding technologies

– Spot welding

– Projection welding

• Brazing technologies

• Technological failure analysis


Mechanical technologies

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• Development of conventional cutting– Turning, drilling, taping, milling, honing, grinding

• Hybrid cutting technologies– Combination of steel, aluminium, magnesium

• Dry cutting and Minimal Quantity Lubrication machining– Economic and environmental aspects

• Technological failure analysis– Reduce or eliminate the failures


Cutting technologies

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Development and optimisation of technologies:

• Laser surface treatment

– Hardening, annealing, remelting, alloying, dispersing, coating

• Laser welding (cw and pulse mode)

– Metals, plastics

• Laser brazing (steel and aluminium)

• Laser cutting (2D, 3D cutting)

• Laser drilling

• Laser marking (coloring, foaming, annealing, engraving, ablation)

• Technological failure analysis


Laser technologies

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• Analysis of assembly lines

• Analysis of assembly workplaces

– Motion analysis

– Ergonomics

• Optimisation of assembly process

• Optimisation of assembly workplaces


Assembly processes

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• Analysis of existing layouts and production

systems

• Determination of losses

• Design of new layout


Optimisation of production lines

Layout

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• Analysis of production systems

• Exploring automation possibilities

• Development of solution alternatives

• Creating the prototype


Automation

Sensor Controller

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• Analysis of surface properties

– Topography

– Roughness

• Analysis of geometrical properties

– Size

– Tolerances

• Weight

• Temperature

• Immersion test of plastics

Measuring and diagnostics research area

Measuring

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• Analysis of fast processes

• Analysis of thermal processes

• Analysis of inner spaces, cavities

• Vibration and noise diagnostics

Measuring and diagnostics research area

Diagnostics

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BOSCH-EJJT Mechatronic Testing Laboratory

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Overview

• Environmental Tests– Climatic tests (Temperature, Humidity)

– Heat shock

– Corrosion

– Vibration (Agree Test)

• Component Tests and Simulation– Vehicle Simulation

– Residual Bus Simulation (CAN. LIN, FlexRay)

• In-Vehicle Tests– Steering robot and measurement wheels

– Vehicle Dynamics measurement

– On-board data acquisition system

– Test Vehicles

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Thermostatic, Climatic Chamber

Size: 1000×1090×1130 mm

Temperature Range :-75 °C ... +180 °C

Temperature accuracy:±0.1 °C ... ±0.8 °C

Temperature gradient:10 °C/min

Humidity Range :10% ... 98%

Agree Test combination: withTV 5500 LS shaker

Anyvib 1200-10

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Shaker

Maximum load: 54 kg

Max. rated travel: 50.8 mm

Frequency range:DC – 3000 Hz

Rated peak force:4000 N (sinus)4000 N (random)8000 N (shock)

Weight (with trunnion):750 kg

TV 5500 LS

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Thermal Shock Chamber

Size:700×700×650 mm

Temperature Range:Over Cabinet: +70 °C ... +220 °CUnder Cabinet: +60 °C ... -80 °C

Thermal Accuracy:±1 °C

Basket Capacity:320 Litres

Basket Moving Time:<10 s

CST 320 / 2T

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Cyclic Salt Spray Chamber

Size:1120×780×935 mm

Nominal Capacity:

1000 Litres

Operation Mode:Cyclic Programmable

Temperature Range :Ambient ... +60 °C

Sheen FMS 1000

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SMT / BGA Rework Station

Features:

Selective Reflow module

Reflow Process Camera module

Precision Placement module

Software module

Extra Features:

Olympus SZT-61 microscope

Complete ESD protected facility for ECU rework

ERSA IR 550

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Vehicle Diagnostics Station

Failure Diagnosis:Reading of DTCs

Parameter Measurement

Directed Failure Analysis

Built-in oscilloscope

Emission Tests:K-line, KWP, CAN

OBD, EOBD communication

MODE01-MODE0A

Gutmann Mega Macs 55

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Vehicle Diagnostics Tester

Data transferBluetooth connection

100 m range

OBD interfacesK and L

SAE and CAN

Attached modulesESI[tronic] software

Gearshift adapter unit

Bosch KTS 570

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CAN Simulator Testbench

CAN Bus SimulationCAN bus analysis

CAN based devices

Residual Bus Simulation

Communication systemMultiplexed CAN-VAN

network

PSA

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LIN Simulator Testbench

Full lighting system from OEM components

Analysis of CAN-LIN communication

Gateway ECU for data exchange

VW

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FlexRay Communication Platform

Communication ChannelsCAN (2 ch)

LIN (1 ch)

FlexRay (2 ch)

Attached Software ModuleDesigner Pro

CPU Performance24 MHz

DecomSYS Node Renesas

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Vehicle Simulations

SDK SimulatorComplete Vehicle Simulation

Animation

CAN interface

Test Cycle Programs

SimPack SimulatorModular Vehicle modelcreation

Animation

DS 1006 interface

Simulink, SimPack, GT Power, SDK

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Vehicle Dynamics Measurement

6 degree of freedom vehicle dynamics sensor unit

CAN bus interface

Analysis of driving styleEffeciency

Safety

VDSU

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Common-Rail Injection System Testbench

Injection layoutinvestigation

Engine revolution and injection pressure control

Maximum pump pressure

1800 bar

Electric Motor Power

7,2 kW

Audi V6 2.7 system

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Professional Injector Tester

Features12 cylinder systemContinuous revolution control with accuracy of ±1 1/minPositioning control with accuracy of 0,1 %Measurement of transport start and prestroke1350 bar operating pressure

ApplicationsSealing examinationBackward quantity measurementQuantitative measurementsInjector categorization (basic, IMA and ISA)

Bosch EPS815

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Thermocamera

Resolution320 x 256

Pixel size30 x 30 µm

Full Frame RateProgrammable 1 Hz - 420 Hz

Temperature range-10°C - +350°C

Temperature accuracy±2°C, ±2%

FLIR ThermoVision SC4000 HS

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Material and Manufacturing TestLaboratory

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Overview

• Material test laboratory

• Sample preparation equipment

• Hardness measurement, Micro

combi tribo tester

• Manufacturing laboratory

• Laser equipment

• 3D coordinate measurement

machines

• Laser interferometer

• Surface roughness measuring

• Screwing bench

• Force measurement equipment

• High speed camera

• Thermocamera

• Endoscope

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Sample preparation equipment

Diamond disc for cutting

Fixing with resin

Abrasive grinding disc

Polishing disc

Chemical etching

Optical microscopes

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Hardness measurement, Micro combi tribo tester

CSM micro combi tribo tester

Local investigation of

Hardness

Elasticity

Tribology

Layer adhesion (coatings)

Features

Programmable CNC table

Half-automatic evaluation

Digital image processing

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3D coordinate measurement machines

Mitutoyo BX303 CMM

Mitutoyo Quick Vision Optical CMM

FARO portable CMM

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Laser equipment

OPL 1.8 KW CO2 laser

cw mode

fixed optics beam guiding

CNC moving of workpiece

Laser Scanner head

LASAG SLS 200, Nd:YAG laser

pulsed mode

felxible beam guiding, optical cable

CNC moving of processing head

Laser diagnostic equipment

Laser power cell

Laser beam analyzer

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Laser interferometer

HP laser source

2 mirrors

PC evaluation

Measured charachteristics:

Distances

Speed

Angle

Resolution 0,1 micrometer

Laser source

Mirrors

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Surface roughness measurement

Mitutoyo Contact measuring with tip

Rodenstock RM600 contactless measuring with laser

beam

Measuring dept 0,6 mm, area 100 x 100 mm

3D topography, 2D roughness, waviness

Comparison of surfaces

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Screwing bench

Screwing machine

Screwing controller

PC evaluation

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Force measurement equipment

Kistler force measuring cell

Measure force and torque

3D force component

Workpiece

HM tool

Kistler force cell

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High speed camera

Olympus i-Speed 3

Maximum frame speed

150 000 frame/s

CMOS:

1280 X 1024

Pixel size

21 micrometer

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Thermocamera

FLIR SC325 thermocamera

Sensor

320 x 240 pixel

Picture frequency

60 Hz

Detector pitch

25 micron

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Endoscope

Olympus IPLEX MX video

endoscope

3 m length optical fiber

Remote positioning of the

head

Detection of inner failures

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Contacts

Vehicle technology:

Dr. Zsolt SZALAY, assistant professor, email: [email protected], Tel.: +36-1-463-3226

Vehicle manufacturing:

Dr. Tamás MARKOVITS, assistant professor email: [email protected], Tel: +36-1-463-3468

Department of Automobiles and Vehicle ManufacturingFaculty of Transportation Engineering and Vehicle EngineeringBudapest University of Technology and Economics6. Stoczek street, H-1111 Budapestwww.gjt.bme.hu

Documents

BME GJT competence v10 · Design of active suspension using: The latest results of robust control theorem ... – Design of brake system components Chassis and electronics Development