Ford Active Suspension Control Me 560

8/8/2019 Ford Active Suspension Control Me 560

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ACTIVE BODY CONTROL OFACTIVE BODY CONTROL OF

FORD TRANSIT CONNECTFORD TRANSIT CONNECT

USING SEMI-ACTIVE SUSPENSIONSUSING SEMI-ACTIVE SUSPENSIONS


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Outline

Introduction

Ford Otosan & Product Development TeamProject Scope & Objectives

Semi-active suspension & CDC Dampers

Vehicle Models

Controller Algorithms

Semi-active suspension control strategies

Hardware infrastructure and prototype vehicleSensors

Actuators

Control hardware

Results

Simulation Results

Experimental Results

Outputs & Conclusion


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Ford has the overall engineering and sign -

off responsibility of Transit and TransitConnect.

Ford Otosan is a design and developmentpartner of Ford in current and future TransitConnect product programs.

Ford Otosan is the lead plant PVT forTransit and Transit Connect

Ford Otosan is leading the design anddevelopment of Puma I5 for use in exportand domestic Transits.

Ford Otosan has the overall engineeringresponsibility of Cargo Heavy truck andEcotorq Engine.

Ford Otosan PD Roles & Responsibilities

Transit/

Tourneo Connect

Transit

Cargo


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Due to the high level of competition in automotive industry,demand for safety and comfort isincreasing while development time and costs need to be reduced. This introduces realchallenge for Motor Companies and especially for PD engineers.

Safety in road vehicles is an important aspect and therefore many automobile industries are

interested in developing vehicle safety systems such as ABS, TCS, ESP etc... However,performance is also an important actor next to safety issues.

In Ford Otosan Chassis Engineering Department, we have started a project to adopt a semi-

active suspension system to our light comercial vehicle.

This project is about the development of an active body control (TABC) system for the FordTransit Connect using semi active suspensions. The control objective is to improve theride comfort and road holding together with achieving roll and pitch stability using

four semi active suspension dampers.

All study was completed by Otosan PD engineers and ITU team. The aim of the project is

to build know-how about new technologies in Otosan PD department, improvetechnical capabilities of PD engineers and build a prototype light commercial vehicle

with its unique controllers.

Project Scope


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Semi-active suspension system involves special type of variable dampers

that are different from passive vehicle suspensions. Damping propertiesof these components can be changed via magnetic or electric effect.

These dampers are controlled by an external control system; thereforetheir damping characteristics can be changed with respect to vehicle androad conditions.

There are sensors that give the necessary feedback about the vehiclesstates and along with actuators and control units on the vehicle.

CVD Dampers Sensors ControllerInfrastructre

Semi - Active Suspension


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Vehicle BodyVehicle Body

On this particular model, only of the vehicle is taken into consideration to

develop a semi-active suspension low level controller. Model is a 2dimensional model because only movement on z direction is taken into

consideration.

Vehicle Models Quarter Car Model


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Model is again a 2 dimensional model which

has a movement only on Z direction.

Vehicle Models Half Car Model

Advantages of this model are;

Vehicle pitch motions can be simulated. Fr and rr damper and spring characteristics

can be modeled differently which is also

different on the actual vehicle.

Body motions and center of gravity effectcan be simulated.


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Model is a 3 dimensional model which has a movement on Z direction.On full-car model;

Vehicle pitch and roll motions can be simulated. Different front and rear suspension system geometries can be modeled (for example,

vehicle has independent suspension on the front and a solid dead beam on the rear and

this can be geometrically modeled on a full car model).

Left and right hand side body and tire motions of the vehicle can be simulatedseparately.

Un-sprung and sprung mass motions can be evaluated for both front & rear right andthe left hand side suspension systems.

Vehicle Models Full Car Model


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Upper Level

Controller

Lower level

Controller

SkyhookGroundhook

Hybrid

Lower Level Control:Individual control of

each shock absorber.

Upper Level Control:Control of whole body

motions like pitch and

roll.

Control Algorithms


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Hardware Infrastructure and Prototype Vehicle


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Sensors

Accelerometers Linear PotentiometerYaw rate sensor

Measure thevertical

acceleration ofbody andwheels.

Used forvalidation of

accelerometers.Measure the

relativedisplacement.

Measure thegeneral states of

vehicle such asyaw rate, roll rate.

Sensors


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Actuators


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controllerhardware is used inthe semi activesuspension system.

Control Hardware

Controller hardware

consists of;

1. Microautobox

2. RapidPro controlUnit

3. Rapid Pro PowerUnit


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Implementation


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During the design process, two main test typeswere performed.

Offline Simulations Real time tests

Test Bench tests Road Tests

Validation of controlleralgorithms and models.

Using squeak andrattle test bench.

Using variousroad profiles

Simulation & Tests


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Simulation Results


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4-Poster Rig Test


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Tests and ResultsTests and Results-Sprung Mass Displacement- Skyhook Controller

INPUT: Road disturbance as asinusodial input

OUTPUT: Sprung MassDisplacement

Sprung mass displacement is

taken into consideration forcomfort.

So input frequencies are 1-5Hzas defined on project scope.

As it is seen form the graphs,Sprung mass (Body)displacements are reduced

with controlled suspensionsystem.

Simulation Results


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Tests and ResultsTests and Results-Unsprung Mass Displacement- Groundhook Controller

INPUT: Road disturbance as asinusodial input

OUTPUT: Un-sprung Mass

Displacement

Un-sprung mass displacement is

taken into consideration for roadhandling

So input frequencies are 7-15Hzas defined on project scope.

As it is seen form the graphs,Un-sprung mass (Tire)displacements are reducedwith controlled suspension

system.

Simulation Results


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I n p u t fr o m tes t bench

Ou tpu t f r omacce le rometers

Simulation Results

Squeak and Rattle Test Bench Results:Squeak and Rattle Test Bench Results:


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Examp les

f r o m Ro a d

Tests

Experimental Results


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Technical Papers:Technical Papers:

"Stability Enhancement of a Light Commercial Vehicle Using Active Steering", SAE Paper,March 2006.

"Compliant Control of Electric Power Assisted Steering Systems", SAE Paper, November2005.

''Semi Active Suspension Control System Development For A Light Commercial Vehicle'Mechatronics 2006 - 4th IFAC-Symposium on Mechatronic Systems Heidelberg,

Germany, September 2006 ''Robust Velocity Scheduled Yaw Stability Control of a Light Commercial Vehicle'', IEEE

Intelligent Vehicle Symposium Tokyo, Japan, June, 2006 ''Robust Yaw Stability Controller Design for a Light Commercial Vehicle Using a Hardware inthe Loop Steering Test Rig', The 2007 IEEE Intelligent Vehicles Symposium

''Observer Based Semi-Active Suspension Control Applied to a Light Commercial Vehicle',2007 IEEE/ASME International Conference on Advanced Intelligent Mechatronics

''Steer-by-Wire Control of a Light Commercial Vehicle Using a Hardware-in-the-Loop TestSetup'' SAE Paper 2007-01-4198, SAE 2007 Commercial Vehicle Engineering Congress &Exhibition

''Transient Active Body Control of a Ford Transit Connect using Semi-active Suspensions' SAE

Paper 2007-01-4268, SAE 2007 Commercial Vehicle Engineering Congress & Exhibition ''Nonlinear Suspension Spring and Damper Characteristic Optimization for Vehicle Ride and

Handling Improvement', SAE 2008 Commercial Vehicle Engineering Congress &Exhibition

Project Outputs


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Other Publications:Other Publications:

''Ford Otosan: Active Chassis Control' dSpace News

''Ford Otosan Semi Active Suspension Control Development for a LightCommercial Vehicle' Ford Motor Company - Vehicle Dynamics Newsletter

Academical Studies & Patents:

3 Msc. Thessis.

1 Phd. Thessis.

2 Patent applications.

Project Outputs


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Conclusion

This project is developed and finalized only by the PD enginners of Ford-

Otosan and Istanbul Technical Universty members. (Without any supportfrom suppliers)

As mentioned before; The aim of the project is to build the know-how

about new technologies in Otosan PD department, improve technicalcapabilities of PD engineers and build a light commercial vehicle

prototype with unique controllers.

And as a result, a semi-active control algorithm is developed for a lightcommercial vehicle and this algorithm guarantees both performance and

transient stability of pitch and roll motions of the vehicle.

The unique control algorithm is tested both in simulation and onexperimental vehicle. Simulation and experimental results show that an

improvement on ride comfort is achieved without compromising handlingquality. Both a four poster and road testing were used for experimental

testing.


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Glck

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Ford Active Suspension Control Me 560