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Turin, January 18, 2008 Mod. 25-P02-00
Semi-Active Suspension
Control system development process
Michele Ieluzzi
Vehicle Systems – Active Systems
Head of Suspension Control System unit
Semi-Active Suspension 2January 18, 2008
Public
This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Semi-Active Suspension development process
Simplify
Vehicle models
Simplify
Vehicle models
Control System
develop. environment
Control System
develop. environment
Handling/Comfort
Vehicle models
Handling/Comfort
Vehicle models
Four poster
test bench tuning
Road tests
Adaptive control strategy tuning
(Lateral & Longitudinal dynamic)
Modal damping gain tuning
Development
Vehicle
Technology Gate
• Vehicle assessment and fine tuning
• Experimental Control development
Actuator SpecificActuator Specific
ECU requirementsECU requirements
Control SW spec.Control SW spec.
DEMONSTRATOR EXPERIMENTAL DEVELOPMENT
SOFTWARE “IN THE LOOP” APPROACH
“Rapid prototype”code generation
• Control gain optimisation• Control Analysis and development• ECU control sw development & debug
Control Development
Semi-Active Suspension 3January 18, 2008
Public
This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Damper velocities
Actuators
Model
Sensor signals Damper forces
Control output
Vehicle model output,states,etc.
Driver Input
2 2
d 2z ACC2
2 1
d 2z ACC1
20
Fa 4
19
Fa 3
18
F a2
17
F a1
1 6
F zterra 4
1 5
F zterra 3
14
F zte rra 2
13
F zterra 1
12
d 2z w4
11
d 2z w3
10
d 2 zw2
9
d 2 zw1
8
dx 4
7
dx 3
6
d x2
5
d x1
4
x4
3
x3
2
x2
1
x1
d zc4
F ba rra 4
d zst 4
F j 4
F zc4
x4
d x4
d2zw 4
F zt er ra4
F a4
C orn er 4
dzc3
Fb arra3
dzst 3
Fj 3
F zc3
x3
d x3
d2zw 3
F zt er ra3
F a3
C orn er 3
d zc2
F barra2
d zst 2
F j2
F zc2
x2
dx2
d2 zw2
Fzt er ra2
F a2
C o rn e r 2
dzc1
Fba rra 1
dzst 1
Fj 1
Fzc 1
x 1
dx 1
d 2zw 1
F zte r ra 1
Fa 1
C o rne r 1
0
C on st a nt 3
0
Co n st an t 2
0
C on st an t 1
0
Co n st an t
F zc1
F zc2
F zc3
F zc4
F ve rt
Mx
My
dzc1
dzc2
dzc3
dzc4
d 2zA C C1
d 2zA C C2
B o dy
x3
x4
F barra3
F barra4
B arra p ost e r i ore
x1
x2
Fba rra 1
Fba rra 2
Ba rra a nt e r io re
7
M y
6
M x
5
F ve r t
4
d zst 4
3
dz st3
2
dz st2
1
dz st1
Vehicle Model
Control
Road input
Control Parameters
“Software in the loop” approach
22
d2 zACC2
21
d2 zACC1
20
F a4
19
F a3
18
F a2
17
F a1
1 6
Fz te rra4
1 5
Fz te rra3
1 4
F zterra2
1 3
Fz te rra1
12
d 2 zw4
11
d 2 zw3
10
d 2 zw2
9
d 2 zw1
8
dx 4
7
dx 3
6
d x2
5
dx 1
4
x4
3
x3
2
x2
1
x1
dzc4
Fba rra 4
dzst 4
Fj 4
Fzc 4
x4
dx4
d 2zw4
Fz te rra4
Fa4
Corn er 4
dzc 3
Fb arra3
dzs t3
Fj 3
Fzc 3
x3
dx3
d 2zw3
Fz te rra3
Fa3
Co rne r 3
d zc2
F barra2
d zst 2
F j2
F zc2
x2
d x2
d2zw2
F zt erra2
F a2
Corn er 2
dzc1
Fba rra 1
dzst 1
Fj 1
F zc1
x1
dx1
d2 zw1
Fzt erra1
F a1
Co rne r 1
0
Con st an t3
0
Co nst a nt 2
0
Co nst a nt 1
0
Co nst a nt
Fzc 1
Fzc 2
Fzc 3
Fzc 4
Fv ert
Mx
My
dzc1
dzc2
dzc3
dzc4
d 2zA CC1
d 2zA CC2
Bo d y
x 3
x 4
F barra3
F barra4
B arra p ost e ri o re
x1
x2
Fba rra 1
Fba rra 2
Ba rra a nt er i o re
7
My
6
Mx
5
F ve rt
4
dz st4
3
d zst 3
2
d zst 2
1
d zst 1
• Virtual assessment and fine tuning
• Actuators specification
• Control gain optimisation
• Control Analysis and development
• ECU control sw development & debug
Actuatorscharacteristics
Virtual vehicle & control system behaviour
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
0.00
0.01
0.02
0.03
0.04
0.05
Ac
c[g
]
Frequency [Hz]
Random input: comfort (60 km/h)
Seat guide verticalacceleration
Passive
Semi Active
Full vehicle
MB model
MATLAB/Simulink Model 10 D.o.F.
Semi-Active Suspension 4January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
MATLAB/Simulink Model 10 D.o.F.
Model components
(D.o.F.):
� Car-body (3)
� Heave
� Roll
� Pitch
� Engine (3)
� Heave
� Roll
� Pitch
� Wheels (4)
� Heave
Fzc → suspension force at vehicle corner
K C Passive suspension:
F = - K·X - C·X.
Simplified vehicle model structure
Fzc3
Fzc4
Hf
Z
X
G
3
Fzc1
Rf
Car-Body
Pf
X
Y Z
G
R fHf
P f
Engine
4
1
2
Fzc2Y
Semi-Active Suspension 5January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Simplified vehicle model validation (example)
Vehicle model 10 d.o.f.
Model validation on the basis of 4 poster bench tests
FL Vert. Acc. FR Vert. Acc.
RL Vert. Acc. RR Vert. Acc.
Comfort track – 60 km/h
Sine-hole passing – 80 km/h
Experimental Model
FL Vert. Acc. FR Vert. Acc.
RL Vert. Acc. RR Vert. Acc.
Semi-Active Suspension 6January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Damper velocities
Actuators
Model
Sensor signals Damper forces
Control output
Vehicle model output,states,etc.
Driver Input
2 2
d2 zACC 2
2 1
d2 zACC 1
20
Fa4
19
Fa3
18
F a2
17
F a1
16
Fzt er r a4
15
Fzt er r a3
14
F zte rr a2
13
F zte rr a1
12
d2zw 4
11
d2zw 3
10
d2z w2
9
d2z w1
8
d x4
7
d x3
6
dx2
5
dx1
4
x4
3
x3
2
x2
1
x1
dzc4
Fbar ra4
dzst4
Fj4
Fzc4
x4
dx4
d2zw4
Fzt err a4
Fa4
Cor ner 4
dzc3
Fbar ra3
dzst3
Fj3
Fzc3
x3
dx3
d2zw3
Fzt err a3
Fa3
C or ner 3
dzc2
Fbar ra 2
dzst2
Fj 2
Fzc2
x2
dx2
d2zw2
Fzt er ra2
Fa2
C or ner 2
dzc1
Fbar ra 1
dzst1
Fj 1
Fzc1
x1
dx1
d2zw1
F zt er ra1
Fa1
Cor ner 1
0
C onsta nt 3
0
C onsta nt 2
0
C onst ant 1
0
Co nsta nt
F zc1
F zc2
F zc3
F zc4
F vert
M x
M y
dzc1
dzc2
dzc3
dzc4
d2zACC 1
d2zACC 2
Body
x3
x4
Fbar ra3
Fbar ra4
B ar ra post er io re
x1
x2
Fbar r a1
Fbar r a2
Ba rr a ant er ior e
7
M y
6
M x
5
Fve rt
4
d zst 4
3
d zst 3
2
dzst2
1
dzst1
Vehicle Model
Control
Road input
Control Parameters
if (x>0)
….
elseControl software specification
ECU requirements specification
Sensors specification
Actuators specifications
Technology Gate
• Virtual assessment and fine tuning
• Actuators specification
• Control gain optimisation
• Control Analysis and development
• ECU control sw development & debug
System Architecture & Component Specification
Semi-Active Suspension 7January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Semi-active suspension system architecture
MM-ECU
CAN bus
Frontactuators
Rearactuators
Front right body
acceleration
Rear right body
acceleration
Front left body
acceleration
Front right wheel
acceleration
Front left wheel
acceleration
Semi-Active Suspension 8January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Suspension damping control architecture
Lateral Dynamics
Longitudinal Dynamics
Hole-passing control
Vertical Dynamics (Skyhook)
Current
manager
Semi-Active Suspension 9January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Single-corner passive suspension model
M = sprung mass x = suspension travel xst = road input Ktyre = tyre stiffness
m = unsprung mass xM = suspended mass pos. K = suspension stiffness
F = suspension force xw = non-suspended mass pos. C = suspension damping ratio
M
mxw
xst
xM
x
F
F
Ktyre
Passive suspension:
K C
F = - K·x - C·x.
MxM - F = 0..
mxw + F - Ktyre(xst - xw)= 0..
MxM + K·x + C ·x = 0..
mxw - K·x - C ·x - Ktyre(xst - xw)= 0..
.
.
• Equations of motion:
• The system has 2 D.o.F. (4 states) and two natural
frequencies:
ω1 =
K·Ktyre
M·(K+Ktyre)
C
2·M
-
2
K
M≅
ω2 =
(K+Ktyre)
m
Ktyre
m≅
(1)
(2)
Semi-Active Suspension 10January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Semi-active control law (Sky-hook )
Controlled suspension:
(Sky-hook control law) 2 tuning parameters
Fdamp = Cabs ·xM + Crel ·x. .
Cabs ; Crel
Semi-active strategy:
(Continuous control) (NO hydraulic energy supply)
Fdamp = Cabs ·xM + Crel ·x. .
if Fdamp ·x > 0.
Fdamp ·x ≤ 0.
Fdamp = 0 if
XM
·
X·
X·
XM
·
Fdamp
NO
NO YES
YES
VREL [m/s]
F [N]
Working area of a semi-active damper
Virtual ’’Skyhook’’ damper
ON-OFF ’’Skyhook’’ strategy
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
0.00
0.01
0.02
0.03
0.04
0.05
Ac
c[g
]
Frequency [Hz]
Random input: comfort (60 km/h)
Seat guide vertical
acceleration
Passive
Semi Active
Semi-Active Suspension 11January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Gain THETA-DVOL [ ]
frequency [Hz]
0
0.02
0.04
0.06
0.08
0.1
0 0.5 1 1.5 2 2.5 3 3.5
Passive
Semi Active
Virtual system behaviour optimisation
Vertical dynamics: DOE simulation plan to optimise SkyhookModal gain on different test track • Random track at different speed
- comfort track- pavè
- highway
• Sine hole passing at different speed
5.0
5.5
6.0
6.5
7.0
7.5
Ico Ivc
PASSIVE
SEMI-ACTIVE
Roll motion & roll velocity Index
Lateral dynamics: control gain optimisation result
Gain THETA-AY [deg/g ]
Frequency [Hz]
2
3
4
5
6
7
8
9
0 0.5 1 1.5 2 2.5 3 3.5
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
0.00
0.01
0.02
0.03
0.04
0.05
Ac
c[g
]
Frequency [Hz]
Random input: comfort (60 km/h)
Seat guide verticalacceleration
Passive
Semi Active
0 2 4 6 8 10 12 14 160
0.01
0.02
0.03
0.04
0.05
0.06
0.07
Frequency [Hz]
Acc
Highway 100 km/h
Passive
Semi Active
Sweep at 100 km/h
Uneven road at
60 km/h
Semi-Active Suspension 12January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Semi-active Suspension Prototype Development
Simplify
Vehicle models
Control System
develop. environment
Control System
develop. environment
Handling/Comfort
Vehicle models
Four poster
test bench tuning
Four poster
test bench tuning
Road tests
Adaptive control strategy tuning
(Lateral & Longitudinal dynamic)
Road tests
Adaptive control strategy tuning
(Lateral & Longitudinal dynamic)
Technologydemonstrator
Technologydemonstrator
Modal damping gain tuning
Development
Vehicle
Development
Vehicle
Technology Gate
• Vehicle assessment and fine tuning
• Experimental Control development
Actuator SpecificActuator Specific
ECU requirementsECU requirements
Control SW spec.Control SW spec.
DEMONSTRATOR EXPERIMENTAL DEVELOPMENT
SOFTWARE “IN THE LOOP” APPROACH
“Rapid prototype”code generation
• Control gain optimisation• Control Analysis and development• ECU control sw development & debug
Control Development
Semi-Active Suspension 13January 18, 2008
Public
This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Rapid prototyping Control application
Damper velocities
Actuators
Model
Sensor signalsDamper forces
Control output
Vehicle model output,states,etc.
Driver Input
2 2
d2zA C C2
2 1
d2zA C C1
20
Fa 4
19
Fa 3
18
F a2
17
F a1
1 6
Fzt er ra4
1 5
Fzt er ra3
14
Fzt er ra2
13
Fzt er ra 1
12
d2zw 4
11
d2zw 3
10
d2 zw2
9
d2 zw1
8
dx4
7
dx3
6
d x2
5
d x1
4
x4
3
x3
2
x2
1
x1
dzc4
F barr a4
dzst 4
F j4
F zc 4
x4
dx 4
d2zw4
F zt er ra 4
Fa4
C orne r 4
dzc3
F barr a3
dzst 3
F j3
F zc 3
x3
dx 3
d2zw3
F zt er ra 3
Fa3
C orner 3
d zc 2
F bar ra2
d zs t2
F j2
F zc2
x2
d x2
d2zw 2
F zter r a2
F a2
C orner 2
dzc1
Fbar ra1
dzst1
Fj1
F zc1
x1
dx1
d2 zw 1
F zter r a1
F a1
C orner 1
0
Co nsta nt 3
0
Co nsta nt 2
0
C onst ant 1
0
Con sta nt
Fzc1
Fzc2
Fzc3
Fzc4
Fv ert
M x
M y
dzc1
dzc2
dzc3
dzc4
d2 zA CC 1
d2 zA CC 2
Bo dy
x3
x4
Fbar ra 3
Fbar ra 4
Ba rra po st er i ore
x1
x2
Fbar r a1
Fbar r a2
B ar ra ant er io re
7
My
6
Mx
5
F ver t
4
d zst 4
3
dzst 3
2
d zst2
1
d zst1
Vehicle Model
Control
Road input
Control Parameters
Automatic Control
Code generation
(RTW)
“Rapid prototyping”
Control ECU
dSPACE MicroAutoBox
RTI 1401 blocksetRTI CAN blockset
ECU I/O management blockset
Virtual environment Control algorithm in MATLAB/Simulink
I/O managersI/O managers
ControlControl
Semi-Active Suspension 14January 18, 2008
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Control parameters calibration interface
Lateral dynamic
control
Longitudinal dynamiccontrol
Vertical dynamic
control
Hole-passing strategycontrol
Semi-Active Suspension 15January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Relative damping gains
15 16 17 18 19
22 23 24 25 26
29 30 31 32 33
36 37 38 39 40
43 44 45 46 47
Sk
yh
oo
k d
am
pin
g g
ain
s
1 2 3 4 5
8 9 10 11 12
6 7
13 14
20 21
27 28
34 35
41 42
48 49
Virtual environment
0 5 10 15 20 25 300
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Acc [m
/s2]
0 0 .5 1 1. 5-3
-2
-1
0
1
2
3
4
5
Passive
Semi-active
Base configuration
Four poster test bench: definition of DOE analysis
Relative damping gains
22 23 24 25
29 30 31 32
36 37 38 39
Skyh
oo
k d
am
pin
g g
ain
s
15 16 17 18
0.45 0.59 0.77
1.0
1.3
1.0
0.7
7
0.5
9
DOE on four poster test bench
Semi-Active Suspension 16January 18, 2008
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Virtual analysis optimisation
DOE experimental plan (over all the mission panel)
6-7
5-6
4-5
3-4
2-3
1-2
0-136 393837
313029 32
242322 25
17 181615
∆∆∆∆RMS Az (seat guide vertical acceleration )
(improvement vs passive [%])
Highway
Mission panel:
• Random track
- comfort track
- pavé
- highway
• Sine hole passing
Modal damping gainsModal damping gains
Four poster test bench: modal damping gain tuning
Relative damping gains
22 23 24 25
29 30 31 32
36 37 38 39
Sk
yh
oo
k d
am
pin
g g
ain
s
15 16 17 18
Semi-Active Suspension 17January 18, 2008
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This document contains information which in proprietary to CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF.
Example of control effect (bench test): vertical dynamics
Sine hole passing: (speed = 80 Km/h)
Seat guide vertical acceleration
Acc [
m/s
^2]
Time [sec]
Passive
Controlled
Comfort Track (speed = 60km/h)
Seat guide vertical acceleration
Acc [
m/s
^2]
Freq [Hz]
Passive
Controlled
Damper working area
Vel [m/s]
Fo
rce [
N]
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Example of control effect (road test): vertical dynamics
Comfort track @ 80 km/h
RMS RMF Moto cassa
7%
6%
15% Passive
Controlled
Body movement
Seat guide vertical acceleration
ac
c[m
/s2]
RMS of Pitch & Roll body acceleration
RMS Pitch RMS Roll
6%
Passive
Controlled
Average on different testsa
cc
[de
g/s
2]
Semi-Active Suspension 19January 18, 2008
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Example of control effect (road test): lateral dynamics
Roll motion and velocity quality index
ICO = Quality index of roll motion
IVC = Quality index of roll velocity
Steering angle
Lateral acceleration
Roll angle
Passive
Controlled
ICO IVC
Passive
Controlled
Best
Worst
ISO lane change @ 90km/h
Semi-Active Suspension 20January 18, 2008
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Gear shift @ 100% gas pedal
Example of control effect (road test): longitudinal dynamics
Cambio marcia 1-2
Max picco-picco
Passiva
Controllata
Cambio marcia 2-3
Max picco-picco
ve
l[d
eg
/s]
Passiva
Passive
Controlled
Input driver
Passive
Controlled
66%
57%
Passive
Controlled
Gear shift 1-2
Peak-to-peak
Average on different tests
64% 5
3%
Gear shift 2-3
Peak-to-peak
ve
l[d
eg
/s]
Gear
Pitch Angle
Pitch Velocity
Semi-Active Suspension 21January 18, 2008
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Ferrari 575 Maranello
[2003]Lancia Thesis 2.4jtd 20v CAE
[2004]
Fiat Stilo 2.4 20v Abarth Seelespeed
[2001-2004]
Systems developed
Iveco StralisS.A. Cab Suspension
[2003-2005]
Alfa Brera 3.2 4WD
SDC
[2005-2006]
Iveco Eurostar
S.A. Suspension[2001-2003]
HST
S.A. Lateral Suspension
[2000-2002]