Component Tests Based on Vehicle Modeling and Virtual Testing

Paper #:
  • 2017-01-0384

  • 2017-03-28
Due to the increasing pressure of shortened development cycles and the desire of saving costs, auto makers are increasingly using analysis tools to validate vehicle design and specify lab testing with less road load data acquisition. Virtual testing is a method that simulates lab testing using analysis software. This approach has been used more and more in vehicle design evaluation. The main advantages of this approach include that the design can be evaluated before a prototype is available and virtual testing results can be easily validated by subsequent physical testing. The combination of physical and virtual testing can accelerate the design process due to the identification and subsequent elimination of physical and virtual prototype deficiencies, such as transducer related errors and model parameter inaccuracies. This paper introduces a real virtual testing project. ADAMS models of component test systems, Multi-Axis-Simulation-Table (MAST) systems, and spindle coupled vehicle testing system (MTS 329) were created. These models have realistic mass and moment of inertia properties as well as the bushing properties. Due to limitations of ADAMS software, hydraulic components (such as servo valves) and control elements (such as PID controller and matrix control algorithm) were not modeled. To model the test systems more accurately and understand the effects of control and hydraulic components, SIMULINK models of the above mentioned test systems were created. In these models, actuator dynamics, servo valve dynamics, PID close loop, three-variable control, matrix control, all filters in the controller, and coordinate transformation were modeled. The specimen had to be simplified significantly due to the limitation of SIMULINK software. Since both ADAMS and SIMULINK models have distinctive advantages, ADAMS-SIMULINK co-simulation models of the above mentioned test rig models were created with hydraulic and control components in the SIMULINK part and mechanical components in ADAMS part of the models. The interaction between ADAMS part and SIMULINK part was done by using ADAMS/Control. The test rig models were used to simulate multiple durability test events of one particular vehicle design. By comparing virtual and physical testing results, the deficiencies of the vehicle models were found and corrected. Much more realistic vehicle model was obtained. Proving ground load signals were reproduced with the virtual testing system models through RPC iteration. Component load time histories were extracted out from the virtual testing result. Based upon the component load time histories, different component test generation methods were used to generate component tests.
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