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Design and Performance Analysis of a Roll Damping Function for an Electromechanical Active Roll Control System

Design and Performance Analysis of a Roll Damping Function for an Electromechanical Active Roll Control System. Meindert Solkesz, Department of Precision and Microsystems Engineering. The Ford Motor Company. a brief introduction. Ford Werke - Merkenich

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Design and Performance Analysis of a Roll Damping Function for an Electromechanical Active Roll Control System

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  1. Design and Performance Analysis of a Roll Damping Function for an Electromechanical Active Roll Control System Meindert Solkesz, Department of Precision and Microsystems Engineering

  2. The Ford Motor Company a brief introduction • Ford Werke - Merkenich • 500.000 m2 of design centres, test tracks, equipment • Global Advanced Vehicle Dynamics • Active suspensions • Active safety

  3. SUV demonstrator vehicle Range Rover Sport -specs • 4.2L supercharged V8 (390Hp) • Hydraulic Active Roll Control system • Airsprings front & rear • 2700 kg

  4. Terminology Degrees of Freedom • Translational directions • x-direction: longitudinal • y-direction: lateral • z-direction: heave • Rotational directions • θx: roll • θy: pitch • θz: yaw

  5. Terminology suspension • linkages • dampers • springs • stabiliser bar

  6. Stabiliser bar even input uneven input

  7. Stabiliser bar Weak vs. stiff • weak • stiff • Cornering • (handling) • Straight driving • (comfort)

  8. Active Roll Control (ARC) Suspension layout

  9. Active Roll Control Hydraulic vs. Electromechanical system • Hydraulic • pros • Lots of power • Relatively simple • Knowledge available • cons • Continuously running oil pump • Slow • Electromechanical • pros • Energy efficient • Fast • cons • Complex

  10. SUV demonstrator vehicle Range Rover Sport –modifications for eARC • Electromechanical actuators at front & rear • Sensors • Programmable control hardware • Data acquisition hardware • LCD-screen

  11. Software modification motivation • Lack of damping in the implemented actuators • Demand for a roll damping function in the existing control • software • Potential of energy regeneration

  12. Objective “Design a roll damping function for an electromechanical active roll control system (eARC) and analyse its performance” • Steps taken: • Modify veDYNA computer model • Validate computer model with SUV demonstrator vehicle • Modify the eARC controller with a roll damping function • Analyse the open-loop for stability • Analyse the closed-loop performance • Implement the controller in the real vehicle • Performance test of the roll damping function with regard to power consumption, comfort and handling

  13. Validation Kinematics & Compliance test rig

  14. Validation • Parameters that qualified for validation: • Tyre stiffness • Vehicle body mass, COG, inertia and roll centre • Vertical stiffness suspension • Roll stiffness

  15. Roll damping function Control loop

  16. Simulations Performance low level controller

  17. Roll damping function Control loop

  18. Roll damping function Open-loop

  19. Open-loop frequency response Bode plot

  20. Open-loop frequency response Nyquist plot Magnitude Phase

  21. Nyquist stability criterion

  22. Open-loop frequency response Nyquist stability criterion

  23. Phase lead filter

  24. Notch filter

  25. Modified roll damping function

  26. Open loop with filter Optimal stability

  27. Performance 4 poster rig measurements

  28. Closed loop response Optimal stability

  29. Closed loop response Optimal performance

  30. Stability optimal performance Nyquist stability criterion

  31. Closed loop response Optimal performance 1.8

  32. 1.8 Hz Passive stabiliser bars Active with roll damping

  33. Power consumption 4 poster test • Roll damping function activated • No net energy regeneration

  34. Power consumption 4 poster test

  35. Comfort

  36. Handling Slalom manoeuvre Without rolldamping With rolldamping

  37. Summary • Computer model modified and validated • Stability analysis performed • Stability improved with the use of notch and phase lead filters • Functioning of the roll damping function judged with regard to power consumption, comfort and handling

  38. Conclusions • Stability of the roll damping feedback loop is improved with a combination of a notch and lead filter. • Filters tuned for optimal stability do not provide optimal performance • The roll damping does not regenerate energy. • The roll damping function has a positive / a negative / no influence on the comfort. • The roll damping function improves the handling.

  39. questions

  40. Validation Vertical stiffness – vertical position

  41. Validation Vertical stiffness - avarage • Rebound stop • Rebound spring • Air bellow • Spring aid

  42. Validation Vertical stiffness – 31 sec bounce cycle

  43. Validation Vertical stiffness - 300 sec bounce cycle

  44. Validation Roll stiffness

  45. Validation Roll stiffness

  46. Active Suspension principles • Fullyactive • energy added • Example: electromechanic/hydraulic actuators at 4 corners • Semi active • no energy added • Example: • damper with adjustable damping coefficients

  47. Vehicle model veDYNA

  48. Controller high-level

  49. Controller low-level

  50. Roll damping function Frequency response

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