LLP Erasmus Intensive Programme LLP Erasmus Intensive Programme Partner: Cologne University of Applied Sciences Turku, Finland, 14 - 27 March, 2010 IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles An Introduction to Automotive Mechatronic Systems Dipl.-Ing. Jan Guderjahn Cologne University of Applied Sciences Cologne Laboratory of Mechatronics
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IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Closer Looks
• Mechatronical Development Cycle - Modeling
• Mechatronical Development Cycle - Analysis and Synthesis
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
What is Mechatronic?
Mechatronic – An Integrative Engineering Science
Development of optimal technical (mechatronical) systems
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
What is Mechatronic? (cont'd)
Contributions of participating disciplines
• Mechanical Engineering: Construction of mechanism
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Aims and Characteristics
• Optimal system behavior for specified objectives
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Mechatronic System Applications
Control System Design
• Feedback of real process/plant is input for real-time CPU
• Real-time CPU computes control algorithms
• Output of real-time CPU is input for real process/plant
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Mechatronic System Applications (cont’d)
Hardware-in-the-Loop (HIL) Simulation
• Real production hardware and software, e.g. automotive production Electronic Control Unit (ECU)
• Real-time CPU computes simulation model (e.g. vehicle model)
• Objectives: Optimization of control parameters and simulation model
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Mechatronic System Applications (cont’d)
Virtual Control Prototyping
• Hybrid form of control system design and HIL simulation
• Real-time simulation and animation of test system
• Implementation of control algorithms on 2nd real-time processor
• Coupling of both real-time systems
• Objective: Simultaneously optimization of mechanism and control system design
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Mechatronical Development Cycle - Modeling
Modeling Stages
1. Real system or system idea
2. Physical analogue model
3. Free body diagram for mechanical parts
4. Laws of nature and applied sciences, components laws and phenomenons (*)
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Components of Mechatronic Systems - Sensors
Light bulb
(LED)
Disc Blind
Photo
transistor
Logic
gate
Count
Position
Incremental encoder
• Position measurement via count of single events, e.g. electric impulses
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Components of Mechatronic Systems - Sensors
Tachometer
• Measurement of angular velocity
• Velocity proportional output voltage at the collector connectors
• Ripple, offset, noise and gain deviation
• Compensation of offset and gain deviation via signal conditioning
• Consideration of ripple and noise during control system design
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Interplay of Components of Mechatronic Systems
Electronic Power Steering (EPS) System
Real system Physical analogue system:
5. VDI Mechatronik Tagung 2003, Innovative Produktentwicklung. Fulda, 07.-08. Mai 2003. Optimale Regelung einer elektromechanischen Servolenkung Hermann Henrichfreise, Jürgen Jusseit Labor für Mechatronik (CLM), Fachhochschule Köln, www.clm-online.de Harwin Niessen Mercedes-Benz Lenkungen GmbH (MBL), Entwicklungszentrum Esslingen
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Mechatronical Development Cycle - Analysis and Synthesis
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Simplest way to describe mechatronic systems
• Solution of homogenous part with and u(t) = 0 leads to the characteristic polynomial
• Location of roots of the characteristical polynomial allow statements on system stability
• Computation of system responses for various system excitations u(t) via particular solution
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Linear Ordinary Differential Equations (ODE) (cont'd)
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Linear Ordinary Differential Equations (ODE) (cont'd)
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Phase / deg
Frequency Responses
Relation between system excitation and system amplitude and phase response
• Only harmonic oscillation as excitation and system response
• Only defined for stable systems
• Only linear time-invariant systems
• Easy to plot and analyze via Bode and Nyquist diagram
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Transfer Functions
Relation between any system excitation and system response
• Laplace transform maps signals from time-domain f(t) (original) to s-domain F(s) (image)
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
State Space Systems
Overview
• Technical systems are often described by a system of coupled ODEs nth order for multiple inputs and ouputs
• Suitable transforms lead to a system of coupled 1st order ODE
General time-invariant linear state space system: A state matrix x state vector B input matrix y output vector C output matrix u input vector D feedthrough matrix
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
State Space Systems (cont’d)
Key benefits
• Linear, non-linear, time-variant and time-invariant systems with any excitation
• Multiple-input-multiple-output (MIMO) systems
• Most numeric simulations are based upon state space systems (e.g. MATLAB/Simulink)
• Many newer control theories are based upon state space systems (especially for MIMO systems)
• Classical control theories become easier to use (e.g. for SISO systems)
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
State Space Systems (cont’d)
state differential equations output equation
Example: � Transform to system of coupled 1st order ODE
and leads to
In matrix-vector form:
Eigen values of state matrix A are the roots of the characteristic polynomial
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Interplay of Components of Mechatronic Systems
Electronic Power Steering (EPS) System
5. VDI Mechatronik Tagung 2003, Innovative Produktentwicklung. Fulda, 07.-08. Mai 2003. Optimale Regelung einer elektromechanischen Servolenkung Hermann Henrichfreise, Jürgen Jusseit Labor für Mechatronik (CLM), Fachhochschule Köln, www.clm-online.de Harwin Niessen Mercedes-Benz Lenkungen GmbH (MBL), Entwicklungszentrum Esslingen
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Rapid Control Prototyping
Overview
• Seamless tool chain as development environment for mechatronic systems
• MATLAB with toolboxes
• dSPACE real-time software and hardware
• Focus only on development objectives
• System validation and optimal prototype
• Specificate requirements for production hardware
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Rapid Control Prototyping – Steps and Tools
1. Modeling and analysis, reveal system deficiencies, specification of control design objectives
2. Control system synthesis, design of control system structure, computation of controller parameters
3. Analysis of non-linear closed-loop system via numeric simulation
4. Controller separation, augmentation of controller model, with real-time hardware interface blocks
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Rapid Control Prototyping – Steps and Tools (cont’d)
5. Controller implementation on prototyping hardware via automatic code generation
6. Real system setup, initialization of hardware and safety environment, visualization of signals for monitoring and control
7. Analysis of real system via experiments, comparison of measurement and simulation results Steps 4 to 6: „Rapid Control Prototyping“
dSPACE ControlDesk and MLIB
dSPACE Control Desk and MLIB MATLAB/Simulink
MATLAB/Simulink and real-time workshop, dSPACE real-time interface and prototyping hardware
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Summary
The presented formal design process, defined by the mechatronical development cycle, leads during the completely tool-based development of mechatronic systems to optimal results and reduces in comparison to traditional methods the overall development time and costs.
This way the interdisciplinary character, the basic idea of optimization and the formal development method establish potentials for the products of the future.
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Activities
• Development of vehicle models
• Control algorithm design for steering systems
• Vehicle dynamics control
• Vehicle dynamics observation
• HIL simulation
Our work at the CLM - Automotive Mechatronic Systems
Models and methods for the development and test of mechatronic autmotive systems
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Development of Vehicle Models
Activities
• Development of specific vehicle multi-body systems
• Development of vehicle component models (suspension, power train, tires, brakes etc.)
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
steering
wheel
steering
column
sensor
gear
EPS motor rack
and pinion
steering lever
and steering rod wheels
EPS-ECU
Control Algorithm Design For Steering Systems
Activities
• Electro-mechanical and hydraulical steering systems
• Superimposed steering systems
• Design of steering-feel adapted to current vehicle dynamics situation
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Vehicle Dynamics Control
Activities
• Steering intervention via superimposition torques
• Driver assistance in critical vehicle dynamics situations
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
0 1 2 3 4 5 6 7 8 9 10
-6
-4
-2
0
2
4
6
time / s
sum
late
ral tire
forc
es fro
nt / kN
Vehicle Dynamics Observation
Activities
• Development of observer for the estimation of vehicle dynamics variables
• Use of signal models instead of tire models
• Estimation of traction potential of tire contact patches
Observer
Reliable estimations independent of road and tire conditions
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
HIL Simulation
HIL test bench for steering systems
• Haptic feedback via steering wheel
• Development of algorithms considering the steering feel
• Front-loading of tests with prototypes to the HIL simulation
Development of algorithms in regard to the driver‘s acceptance of the steering feel
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles
Drive systems
• Rapid Control Prototyping
• Development of software tools
Aviation
• Estimation of gusts and structural loads for commercial aircrafts
IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles IP 2010 - Ecology and Safety as Driving Forces in the Development of Vehicles