Functional Development Process of the electric Anti-Roll-Stabilizer ears Dipl. Ing. Daniel Lindvai-Soos Dr. techn. Walter Rosinger
AGENDA Introduction Magna Project House Functional Development Process General System Overview Vehicle Dynamics Control & Simulation Component Design and System Simulation Component Test Bench Conclusion & Outlook Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 2
PROJECT HOUSE Functional Areas E-Corner Technology Hybrid/EV Powertrain Act.Body Control Steering Brake Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 3
PROJECT HOUSE Main Goals The Project House is a cooperation of Magna Steyr, Magna Powertrain and Magna Electronics. Goals Identification of new products for the participating Magna groups Pre-development of prioritized projects Design and assembly of the first prototypes Concept proof After concept proof, the Project House will hand-over the product to the MAGNA group, which will do the serial development and production of this product. Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 4
Functional Development PH Idea Generation (Phase 0) Concept Evaluation & Demo (Phase I) Realization & Validation (Phase II) Serial-Development Support (Phase III) Calculation & Simulation Modelbased verification Vehicle Validation Concept Eval. & Sketching Functional Testing Integration & Calibration Functional Concept (Virt. PT) Component Testing Detail Design & Drawings Subsystem Testing Mechanical, Electrical, & Controller Development First Prototype Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 5
Idea Generation Customer-Oriented Chassis Development Customer Requirements / Brand Philosophy Ride comfort, driving safety, handling Costs, Package Environmental friendly, CO 2 Reduction, Weight Vehicle Dynamics / Vehicle Requirements Idea Generation (Phase 0) Roll angle control, yaw behavior control: over- / understeering Package requirements, same parts, 12V on-board electrical system Less energy consumption, weight Component Specifications Full active suspension control Anti-Roll-Stabilizer electric Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 6
Concept Evaluation Idea Generation (Phase 0) Concept Evaluation & Demo (Phase I) Realization & Validation (Phase II) Serial-Development Support (Phase III) Calculation & Simulation Modelbased verification Vehicle Validation Concept Eval. & Sketching Functional testing Integrationtest & Calibration Functional Concept (Virt. PT) Component Testing Detail Design & Drawings Subsystem Testing Mechanical, Electrical, & Controller Development First Prototype Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 7
Concept Evaluation Requirement specification Max. Torque Dynamics Energy consumption Benchmark OEM Specifications Full Vehicle Simulation Concept Evaluation & Demo (Phase I) Validation Component based Full vehicle based results in Tast cases Driving maneuvres MAGNA rating matrix Optimized + verified Concept Hardware (e.g. active stabilizer) Software (Functional SW & VDC Controller) Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 8
ears VDC Simulation Simulation Environment: TESIS vedyna Vehicle: SUV R6 2.5 Otto Active Vehicle: Active Roll Control Active Stabilizer Torque Distribution vedyna driver Concept Evaluation & Demo (Phase I) Steady State Cornering Slalom Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 9
ears VDC Simulation Steady State Cornering Reference Values: Results: Concept Evaluation & Demo (Phase I) Different Reference Curves: Potential Analysis OEM Specification Define Brand Specific Characteristics Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 10
ears VDC Simulation Slalom Concept Evaluation & Demo (Phase I) Steering Wheel Angle -15.5% Roll Angle -50% Roll Angle Acc. -50% Vehicle Velocity ~80km/h Lateral Acceleration: 6m/s2 Improvement in Safety and Comfort Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 11
ears VDC Simulation Slalom Concept Evaluation & Demo (Phase I) Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 12
Subsystem Development Idea Generation (Phase 0) Concept Evaluation & Demo (Phase I) Realization & Validation (Phase II) Serial-Development Support (Phase III) Calculation & Simulation Modelbased verification Vehicle Validation Concept Eval. & Sketching Functional testing Integrationtest & Calibration Functional Concept (Virt. PT) Component Testing Detail Design & Drawings Subsystem Testing Mechanical, Electrical, & Controller Development First Prototype Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 13
Sub-System-Development: BLDC-Motor EMotor: AMESim - System-Simulation Planet Gears with Inertia, Coulomb Friction, Viscous friction torque, Stiction Torque and Tooth & Bearing Losses Bearing Losses Realization & Validation (Phase II) Reduced Stabilizer Bar stiffness Emotor with Thermal port ECU Battery Target Definition of E-Motor- Spec. Load Profile: Torque, Speed, Thermal Component Controller Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 14
Speed [rpm] Spitzen-Leistung in W Torque [Nm] Speed [rpm] Sub-System-Development: BLDC-Motor Result-Sheets: EMotor: ramp-up with symmetric profile Realization & Validation (Phase II) Time [sec] BLDC-Motor Development: Specification from Component Simulation & CAD Time [sec] 3000 2500 2000 1500 Working-Area-Plot Stellzeit t=0.3s Stellzeit t=0.4s Stellzeit t=0.5s Optimization of Geometry High Dynamics, Low Inertia, HighEfficiency, Low Torque Ripple, 1000 500 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Torque Stabilisatorsteifigkeit [Nm] in Nm/rad Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 15
Component Testing Idea Generation (Phase 0) Concept Evaluation & Demo (Phase I) Realization & Validation (Phase II) Serial-Development Support (Phase III) Calculation & Simulation Modelbased verification Vehicle Validation Concept Eval. & Sketching Functional testing Integration & Calibration Test Functional Concept (Virt. PT) Component Testing Detail Design & Drawings Subsystem Testing Mechanical, Electrical, & Controller Development First Prototype Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 17
ears Test Bench Lay-Out Realization & Validation (Phase II) Stabilizer Bars from SUV Voltage Supply: 12V from Battery Force Sensors, Temperature Sensors, Testing Procedures: Static Testing Dynamic Testing Thermal Testing Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 18
Current [A] Speed [rpm] Torque [Nm] ears Test Bench Results 1000 800 600 Torque Step Input Realization & Validation (Phase II) 400 200 1200 1000 800 600 400 200 120 100 Target torque actual. torque 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0 0 0.1 0.2 0.3 0.4 0.5 0.6 80 60 40 20 800Nm in 280ms Time in sec. BLDC-Motor Development: Ramp-Up Profile Optimization of Geometry High Dynamics, Low Inertia, High Efficiency, Low Torque Ripple, 0 0 0.1 0.2 0.3 0.4 0.5 0.6 Time [sec.] Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 19
Conclusion and Outlook Functional Development Process Optimized + verified Concept Hardware Software VDC Controller electric Anti-Roll-Stabilizer ears Functional Targets: Actuation Torque: 800Nm High Dynamics: 300ms Improved Response Time Fail Safe Mechanism Optimum of Package & Weight Cost Effective & Energy Efficient Target Vehicle Segments: Upper Middle, Premium Class, SUV Outlook o o On-Vehicle tuning and testing (VDC subjective rating) Serial Development SOP 2012 possible Datum 06/ 2010 Autor: D. Lindvai-Soos Disclosure or duplication without consent is prohibited 20