Combining virtual simulation and physical vehicle test data to optimize durability testing

Abstract

This paper describes an ongoing project to model a vehicle on a computer with a multibody dynamics simulation software package and to merge that work with physical proving ground and laboratory tests in order to shorten vehicle development time. The intention is to mirror as closely as possible the behaviour of a physical vehicle in order to assist in determining its durability characteristics under varying road conditions. This modelling work is important because, if done with sufficient fidelity, it can be used in order to assess vehicle responses by using different suspension components or payloads. Also, potential issues associated with vehicle structure, suspension components or payload positioning can be observed on a computer prior to performing physical tests. The process has the potential to reduce vehicle development cost and time. The virtual dynamic vehicle model has been created by using Automatic dynamic analysis of mechanical systems (ADAMS) software package. The calculated outputs from the model are being compared to force and displacement data collected from actual vehicle on‐road testing or a servo‐hydraulic road test simulator (RTS). The virtual model can be adjusted until the calculated responses are in close agreement with those of the physical vehicle, thus linking the virtual and real‐world results.

Virtual Validation of Automotive Measurement Services Based on JT (ISO 14306:2012)

“…The ability to analyze single components in test beds and fully equipped vehicles in road tests on proving grounds with different sensors lead to a high complexity and data diversification. Beside strain gauges, accelerometers and force sensors, wheel force sensors are used for vehicle dynamics and operating load measurements [2]. The measuring process is analyzed using SADT [3], [4].…”

“…A consistent digitalization of products and processes offer huge potential to improve interoperability and ensure a defined quality level in the entire product life cycle. Despite the benefits and manifold application possibilities of virtual methods, automotive measurement services often lack a fully digital integration of underlying processes [2]. Measuring services are characterized by media discontinuities and are based on the knowledge of each individual engineer.…”

Condition detection and fault diagnosis system for recoil system based on simulation

“…Appropriate constraints are applied to the subsystems under ADAMS environment in order to establish the corresponding virtual prototyping. The flow table of virtual prototyping establishment is shown as Figure 2 and the virtual prototyping for a type of Self-Propelled Gun is shown as Figure 3 [2] [3] :…”

Frame loads accuracy assessment of semianalytical multibody dynamic simulation methods of a recreational vehicle

“…A second evaluation approach often considered to estimate frame loads is the use of wheel force transducers (WFTs) that monitor forces and moments transmitted at the wheel hubs [3][4][5]. WFTs are widely used for durability analysis, multibody dynamics (MBD) modeling and handling analysis [6][7][8][9][10][11]. Although these transducers do not directly provide chassis loads, their data can be used in MBD simulations to predict loads transmitted to the frame.…”