SRM INSTITUTE OF SCIENCE AND

TECHNOLOGY

DEPARTMENT OF AUTOMOBILE
ENGINEERING

REPORT
VEHICLE MAINTENANCE
18AUE453T
REGULATION 2018

Faculty of Engineering and Technology

SRM Nagar, Kattankulathur
Kancheepuram, Tamil Nadu-603203
 18AUC401J- VEHICLE DYNAMICS LABORATORY
CONTENTS

S.
Name of the experiment Page Marks Sign
No.

1 Modelling and Simulation using Modelica

2 Analysis of vibration system

3 Quarter car model

4 Magic formula tire model

5 Generation of road profile

6 Car Maker – Study

7 Analysis of braking dynamics using Carmaker

software

8 Analysis of lateral dynamics using Carmaker

software

9 Rollover analysis using Carmaker software

10 Active suspension - Study

 SRM Institute of Science and Technology, Department of Automobile Engineering, KTR
Campus

EXP. NO. 1: MODELLING AND SIMULATION USING OPEN

MODELICA
Aim:

1. To learn the fundamentals of syntax / constructs of Modelica

2. To learn the simulation of dynamic systems using Modelica

Apparatus / Software required:

1. Desktop / Laptop with minimum 4GB RAM
2. Modelica installation using OpenModelica

Prelab questions:
1. List any three numerical computational packages you know.
2. What is the difference between modeling and Simulation?
3. What is meant by causal modeling?
4. What is meant by acausal modeling?
5. What is meant by a dynamic system?

Modelica:
Introduction to Modelling:
There are two approaches in modeling of engineering systems:
1. Causal modelling / Signal flow approach / block-based modeling
2. Acausal modelling / Network Approach / component-based modeling
Models designed using classical causal networks provide a clear graphic
visualization of individual mathematical relationships. Signals flow in connections
between individual blocks, transmitting values of individual variables from the
output of one block to inputs of other blocks. Processing of input information to
output information takes place in the blocks. Interconnection of the blocks in causal
software like Simulink thus reflects rather the calculation procedure than the very
structure of the modelled reality. This is the so called causal modelling. However, it
is important in designing and especially presenting and describing the model that
the very structure of the model, rather than the very algorithm of the simulation
calculation, captures well especially the physical essence of the modelled reality.
Therefore, declarative (acausal) notation of models is starting to be used in a
growing extent in modern simulation environments; this means that individual
components of the model describe the equations directly and not the algorithm of
their solution. By interconnecting individual components, the systems of equations
become connected with each other. Interconnection of the components does not
define the calculation procedure but the modelled reality.
Modelica is an acausal modelling software (syntax). There are many
commercial softwares based on Modelica standard such as Dymola of Dassault
Systems, SimulationX of ESI group, AMESim of Siemens, Simscape (Library in
Simulink) of Mathworks, Impact Libraries from Modelon, etc. The free open source
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version is the OpenModelica from the Open Source Modelica Consortium. The
laboratory sessions utilizes OpenModelica for modelling and simulation.

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OpenModelica:

Acausal modelling:
Acausal modeling is a declarative modeling style, meaning modeling based
on equations instead of assignment statements. Equations do not specify which
variables are inputs and which are outputs, whereas in assignment statements
variables on the left hand side are always outputs (results) and variables on the
right-hand side are always inputs. Thus, the causality of equation- based models is
unspecified and becomes fixed only when the corresponding equation systems are
solved. This is called acausal modeling. The term physical modeling reflects the fact
that acausal modeling is very well suited for representing the physical structure of
modeled systems. The main advantage with acausal modeling is that the solution
direction of equations will adapt to the data flow context in which the solution is
computed. The data flow context is defined by stating which variables are needed
as outputs and which are external inputs to the simulated system.

Software Component Model in Modelica:

Modelica offers quite a powerful software component model that is on par
with hardware component systems in flexibility and potential for reuse. The key to
this increased flexibility is the fact that Modelica classes are based on equations.
The software component model includes the following:
1. Components
2. Connection Mechanism
3. Component framework
Components are simply instances of Modelica classes. Those classes should
have well efined interfaces, sometimes called ports, in Modelica called connectors,
for communication and coupling between a component and the outside world. A
component is modeled independently of the environment where it is used, which is
essential for its reusability. Components are connected via the connection
mechanism, which can be visualized in connection diagrams. The component
framework realizes components and connections and ensures that communication
works and constraints are maintained over the connections. For systems composed
of acausal components the direction of data flow, that is, the causality is
automatically deduced by the compiler at composition time. Connections between
components can be established between connectors of equivalent type. Modelica
supports equation-based acausal connections, which means that connections are
realized as equations. For acausal connections, the direction of data flow in the
connection need not be known.
Modelica Libraries:
Much of the power of modeling with Modelica comes from the ease of
reusing model classes. Related classes in particular areas are grouped into
packages to make them easier to find. A special package, called Modelica, is a
standardized predefined package that together with the Modelica Language is
developed and maintained by the Modelica Association. This package is also known
as the Modelica Standard Library. It provides constants, types, connector classes,
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partial models, and model classes of components from various application areas,
which are grouped into sub packages of the Modelica package, known as the
Modelica standard libraries.

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The following is a subset of the Modelica standard libraries currently available:

Library Name Library Components

Modelica.Constants Common constants from

mathematics, physics, and so on

Modelica.Icons Graphical layout of icon definitions

used in several packages

Modelica.Math Definitions of common mathematical

functions
Type definitions with SI
Modelica.SIUnits (international system of units)
standard names and units
Modelica.Electrical Common electrical component
models
Input–output blocks for use in block
Modelica.Blocks diagrams

Modelica.Mechanics.Translati One-dimensional (1D)

mechanical translational
onal components
Modelica.Mechanics.Rotation 1D mechanical rotational
al components
MBS library—3D mechanical
Modelica.Mechanics.MultiBo rigid body multibody models
dy
Modelica.Thermal Thermal phenomena, heat flow,
and other like components

The following steps illustrate basic steps for simple mathematical analysis and
dynamic analysis.
Case (i) Addition of two numbers:
Step 1:
Start OpenModelica. The interface is similar to the following figure. (In dark
mode)

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The items on the left side represents the libraries available in the software.
We can load the necessary libraries if they are not present in the side menu.
Step 2:
Let us assume we need to add two numbers 10 and 15. We need to first
create a new file for the project. File – New Modelica Class. Assign a name
to the new modelica class file. Step 3:
We need to add two constant numbers. The constant block for mathematical
calculations is available in the following library:
Modelica – Blocks – Sources
Drag the constant block from the library and paste it in the workspace.
Double click it and change its value to 10. Similarly drag another constant
block and assign it to the value of
15. The addition block is available in the following library:
Modelica – Blocks – Math
Drag the add block and paste it in the workspace. Connect the blocks as
shown in the figure. The blocks in the workspace is similar to the figure
shown below:

Step 4:
We can check the models by clicking the double arrow icon in the menu bar.
It display whether any error is present in the model. Then to run the model,
click the forward arrow icon present in the menu bar. The program runs in a
couple of seconds.
Step 5:
Once the program is run, a new variables browser is open in the right side
of the work space. It contains all the variables representing all the inputs,
outputs and other relevant variables. The check boxes are available near
each of the variable. We can check the variable for which we need the plot.
The outputs is shown in the graph format as shown in the figure.

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Case (ii):
Differentiation of a sine wave:
Step 1:
The block for sine wave is available in the following library:
Modelica – Blocks – Sources
Drag the block and paste it in the workspace. Double click the sine wave
icon and enter the parameters of the sine wave like amplitude, frequency,
etc.
Step 2:
The block for differentiation is available in the following
library: Blocks – Continuous - Derivative
Drag the block and paste it in the workspace. The final model is as shown in the
figure:

Step 3:
To run the model click the forward arrow icon present in the menu bar. a
new variables browser is open in the right side of the work space. It
contains all the variables representing all the inputs, outputs and other
relevant variables. The check boxes are available near each of the variable.
We can check the variable for which we need the plot. The outputs is shown
in the graph format as shown in the figure. The graph shows the derivative
of the sine wave.

Result:
The fundamentals of syntax / constructs of Modelica have been learnt. The
simulation of dynamic systems using Open Modelica modeling environment
has been practice
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EXP. NO. 2: ANALYSIS OF A VIBRATION SYSTEM

Aim:
To model a basic vibration system consisting of a spring, mass and
damper using
Modelica modeling environment and simulate for varying parameter values.

Apparatus / Software required:

1. Desktop / Laptop with minimum 4GB RAM
2. OpenModelica modelling environment

Prelab questions:
1. State Newtons Second law of motion.
2. Define stiffness.
3. State the expression for damping factor.
4. What is meant by critically damped condition?
5. Give an example for under damped vibration.

Vibration system:
The vibration system consists of three fundamental elements:
a) Mass - Representing inertia element
b) Spring - Representing stiffness element
c) Damper - Representing friction / damping element

The governing equation for the problem is:

m x¨+c x˙+kx=0
where x represents displacement, ẋ represents velocity and ẍ represents

acceleration, k represents spring stiffness, c represents damping constant.

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Consider a single degree of freedom vibration system with mass of 450 kg,
spring stiffness 26519 N/m, damping of 1000 Ns/m. Obtain the displacement
plot of the mass for the following three conditions:
(i) Critically damped, (ii) Under damped and (iii) Over damped.

We know critical damping constant is given by

k 26519
=2∗ 450
√ √
m 450
c c=2mω =n2 m =6909 Ns
Any damping value below this is under damped and above this value is over
damped.
/m

Procedure:
The procedure for drawing the block diagram layout is shown in the
following
steps:
Step1:
Create a new Modelica Class file:
File – New Modelica Class. Assign a name to the new modelica class file.

Step2:
Include the mass block from the following
library. Modelica – Mechanics – Translational -
Components Double click the block and set the
mass value to 450.

Step 3:
Include the Spring damper block from the following
library. Modelica – Mechanics – Translational -
Components
Double click the block and change the stiffness value to 26519 and damping
value for the required damping condition (Critical / Under damped / Over
damped)

Step4:
Add a position sensor block to easily find the position of the mass from the
following library and connect it to the bottom port of the mass block.
Modelica – Mechanics – Translational - Sensors

Step5:
As it is a free vibration case, we need to give an initial disturbance in the
form of displacement input. Add the position block from the following library.

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Modelica – Mechanics – Translational – Sources
To give the numerical value to the position block add the pulse signal from the
following library:
Modelica – Blocks – Sources

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Double click the pulse signal and change the amplitude to 0.05 and the
number of periods to 1.

Step6:
Run the program by clicking forward arrow icon.

Step7:
The displacement of the mass can be plotted from the position sensor flange
displacement variable. Plot the displacements for critically damped, under
damped and over damped conditions.

Model diagram:

Result:
Thus, a basic vibration system consisting of a spring, mass and damper using Modelica
modeling environment has been modelled and simulated for varying parameter values.

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EXP. NO. 3: QUARTER CAR MODEL

Aim:
To model a quarter car model consisting of a sprung mass, unsprung
mass,
suspension system with a shock absorber and damper using Modelica
modeling environment and simulate for varying parameter values.

Apparatus / Software required:

1. Desktop / Laptop with minimum 4 GB RAM
2. OpenModelica modelling environment

Prelab questions:
1. Define degrees of freedom.
2. What is the number of degrees of freedom for a quarter car model?
3. Define sprung mass.
4. Define unsprung mass.
5. What is the SI unit of spring stiffness?

Quarter car model:

Construct a quarter car model with the following specifications:
Sprung mass = 208 kg, Unsprung mass = 28 kg, Suspension stiffness =
18709 N/m, Suspension damping = 1300 Ns/m, Tire stiffness = 127200 N/m,
Tire damping = 10 Ns/m.

Procedure:
The procedure for drawing the block diagram layout is shown in the
following steps: Step1:
Create a new Modelica Class file:
File – New Modelica Class. Assign a name to the new modelica class file.

Step2:
Include two mass blocks from the following library.
Modelica – Mechanics – Translational -
Components Double click the block and set the
mass value to 208 and 28.

Step 3:
Include two Spring damper block from the following
library. Modelica – Mechanics – Translational -
Components
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Double click the block and change the stiffness value to 18709 and damping
value of 1300. For the tire properties, double click the block and change the
stiffness value to 127200 and damping value of 10.

Step4:
Add a position sensor block to easily find the position of the sprung mass
and unsprung mass from the following library and connect it to the bottom
port of the mass block.
Modelica – Mechanics – Translational - Sensors

Step5:
We shall give the road disturbance as a displacement input. Add the position
block from the following library.
Modelica – Mechanics – Translational – Sources
To give the numerical value to the position block add the pulse signal from the
following library:
Modelica – Blocks – Sources
Double click the pulse signal and change the amplitude to a suitable value
and the number of periods to 1.

Step6:
Run the program by clicking forward arrow icon.

Step7:
The displacement of the sprung mass, unsprung mass as well as their
velicties and acceleration can be plotted from the position sensor flange
displacement variable. Plot the displacements, velocities and acceleration
for the sprung mass and the unsprung mass.

Result:
Thus, a quarter car model consisting of a sprung mass, unsprung mass, suspension system
with a shock absorber and damper was modelled using Openmodelica modeling environment and
simulated for varying parameter values.

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Model diagram:

Plot for displacement of sprung mass and unsprung mass:

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EXP. NO. 4 : MAGIC FORMULA TIRE MODEL

Aim:
To calculate the longitudinal force generated in a tire during
acceleration or
braking as a function of vertical load acting on the tires.

Apparatus / Software required:

1. Desktop / Laptop with minimum 4 GB RAM
2. HTML / Java compliant web browser
3. Xcos / Scilab modelling environment

Prelab questions:
1. The torque acting about the z axis of a tire is termed as .
2. The torque acting about the y axis of a tire is termed as .
3. Define longitudinal slip of a tire.
4. Define slip angle of a tire.
5. What is the relation between linear velocity and angular velocity?

Magic formula:
Magic formula for tires was developed by HB Pacejka. They were
named the "Magic Formula" because there is no particular physical basis for
the structure of the equations chosen, but they fit a wide variety of tire
constructions and operating conditions. Each tire is characterized by 10–20
coefficients for each important force that it can produce at the contact
patch, typically lateral and longitudinal force, and self- aligning torque, as a
best fit between experimental data and the model. These coefficients are
then used to generate equations showing how much force is generated for a
given vertical load on the tire, camber angle and slip angle. The following
figure shows the forces and moments acting on a tire.

where

Fx[N] – longitudinal tire

force Fy [N] – side (lateral)
tire force Fz [N] – vertical
tire force
Mz [Nm] – tire aligning torque
Ω [rad/s] – tire angular velocity
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V [m/s] – tire longitudinal velocity
α [fl] – tire slip angle

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The longitudinal force of the tire is generated when the vehicle is traveling
in a straight line, during acceleration or braking. The side (lateral) wheel
force is generated when the vehicle is changing direction, during cornering.
The vertical tire force is given by the weight of the vehicle and depends on
the dynamic behavior of the suspension.

In this lab exercise, the longitudinal forces are calculated using

Magic formula. The Magic formula is given by
Fx=Fz ⋅ D⋅ sin (C ⋅ arctan {B⋅ k ⋅ − E [B⋅ k − arctan (B ⋅ k )]})
where the values of the parameters are given in the table given below:
Surface B C D E

Dry tarmac 10 1.9 1 0.97

Wet tarmac 12 2.3 0.82 1

Snow 5 2 0.3 1

Ice 4 2 0.1 1

Procedure:
The code for generating the plot is given below:
clear
()
clc()
clf()

// Tire model constant coefficients

B = [10 12 5 4];
C = [1.9 2.3 2 2];
D = [1 0.82 0.3 0.1];
E = [0.97 1 1 1];

// Vehicle
parameters mv =
2000;
g = 9.81;
Fz = (mv*g)/4;

// Plot setup parameters

surface = ["Dry tarmac" "Wet tarmac" "Snow"
"Ice"]; colors = ["k" "purple" "steelblue"
"deepskyblue"];

// Wheel slip
slip = [-
1:0.01:1];

// Plot

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for i=1:length(B)
for j=1:length(slip)
Fx(i,j) = Fz * D(i) * sin(C(i)*atan(B(i)*slip(j)-E(i)*(B(i)*slip(j)-
atan(B(i)*slip(j))))); end

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plot(slip,Fx(i,:),"Color",colors(i),"LineWidt
h",2) end
xgrid()
xlabel("Wheel slip [-]")
ylabel("Tire longitudinal force, Fx [N]")
title("Longitudinal Force vs Longitudinal Slip","Color","blue")
legend(surface,2)

The above code is employed for generating longitudinal forces. The same
formula can be utilized for generating lateral forces by replacing slip with
slip angle. The slip angle can be taken from -2 degrees to +2 degrees in
steps of 0.001. The x axis is the slip angle and the y axis is the lateral force
and the title of the plot is Lateral force vs Slip angle. The code for such a
plot is given below:

clear
()
clc()
clf()

// Tire model constant coefficients

B = [10 12 5 4];
C = [1.9 2.3 2 2];
D = [1 0.82 0.3 0.1];
E = [0.97 1 1 1];

// Vehicle
parameters mv =
2000;
g = 9.81;
Fz = (mv*g)/4;

// Plot setup parameters

surface = ["Dry tarmac" "Wet tarmac" "Snow"
"Ice"]; colors = ["k" "purple" "steelblue"
"deepskyblue"];

// Wheel slip angle

slipangle = [-2:0.0001:2];

// Plot
for i=1:length(B)
for j=1:length(slipangle)
Fy(i,j) = Fz * D(i) * sin(C(i)*atan(B(i)*slipangle(j)-E(i)*(B(i)*slipangle(j)-
atan(B(i)*slipangle(j))))); end
plot(slipangle,Fy(i,:),"Color",colors(i),"LineWid
th",2) end
xgrid()
xlabel("Wheel slip angle [-]")
ylabel("Tire lateral force, Fy [N]")
title("Lateral force vs slip angle","Color","blue")
legend(surface,2)
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Note:
For the exam, the parameter values of B, C, D, etc will not given. The
student
has to memorize these values. The mass of the vehicle (mv) shall be changed
in the question and the students has to plot the longitudinal and lateral
forces for the given mass. Result:
Thus, the longitudinal force generated in a tire during acceleration or
braking was calculated as a function of vertical load acting on the tires.
Similar procedure can also be applied for calculating lateral forces and
Moment about vertical axis.

Plot for magic formula:

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EXP. NO. 5 : GENERATION OF ROAD PROFILE

Aim:
To identify a statistical method for road profile generation and to create
a block
diagram model for the same.

Apparatus / Software required:

1. Desktop / Laptop with minimum 4 GB RAM
2. HTML / Java compliant web browser
3. Xcos / Scilab modelling environment

Prelab questions:
1. In a sine wave equation what are the parameters involved?
2. Define frequency of a signal.
3. What suspension parameters are involved in vertical dynamic analysis?
4. Vertical dynamics analysis of automobiles are carried over in
coordinate.
5. What is meant by a random signal?

Road profile:
The fundamental source of excitation to an automobile is the road
surface. The parameters which influence the vertical dynamic behaviour of
vehicles are :
1. Parameters like height, shape, frequency of irregularities of road
surface
2. Vehicle speed
3. Chassis / Suspension parameters.
It is essential for a vehicle dynamics engineer to generate a proper road
profile to be employed in vehicle dynamic studies. In engineering analysis,
one of the first assumptions in generating inputs is the generation of
periodic signals such as sine wave signal and analyzing the engineering
system. Hence, an initial study of road signal is derived from assuming road
profile to be a periodic signal based on a sine wave representation.

The general format for a sine wave periodic road signal is given by
h (x )=h0 sin (ωt +ϵ ) (1)
where h(x) is the road profile height in m
h0 is the road irregularity amplitude
in m L is the road irregularity

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length in m
t is the time in seconds
x is the distance along the road surface in m
ω is the angular frequency in rad/s

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ε is the phase offset angle

The angular frequency can be determined from the
vehicle speed (v)
2πv (2)
ω= L

As a first step, the above road profile equation (1) based on sinusoidal signal
can be found out using Xcos. In the following Xcos model one can plot the
road profile by varying the values of the following parameters:
1. Phase angle
2. Angular velocity
3. Road irregularity amplitude

Fig. Xcos model for sine wave road profile generator

The following table gives the statistical data for different types of road profiles.

Road type h0 [mm] L [m]

Motorway / Highway 10 – 20 10 – 15
Urban roads (asphalt 10 – 20 1.0 – 2.0
concrete)
Pavement roads (cobbles) 30 – 40 0.15 – 0.30
Offroad 50 – 70 0.10 – 0.15

Random road profile:

A more realistic road profile can be generated using a periodic signal as a sum
of several harmonics. The mathematical model can be represented as a
Fourier series which is a sum of sine functions with different frequencies and
amplitudes.
h (t )=b0+b1 sin ( ωt +ϵ1 )+b2 sin ( ωt +ϵ 2 )+b3 sin (ωt +ϵ3 )+b4 sin ( ωt +ϵ 4 )+.. . (3)

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b0, b1, b2, …[m] – are the amplitudes of the harmonic components (known
also as

Fourier coefficients) where

ε1, ε2, … [rad] – are the phase offsets for each harmonic.

For simplification, in this model, we considered that all the phase offsets are
0, b0 is 0 and ω is 1. The order of the harmonics is 6.

These mathematical models for the road height function of time will be used
in future articles, as road input signals for wheel dynamics study models
(e.g. quarter car model).

Result:
Thus, the road profile has been generated using the random road
profile generation model in Xcos.

Plots for Road profile:

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EXP. NO. 6: CAR MAKER INTRODUCTION

Starting Car Maker:
Start - Programs - IPG - CarMaker Version No. - CarMaker
The first thing the user sees is the CarMaker main GUI (main
Graphical User Interface), as displayed in the figure below. This is
CarMaker’s control center, with which all functionalities and sub windows
are accessed.

TestRun
Performing a simulation in CarMaker requires info about the type of
vehicle, tires, driver, test track and a maneuver, that the driver is to
perform. A combination of these models and settings form what is called a
TestRun.
TestRun represents a test scenario in which all parameters of the
virtual environment (vehicle, driver, tires, etc.) are sufficiently defined.
Data set:
It is the process of providing values for
the testrun cases. For example, selecting the
exact type of vehicle, selecting or designing
a road, defining a type of driver and defining
a maneuver. Thus, a data set is manually
implemented or loaded for each of the
models.
Virtual vehicle environment:
All the above settings of virtual road, virtual
driver, virtual tires, etc form the virtual vehicle environment. In CarMaker,
the virtual vehicle is made up of mathematical models that contain the
equations of motion, kinematics, etc. along with other mathematical
formulas that define the multibody Project folder:
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It contains all the TestRun data, needs to be created. This is done by
selecting File > Project Folder > Create Project in the CarMaker main GUI.

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Inputs to be given while starting a testrun:

To start a simulation, we need information required to parameterize
the virtual vehicle environment. TestRun composes of a different number of
modules for which data is to be provided. The minimum modules to be given
info are:
1. Vehicle - Definition of the vehicle data set used
2. Road - Parameterization of the test track
3. Maneuver - To specify the driver’s task
4. Driver - Set driver behavior

Additional options available are:

1. Trailer - To simulate a test car with trailer configuration
2. Tires - Overwrite the default tire data set referred in the vehicle model
3. Traffic - Add other static or moving traffic objects
4. Environment - Configuration of the test environment with date, time
and ambient conditions

Fig. Contents of the

Testrun file

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Steps involved in creating a testrun case:

1. Select a vehicle (if it does not exist, first build a vehicle data set)
2. Choose or define a test track with obstacles and the desired
conditions
3. Specify the type of driver or use a simple closed loop controller
4. Specify the tires and loads
5. Define the Maneuver
6. Optionally, select a trailer
7. Save the TestRun

Scenario editor:
• Scenario Editor is the graphical user interface (GUI) that enables the
creation of highly complex road networks for vehicle and driving
simulation.
• It is accessible via the CarMaker GUI by clicking the Parameters menu
and selecting Scenario/Road.
• The Scenario Editor is the front end of the road building module while
IPGRoad, the back-end module, is a software library used to build
roads and scenery in CarMaker.

Components of the Scenario editor:

Name Description
Junction Road element used to join different Links
Link A section of the road network, usually one road
Reference Line Road curvature, defined in the global (x,y,z)-coordinates

Lane Lateral extension of a Link

Lane Section Sections of a Link with constant number of lanes
Elevation Profile Lateral, longitudinal and camber profile changes
Route Reference line defining the course of the vehicle travel
on the road
Path Actual course of the vehicle travel on the road

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The interface of the scenario editor is shown in the following figure:

Fig. Scenario editor

Maneuver:
• It explains the driving scenario for a vehicle under study.
• It consists of one maneuver and several minimaneuvers.
• Maneuver represents the overall driving action whereas
minimaneuver represents the individual actions like
accelerating/braking, steering, etc.

Fig. Maneuver dialog box

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To build a driving scenario, you have to add and parameterize successively

the various maneuver steps necessary to control the vehicle as you want.

Driver:

Fig. Driver Window

IPG Driver is a controller for following a course and a speed controller on a
given track. IPG Driver enables you to add the control actions of a human
driver to your complete vehicle simulation. These actions include the
steering, braking, throttle position, gear shifting and clutch operation. But
you can decide to use IPG Driver only to control the course and not the
speed or vice versa.

The driver actions include:

1. Choice of driving course within the lane borders (corner cutting)
2. Steering
3. Choice of the driving speed according to the course and the vehicle
behavior
4. Influence on the speed over the accelerator and brake pedal, as
well as over the clutch pedal and gear selection
5. Regard traffic objects and follow

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Traffic:

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IPG Traffic allows, additional road users and ambience to be added

to the TestRun which replicates a typical traffic scenario as seen in reality.
This can be primarily classified into two different modes: Movable and
Stationary. Movable mode includes Parking vehicles, Slow driving cars,
Vehicles that change the driving lane abruptly, Cars that coincide at a
crossing, Bicycle riders, Pedestrians and/or Animals crossing the road etc.
Stationary mode includes objects like Residential buildings, Office buildings,
Parking garages and gas stations, etc. The interface for traffic window is
shown below:

Fig. IPG Traffic configuration dialog

The traffic dialog primarily consists of three sections (1, 2 and 3) where, Box
1 is the section where traffic objects can be added to the TestRun. Box 2 as
seen in Figure, is the main window where attributes of each individual
traffic object can be parameterized and their motions can be defined. To
parameterize a specific object, the respective traffic object has to be first
selected from the box 1, and as a result the corresponding parameterization
is available in box 2. Box 3 is a similar option as Input from File for the test
vehicle.

Environment:
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The Environment module under Parameters > Environment,

enables to define environmental conditions like the temperature, the time of
day or the wind velocity for your simulation. If your model takes these
parameters into account, they will influence the results of your simulation.

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EXP. NO. 7: CAR MAKER – OVAL TRACK – BRAKING DYNAMICS

Date:
Aim
To simulate a vehicle for the given conditions and analyse the braking
dynamic
behavior for the given oval track.

Importance/Significance :
The ground reaction forces for the given test conditions need to be
determined in the design stage itself for the vehicle designer for designing
appropriate suspension system components and chassis structure.

Apparatus required & Specifications :

S.No Apparatus Required Specifications

Processor: i7 processor; Ram: 8 GB
1 Computing machine
Graphics Memory: 2 GB
2 Simulation software IPG Carmaker

Theory
The function of an automotive friction brake is to generate a braking
torque to retard the road wheel and thus the vehicle to which it is fitted. The
working principle of a friction brake is that friction material stators are
pressed against a rotor, generating frictional forces that slow down the rotor
and anything connected to it such as a road wheel. The torque reaction is
transmitted from the stators to the vehicle structure, usually via the
suspension components.
A torque or moment exists when two parallel and opposite forces of
equal magnitude, separated by a distance, act on a body. In the case of a
disc brake, the two parallel forces are the drag forces between pads and
rotor, and the bearing force. The distance is the effective rotor radius
measured from the center of the bearing spindle to the rotor drag force. The
brake torque is computed by taking the product of total drag force acting on
the drum or rotor and the drum radius or effective rotor radius. The brake
torque is reacted upon by the road torque which produces the braking force
between tire and roadway.

Procedure
1. Open the Carmaker software through Windows OS.

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2. In File menu, create a new Project

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3. Under parameters menu, select Car option. A new tab titled vehicle
data set is open. In Vehicle data set tab, click File > Open, Click
Product examples. Click the appropriate car given in the question –
Audi R8. Close the Data Set tab.
4. Under parameters menu, select Scenario/Road. The Scenario editor
tab is open. All the options for creating the road/test track shape is
given in the left side menu. Create the shape of the track given in
the question using the options – Oval shape.
5. Click the Route button in Traffic tab and then double click the track
shape.
Now the track is converted into a route for the vehicle. Close
the Scenario editor.
6. Under parameters menu, select Maneuver option. Create the
various steps of maneuver as per the instructions given in the
question by clicking the New button for each step. Close the
Maneuver dialog box.
7. To view the simulation video goto File > IPGMovie. In the movie
animation, the longitudinal tire forces are shown in green color,
lateral forces in blue color and vertical forces in red color.
8. To plot the required graphs goto File IPGControl 1.18. Select the
appropriate parameter from the quantities given in the bottom
menu. In this exercise, the
braking torques of all the four wheels
(Brake.Trq_FL_Tot,Brake.Trq_FR_Tot, Brake.Trq_RL_Tot,
Brake.Trq_RR_Tot)need to selected. They are plotted.
9. Start the simulation from the main windows and once the simulation
is over
right click in the IPGControl window and select Totalfit. All the
plots now come in the single window. Convert the plots to pdf
print.

Prelab Questions :

1. What is meant by braking torque?

2. What materials are used for frictional materials for brakes?
3. Define stopping distance.
4. What is meant by ABS?
5. What are the components of ABS?

Inferences:

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The variation of the forces generated in the tire ground interface was
visualized and seen.

Result :
The ground reaction forces at wheels/tires for the given vehicle model
and test track was simulated and plotted.

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Output (Display or Graph Plot) :

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EXP. NO: 8 CAR MAKER – ∞ SHAPE TRACK - LATERAL DYNAMICS

Date:
Aim
To simulate the performance of a car in the lateral Y direction and analyse
the
lateral dynamics of the selected vehicle.
Importance/Significance :
The vehicle roll behaviour affects the stability of a vehicle. It is
important to understand the roll dynamics of a vehicle for a vehicle
dynamics engineer to design the vehicle.

Apparatus required & Specifications :

S.No Apparatus Required Specifications

Processor: i7 processor; Ram: 8 GB
1 Computing machine
Graphics Memory: 2 GB
2 Simulation software IPG Carmaker

Theory
The lateral motion of a vehicle is needed to follow the road curves,
select route in intersections and laterally avoid obstacles, which all involve
steering. The turning manoeuvres of vehicles encompass two sub-attributes.
Handling is the driver’s perception of the vehicle’s response to the steering
input. Cornering is the physical response (open- loop) of the vehicle
independent of how it influences the driver. The lateral dynamics of vehicles
is often experienced as the most challenging for the new automotive
engineer. Longitudinal dynamics is essentially motion in one plane and
rectilinear. Vertical dynamics may be 3 dimensional, but normally the
displacements are small and in this compendium the vertical dynamics is
mainly studied in one plane as rectilinear. However, lateral dynamics
involves motion in the vehicle coordinate system which introduces
curvilinear motion since the coordinate system is rotating as the vehicle
yaws.

Procedure
1. Open the Carmaker software through Windows OS.
2. In File menu, create a new Project
3. Under parameters menu, select Car option. A new tab titled vehicle
data set is open. In Vehicle data set tab, click File > Open, Click
Product examples. Click the appropriate car given in the question –
BMW_5. Close the Data Set tab.
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4. Under parameters menu, select Scenario/Road. The Scenario editor
tab is open. All the options for creating the road/test track shape is
given in the left

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side menu. Create the shape of the track given in the question

using the options – ∞ shape.

5. Click the Route button in Traffic tab and then double click the
track shape. Now the track is converted into a route for the
vehicle. Close the Scenario editor.
6. Under parameters menu, select Maneuver option. Create the
various steps of maneuver as per the instructions given in the
question by clicking the New button for each step. Close the
Maneuver dialog box.
7. To view the simulation video goto File > IPGMovie. In the movie
animation, the longitudinal tire forces are shown in green color,
lateral forces in blue color and vertical forces in red color.
8. To plot the required graphs goto File > IPGControl 1.18. Select the
appropriate parameter from the quantities given in the bottom
menu. In this exercise, Lateral forces (Car.Fyfl, Car.Fyfr, Car.Fyrl,
Car.Fyrr) for all the four wheels and the Lateral acceleration (Car.ay)
need to selected.
9. Start the simulation from the main windows and once the
simulation is over right click in the IPGControl window and select
Totalfit. All the plots now come in the single window. Convert the
plots to pdf print.

Prelab Questions :

1. Which coordinate of vehicle coordinate system, is lateral dynamics

analysed?
2. What is meant by understeer condition?
3. What is the value of understeer coefficient for neutral steer conditions?
4. What is meant by data set in Carmaker?
5. What is meant by testrun in CarMaker?

Inferences:
The variation of the forces generated in the tire ground interface was
visualized and seen.

Result :
Thus, the performance of a car in the lateral Y direction has been
simulated and the lateral dynamics of the selected vehicle has been
analysed.
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Output (Display or Graph Plot) :

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EXP. NO: 9 CAR MAKER – ∞ SHAPE TRACK - ROLLOVER DYNAMICS

Date:
Aim
To simulate the performance of a car in the roll motion and analyse the
rollover
dynamics of the selected vehicle.
Importance/Significance :
The vehicle roll behaviour affects the stability of a vehicle. It is
important to understand the roll dynamics of a vehicle for a vehicle
dynamics engineer to design the vehicle.

Apparatus required & Specifications :

S.No Apparatus Required Specifications

Processor: i7 processor; Ram: 8 GB
1 Computing machine
Graphics Memory: 2 GB
2 Simulation software IPG Carmaker

Theory
Roll centre and roll axis are important concepts for studying vehicle
handling and are also used in the calculation of lateral load transfer during
cornering operations. The roll centre is a point in the transverse plane
through any pair of wheels at which a transverse force may be applied to the
sprung mass without causing it to roll. The roll centre is the point about
which the body can roll without producing any lateral movement at either of
the wheel contact areas. The roll centre heights in the front and rear wheel
planes tend to be different. The line joining the centres is the roll axis. It
derives from the fact that all suspensions possess a roll axis. which is the
instantaneous axis about which the unsprung mass rotates with respect to
the sprung mass when a pure couple is applied to the unsprung mass. The
roll center is the intersection of the suspension roll axis with the vertical
plane through the centers of the two wheels. These definitions are
illustrated in Figure. The roll center height is the distance from the ground
to the roll center. Once the front and rear suspension roll centers are
located, the vehicle roll axis is defined by the line connecting the centers.
This axis is the instantaneous axis about which the total vehicle rolls with
respect to the ground.

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Procedure
1. Open the Carmaker software through Windows OS.
2. In File menu, create a new Project
3. Under parameters menu, select Car option. A new tab titled vehicle
data set is open. In Vehicle data set tab, click File > Open, Click
Product examples. Click the appropriate car given in the question –
BMW_5. Close the Data Set tab.
4. Under parameters menu, select Scenario/Road. The Scenario editor
tab is open. All the options for creating the road/test track shape is
given in the left side menu. Create the shape of the track given in
the question using the options –

∞ shape.
5. Click the Route button in Traffic tab and then double click the
track shape. Now the track is converted into a route for the
vehicle. Close the Scenario editor.
6. Under parameters menu, select Maneuver option. Create the
various steps of maneuver as per the instructions given in the
question by clicking the New button for each step. Close the
Maneuver dialog box.
7. To view the simulation video goto File > IPGMovie. In the movie
animation, the longitudinal tire forces are shown in green color,
lateral forces in blue color and vertical forces in red color.
8. To plot the required graphs goto File > IPGControl 1.18. Select the
appropriate parameter from the quantities given in the bottom
menu. In this exercise, the parameters (Car.roll, Car.rollvel),
vertcial forces (Fzfl, Fzfr, Fzrl, Fzrr) for all the four wheels need to
selected.
9. Start the simulation from the main windows and once the
simulation is over right click in the IPGControl window and select
Totalfit. All the plots now come in the single window. Convert the
plots to pdf print.
Prelab Questions :
1. What is meant by overturning moment?
2. Vehicle roll is rotation of the vehicle about direction.
3. What is meant by aligning torque?
4. Define roll center.
5. Define roll axis.

Inferences:
The variation of the forces generated in the tire ground interface was
visualized and seen.
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Result :
Thus, the performance of a car in the roll motion has been simulated and
the the rollover dynamics of the selected vehicle has been analysed.

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Output (Display or Graph Plot) :

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EXP. NO: 10 ACTIVE SUSPENSION STUDY

Date:
Aim:
To study the principles of active suspension and the control systems for
active
suspension system.
Importance/Significance:
Active suspension system represents the ideal performance
requirements of an automotive suspension system. The study of active
suspension system and the control algorithms are useful in the design of
semi active suspension systems.

Apparatus required & Specifications :

S.No Apparatus Required Specifications

Force: 1 ton, Velocity: 0.52 m/s, Stroke
1 Damper Testing Machine length : Upto 100 mm; Stroke mechanism:
AC motor with variable cam
2 Shock absorber / Damper Shock absorber used in vehicle fitments

Theory:
The Active Suspension consists of three masses, or plates. Each mass
slides along stainless steel shafts using linear bearings and is supported by a
set of springs, as shown in Figure1. The upper mass (blue) represents the
vehicle body supported above the suspension, also known as the sprung
mass. The middle mass (red) corresponds to one of the vehicle’s tires, or the
unsprung mass. Finally, the bottom (silver) mass simulates the road. The
upper mass is connected to a high-quality DC motor through a capstan to
emulate an active suspension system that can dynamically compensate for
the motions introduced by the road. The lower plate is driven by a powerful
DC motor connected to a lead screw and cable transmission system. It is
used to simulate different road profiles. Students can tune the supplied
controller or design their own controllers to optimize the various suspension
performance parameters which include:
Ride Comfort - is related to vehicle body motion sensed by the passengers. It
can be measured using either the accelerometer that is mounted on the top
plate, or the encoder (for a direct position measurement).
Suspension Travel - refers to relative displacement between the vehicle
body and the tire and is constrained within an allowable range of motion.

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This can be measured using the suspension encoder that is mounted on the
capstan.

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Road Handling - is associated with the contact forces between the road
surface and the vehicle tires and depends on tire deflection. Tire deflection
is the relative displacement between the tire and the road and it can be
measured using all the encoders.

Fig. Active suspension test rig

Procedure:
1. Open the ASE Simulation Control.vi VI, shown in Figure 4.3. Make sure you choose
your model file using the File Path control.
2. Run the VI. The state space representation of ASE will be loaded and demonstrated in
the white window. The second column in the B matrix corresponds to the control action Fc.
3. The road input is a square shape signal with an amplitude of 0:01m and frequency of: 3Hz
4. You can use any of the three different control strategies to design a closed loop
controller for the active suspension system, i.e.
• Manual Gain Tuning
• Pole Placement Design
• LQR Control Design
5. For instance, in LQR Design tab, tune the elements inside Q and R matrices and the
resulting feedback gain will be automatically updated. Any of these methods can be chosen
by clicking on their respective tab. The control gain will be automatically updated on the fly
and the closed loop performance of the system can be observed. The closed loop gain is
shown inside the Controller Feedback Gain (K). The default value of this gain is set to keep
the system stable. In addition, the closed loop poles of the system are shown in the Closed
Loop Poles Map.

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6. Zr represents the bottom plate position that refers to the road. Zus represents the middle
plate position that refers to vehicle tire. Zs represents the top plate position that refers to
vehicle body.
7. After the desired control performance is achieved in simulation, write down the Feedback
Gain to use it in the experiment.
8. Stop VI by pressing the Stop button..

Prelab Questions :
1. Compare passive and semi active suspension system.
2. Compare active and semi active suspension system.
3. State any two control algorithms used in automotive suspension design.
4. What is meant by state space model?
5. What is meant by unsprung mass?

Inferences:
The sprung mass acceleration, suspension travel and tire deflection
parameters have been plotted.

Result :
Thus the principles of active suspension and the control systems for
active suspension system has been studied.

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Output Graph / Plot:

0.5

0.4 Uncontrolled
Active
0.3

0.2
Sprung mass acceleration (m/s2)

0.1

-0.1

-0.2

-0.3

-0.4

-0.5
0
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Time (sec)

x 10-4
6
Uncontrolled
4 Active

2
Tire deflection (m)

-2

-4

-6
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Time (sec)

x 10-3
6

Uncontrolled
4 Active

2
Suspension travel

-2

-4

-6
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Time (sec)

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