EUROMECH Colloquium 452

on
Advances in Simulation Techniques
for Applied Dynamics

Simulation of
Hydraulic Components
for Passenger Cars
Werner Schiehlen
Institute B of Mechanics
University of Stuttgart
Stuttgart, Germany

Thomas Schirle
Research and Technology
DaimlerChrysler AG
Stuttgart, Germany
Contents

1. Introduction

2. Modelling and mathematical description of hydraulic systems

3. Integration algorithm with mass conservation

4. Component export for multidomain models

5. Active Tire Tilt Control-chassis system

1. Introduction

Hydraulic components and systems

for passenger car suspensions active

electro-hydraulic brakes
passive
Active Tire Tilt Control

hydropneumatic suspension
hydraulic
hydraulic systems
systems

shock absorber
without
without reservoirs:
reservoirs:

suspension hydromounts
closed
closed circuit
circuit systems
systems

engine hydromounts

power steering

brakes

semi active

anti roll systems

electronically controlled shock absorber conservation
conservation ofof fluid
fluid mass
mass

Active Body Control suspension system is
is necessary
necessary for
for regular
regular

speed dependent & electrohydraulic operation
operation of
of component
component !!
power steering
1. Introduction

Demands for dynamic simulation

of automotive chassis systems
Multi-domain simulation task:

mechanics

hydraulics

electrics

electronics & control

for systems with

highly nonlinear effects

huge number of elements

different subsystem time scales

Example:
Full vehicle active suspension simulation with
supporting

time efficiency
car, driver and environment

robustness

detailled suspension and tyres

different engineering disciplines

Active Body Control and steering hydraulics

controller algorithm and electrical valves

2. Modelling and mathematical description
of hydraulic systems

Conservation equations for fluid mass, impulse and energy

general transport theorem for a mass specific property b
B(t):
  quantity of b
d
dt b dV
V(t)
=
V0

t
( b) dV + b u dA = B( t )
A0
within moving
volume V(t)

! d !
Conservation: B(t) = const. , B(t) = 0
dt

Conservation of: mass impulse energy

b=1 b=u b = e + u2/2
leads to
equation for

1-D model: volume pipe resistance

2. Modelling and mathematical description
of hydraulic systems

Basic elements for distributed 1-D hydraulic systems

volume potential-block

x
mass within volume fluid state equation
m
p(m,V) m = m dt = 1 dt ) = p(
p( 0) + E * ln
0
= m/V
1

fluid inertia / pipe

mass flow
m12

m = Al m12 = m A(p1-p2) - FR dt FR wall friction force
p1 p2
l A

resistance flow-block
pressure loss

p1 p2 p1- p2 = claminar 12 + cturbulent 122

12
2. Modelling and mathematical description
of hydraulic systems

Connecting submodels to total system

U: xp 7 connections single-port approach
U: xp_dot Y: Fp
submodels have separate ports for
Y: p1 input (U) and output (Y) variables
U: m1_dot

port information propagation in single
U: m2_dot Y: p2 direction

signal oriented modelling

complex:
complex:
Y: m1_dot U: p1

many
many connection
connection lines
lines


user
user has
has to
to adopt
adopt U/Y-concept
U/Y-concept
Y: m2_dot U: p2

multi-port approach
3 connections U: xp,xp_dot

combined input/output ports for
Y: Fp
mech 1d
related physical flow and potential
m2,V2 m1,V1 variables
p2 p1
Y: p2 Y: p1
port information propagation in two
U: m2_dot U: m1_dot directions with multiple variables
hydr 1d hydr 1d
physics oriented modelling
U: p2 U: p1 more
more simple:
simple:
Y: m2_dot Y: m1_dot

few
few connection
connection lines
lines
hydr 1d hydr 1d

correlates
correlates to
to hydraulic
hydraulic circuit
circuit layouts
layouts
2. Modelling and mathematical description
of hydraulic systems

Structures of system equations for hydraulic systems

1. ODEs

regular connection of potential and flow blocks states: z = [m1 m2 m3 m4]T

m1 m2 m3 m4
p1=p(m1,V1) p2=p(m2,V2) p3=p(m3,V3) p4=p(m4,V4)

12(p1-p2) 23(p2-p3) 34(p3-p4)

potential-block flow-block

2. ODEs + switching function residual equations res

+ discontinuities due to e.g. switching valves, friction, cavitation

z,u,t

3. ODEs + implicit constraint equations (DAEs)

+ zero-volumes for direct (implicit) coupling of flow blocks
m1 V=0 m3
p2 : 12(p1-p2) - 23(p2-p3) = = 0 p1=p(m,V) p3=p(m,V)
p2

12(p1-p2) 23(p2-p3)

+ implicit mass conservation constraints for closed circuits

d
m = const. resp. m=m=0
dt
2. Modelling and mathematical description
of hydraulic systems

Properties of hydraulic system equations

and their implications for time domain solvers
(differential) equations describing a hydraulic system can be:

ODE-Solvers
ODE-Solvers
stiff: high bulk-modulus, ...

nonlinear: cavitation, ...

Solvers
Solvers for
for
ODEs
ODEs with
with
root
root finding
finding
discontinuous: switching valves, ...

algebraic eqns: implicit coupling of hydraulic oresistances,

ft
fluid mass conservation negl en
DAE-Solvers
DAE-Solvers
ect
ed

difficult task for integration algorithms

even more demanding when looking for stability and time efficiency

mass conservation by DAE-solvers resulting in low computational

efficiency
3. Integration algorithm with mass conservation

Explicit Euler integration scheme

1st order,
zt+h = zt + h zt single step method

advantages:
mass conservation preserved

small computational effort per step

disadvantages:
small stability domain

requires small stepsizes -> numerical drift (round off error)

our experience:
even with stepsize control not suitable even for
simple systems because of bad computation time
efficiency
3. Integration algorithm with mass conservation

Linear-implicit Euler integration scheme

z
zt+h = zt + h [ I - h ]-1 zt
z z=z
T
t
1st order,
J single step method
C provides
C numerical damping

advantages:
large stability domain

sufficiently accurate

disadvantages:
numerical determination of J: nz*nz rhs-evaluations

computation of C requires matrix inversion

mass conservation not preserved !

our experience:
robust and efficient algorithm

even for heavy nonlinear and stiff systems
3. Integration algorithm with mass conservation

Wheres the leak?

simple test model, initial: p1 > p2

potential-block flow-block potential-block

m1 m2 states
p1=p(m1,V1) p2=p(m2,V1)
z = [m1 m2]T
12=c*(p1-p2)
12
m1 = - m2 = 12

explicit Euler step: C = I zt+h = zt + h C zt linear-implicit Euler step: C I

m1 - 12
m1 = h I - 12 = h c11 c12
m2 12 m2 c21 c22 12

mm1|-|-|
|
| mm2||==00 mm1|-|-|
| mm2||00
1 | | 1 |
2 2
for C CT
mass
massconservation
conservation mass
massdefect
defect! !
3. Integration algorithm with mass conservation

Sealing it locally without ending up with iteration ik

mi
1. Process the scaled mass rate of change for each potential block i pi=p(mi,Vi)

physical: m(0) = [ m1(0) ... mnz (0) ]T = zt mi(0) - mi(1) for sgn mi(0) = sgn mi(1)
mi(1) =
scaled: m(1) = C m(0) 0 for sgn mi(0) sgn mi(1)

ik(0)
mi(1) =
1st modifcation
ik(1) = ik(0) - mi(1) so that: ik(1)
of flow for port k mi(1) k

jlF
2. Ensure mass conservation for each flow block j
demands for
2nd modification jl(2) =! 0 | jl(2) | | jl(1) | sgn jl(2) = sgn jl(1)
of flow for port l

3. Compute new mass rate of change for each potential block i

satisfies stability conditions mi(3) mi(1) mi(0)
mi(3) =
k
ik(2)
mass conservation is achieved on port level!

no iteration required
4. Component export for multi domain models

Multi-domain models: coupling of different simulators

vs. model export into one simulator
simulator coupling

e.g. AMESim
AMESim ++ CASCaDE
CASCaDE

BILD!!!

abc pump torque [Nm]

steering angle [deg]

gear selector [-]

accelerator [-]

brake pedal [-]

disadvantages:

simulator must have master/slave capability

ensure consistency of interfaces and models

possible communication overhead

advantages:

simulator specific pre- and post-processing
4. Component export for multi domain models

Multi-domain models: coupling of different simulators

vs. model export into one simulator
model export matlab
matlab
e.g. hydraulic
hydraulic power
power steering
steering hydraulics
hydraulics
exportable
exportable model
model

CASCaDE
CASCaDE

disadvantages:

simulator must provide user-model option

simulator-specific interface-layer required

advantages:

only one simulator in action DADS
DADS

model + included solver remains unchanged

therefore

one set of parameters for all applications

model specific efficient numerics can be applied

5. Active Tire Tilt Control-chassis system

Active Tire Tilt Control - Concept

Purpose:
Exploiting grip potential
of special asymmetric tire

adding:
+30% lateral force
+10% longitudinal force

resulting in

increased stability

higher safety

more driving fun

Key system elements:

asymmetric tire and wheel carrier with angular joint

hydraulic actuator and power hydraulics network

ECU with ATTC-vehicle dynamics algorithm, sensors

5. Active Tire Tilt Control-chassis system

Suspension system modelling and simulation

within the development process of the F400 Carving
5. Active Tire Tilt Control-chassis system

Simulation example: Carving through a bend

ATTC-actuator
front right tilt
pressure pout

pout

pin

pin=180bar = const.
6. Summary

Summary

Hydraulic chassis system components and simulation demands

Basic equations for 1-D hydraulic system models

Stiff and nonlinear system equations require efficent implicit integration

Presented method shows mass conservation on port level without iteration

Model export has advantage over simulator coupling

in the field of complex chassis system simulation

Successful application of the presented methods during development of

the Active Tire Tilt Control system