Post on 01-Mar-2021
6/25/2015
1
Aerospace Ground Vehicles Materials
MTS Test MTS Sensors
MTS Systems
Biomedical
Vehicle & Component Measurement & Testing
MTS Proprietary January 2013
6/25/2015
2
» Safety Requirements Increasing
» Electronic Stability Control (ESC)
» Global competition requires differentiation
» Vehicle Handling
» Ride Comfort
» Fuel Efficiency Standards Adoption
Trends in Vehicle Performance Testing
MTS Proprietary Page 3
New regulations and globalization drive the need for new testing tools and methods
Market Driver – Globalization» Improving Ride Comfort
– Key factor in customer satisfaction and purchasing decisions
– Lower background noise from engine (EV/HEV) and steering (EPS) expose passengers to more aerodynamic and suspension acoustics in the cabin
– Semi-Active and Active suspensions have made tuning more complex Typical Vehicle Interior Noise Spectrum
From: Jun Lu, Passenger Car Interior Noise Reduction by Laminated Side Glass, Proceedings of Inter-Noise 2002, Institute of Noise Control Engineering
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Market Driver – Globalization» Increased global competition pushes OEMs to differentiate platforms with
performance
» Improving Vehicle Handling
– Move from Suspension/Tire Characterization to more Vehicle Based Maneuver Simulation
Fy (N) vs SA (degrees)
-8000.00
-6000.00
-4000.00
-2000.00
0.00
2000.00
4000.00
6000.00
8000.00
-10.00 -8.00 -6.00 -4.00 -2.00 0.00 2.00 4.00 6.00 8.00 10.00
SA (degrees)
Fy (N
)
Series1 Series2 Series3 Series4 Series5 Series6 Series7
Fy (N) vs SA (degrees)
-8000.00
-6000.00
-4000.00
-2000.00
0.00
2000.00
4000.00
6000.00
8000.00
-10.00 -8.00 -6.00 -4.00 -2.00 0.00 2.00 4.00 6.00 8.00 10.00
SA (degrees)
Fy (N
)
Series1 Series2 Series3 Series4 Series5 Series6 Series7
Series InformationSeries 1 Fz = -9283 NSeries 2 Fz = -7547 NSeries 3 Fz = -5804 NSeries 4 Fz = -4655 NSeries 5 Fz = -2915 NSeries 6 Fz = -1125 N
Series InformationSeries 1 Fz = -9283 NSeries 2 Fz = -7547 NSeries 3 Fz = -5804 NSeries 4 Fz = -4655 NSeries 5 Fz = -2915 NSeries 6 Fz = -1125 N
Vehicle based maneuver simulationTire Characterization– not vehicle based
MTS Proprietary Page 5
Market Driver – Safety Requirements » Electronic Stability Control (ESC)
– Active vehicle intervention for safety
» 2012 Requirement in the US on all new passenger vehicles under 10,000 lbs (4536 kg) – (FMVSS) No. 126
» 2014 Requirements for EU on new vehicles – (EC) No. 661/2009
» OEMs need limit tire data for ESC Maneuver to go into vehicle models
» Electronic Power Steering (EPS) is increasingly used in ESC assistance
ESC Maneuver
MTS Proprietary Page 6
6/25/2015
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Flat-Trac® Roadway
» With a vehicle on a laboratory rig:
– Measure static and dynamic handling performance
– Study the effects of vertical road motion on maneuvering, vibration, and durability
MTS Proprietary Page 7
SteerVertical
RoadSpeed
CG Restraint
MTS Flat-Trac® Handling Roadway coordinate flat belt units in speed and
direction to measure suspension and vehicle ride and handling performance
MTS Proprietary
6/25/2015
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Handling Roadway – Function
» Restraint in only 3 axes (x, y, yaw)
» No restraint in suspension directions
» Determine instant road acceleration and velocity
» Present correct road velocity to each tire
» Repeat fast enough to minimize simulation lag
» Measure vehicle response
The vehicle is in the loop, it reacts the same as on the real road, for all maneuvers
MTS Proprietary
Handling Roadway – Features
» Flat Surface
» 230 kph
» All 3 Road Motions
» Free Suspension
» Road Speed or Road Load
» Vertical Vibration to 20 g
» Body Force Simulation System
» 6 Component Tire Force
» Autopilot
» Automated routine tests
MTS Proprietary
6/25/2015
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Handling Roadway – Applications» Open Loop
– Steer Step– Throttle Off in Curve– Sine Steer– Straight Acceleration– Brake in a Curve
» Closed Loop– Constant Radius Skid Pad– Constant Velocity Skid Pad
» Durability– Rough Road– Driving Cycles
Page 11
MTS Proprietary
Handling Roadway – Results
» Skid Pad
– steer vs. ay
– 40 tests repeated
» J Turn
– Ay vs. time
– 26 tests repeated
Test Repeatability
Page 12
MTS Proprietary
6/25/2015
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Suspension Kinematics and Compliance (K&C) Deflection Measurement Systems
MTS Proprietary Page 13
System Operation Limits Use •Quasi-static to 5 hz •Static K&C Tests•0.6 m/sec velocity •Chassis Torsional Rigidity Testing
•Cornering Simulation•Time History Playout•Vehicle Inertia Measurement (option)
•Quasi-static to 20 hz ADDITIONAL CAPABILITY:•0.6 m/sec velocity •Dynamic K&C Deflections
•mHIL Capability•Lower Frequency Transient Replication
•Quasi-static to 35 hz ADDITIONAL CAPABILITY:•2 m/sec velocity •FRF Analysis
•Degradation•Higher Frequency Transient Replication
K&C (Base System)
K&C(with Dynamic Simulation Option)
DK&C
» Functions
– Static K&C Tests
– Dynamic K&C Deflections
– Frequency Response Function (FRF) Analysis
– Degradation
– Maneuver Analysis
– Inertia Measurement
Dynamic Kinematics and Compliance (DK&C)Deflection Measurement System
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» Applications
– Suspension Development
– Benchmarking
– Dynamic Model Verification
– Maneuver Analysis
– Vehicle in the Loop Maneuvering
» Benefits
– Precision
– Throughput
– Flexibility
Dynamic Kinematics and Compliance (DK&C)Deflection Measurement System
MTS Proprietary Page 15
K&C Data Examples
MTS Proprietary
6/25/2015
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Fy vs. Slip Angle
-10000
-8000
-6000
-4000
-2000
0
2000
4000
6000
8000
10000
-30 -20 -10 0 10 20 30
Slip Angle - degree
Fy
- N
11570.339256.264
6942.1984628.132
2314.066
Inclination Angle = 6 degree
Tire Load
P205/60R15
Speed = 88.5
Inflation Pressure = 260 kPa
Mz vs. Slip Angle
-400
-300
-200
-100
0
100
200
300
400
500
-30 -20 -10 0 10 20 30
Slip Angle - degree
Mz
- N
m
11570.339256.2646942.1984628.1322314.066
Inclination Angle = 6 degree
Tire Load
P205/60R15
Speed = 88.5 km/hInflation Pressure = 260 kPa
Friction Elipse Fy vs Fx
-5000
-4000
-3000
-2000
-1000
0
1000
2000
3000
4000
-8000 -6000 -4000 -2000 0 2000 4000 6000 8000
Fx - N
Fy
- N
Tire Load = 5780 N Speed = 65 km/h
Inclination Angle = 0 degreeInflation Pressure = 260 km/h
Slip Angle = -2 degree
Slip Angle = 4 degree
MTS Proprietary
Expanded capability
Safer Vehicles through advances in Tire Testing» Increased range of tire testing conditions
– Improve models with greater range of empirical data
– Extend range of dynamic modeling and simulation
MTS Proprietary Page 18
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Flat-Trac® Tire Test System
» Measure tire force and moment properties – data used for CAE
» Establish the tire's contribution to vehicle dynamic performance
– Cornering characteristics» Lateral Force (Fy) vs. Slip Angle
» Aligning Torque (Mz) vs. Slip Angle
– Camber stiffness characteristics» Lateral Force (Fy) vs. Camber
» Aligning Torque (Mz) vs. Camber
– Traction Characteristics» Slip ratio testing
» Combined lateral with slip
Data used with Empirical and Analytical models.
» Controlled
» Repeatable
» Eliminates uncertainty of curved drum
» Emulates flat roads
» Test data correlation with real roads
MTS Proprietary Page 19
Flat-Trac CT Plus F&M Measurement System
MTS ProprietaryPage 20
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R20070307Proprietary 21
Example: Steady-State F&M TestFy (N) vs SA (degrees)
-8000.00
-6000.00
-4000.00
-2000.00
0.00
2000.00
4000.00
6000.00
8000.00
-10.00 -8.00 -6.00 -4.00 -2.00 0.00 2.00 4.00 6.00 8.00 10.00
SA (degrees)
Fy
(N)
Series1 Series2 Series3 Series4 Series5 Series6 Series7
Fy (N) vs SA (degrees)
-8000.00
-6000.00
-4000.00
-2000.00
0.00
2000.00
4000.00
6000.00
8000.00
-10.00 -8.00 -6.00 -4.00 -2.00 0.00 2.00 4.00 6.00 8.00 10.00
SA (degrees)
Fy
(N)
Series1 Series2 Series3 Series4 Series5 Series6 Series7
Series InformationSeries 1 Fz = -9283 NSeries 2 Fz = -7547 NSeries 3 Fz = -5804 NSeries 4 Fz = -4655 NSeries 5 Fz = -2915 NSeries 6 Fz = -1125 N
Series InformationSeries 1 Fz = -9283 NSeries 2 Fz = -7547 NSeries 3 Fz = -5804 NSeries 4 Fz = -4655 NSeries 5 Fz = -2915 NSeries 6 Fz = -1125 N
R20070307Proprietary 22
Example: G-Spline Analysis Report - FyFy vs SA and Fz
SA Joints-6.1
-1.521.526.1
Fz Joints0
38008900
Force and Moment - Carpet Plot
8000 N 7000 N6000 N
5000 N
4000 N
3000 N
2000 N
1000 N
0 N
6 deg
5 deg
4 deg
3 deg
2 deg
1 deg
0 deg0
1000
2000
3000
4000
5000
6000
Fy (N
)
Date Tested Apr-21-1998 12:38:31 PM Belt Speed 3.50 Wheel Dia. Tire Size P205/65R15Operator RLJ Avg IA 0.00 Rim Width Construction TR: 2stl 1 poly SW: 2 polyManufacturer Cooper Tire Inflation 180.0 Ref Load 5395 Adapter ID MTSTire Type Passenger Infl Control Ref 180.00 DOT Code
degkPa N
kPa
Test Data File Coordinates UsedTest Tire ID
Z:\FAM-SC_Cooper-Touring_015_21APR98-a.dataSTD GM 6 DEG
SAE15Break In FALSE
kph6.0 in15 in
Fy vs SA and Fz
SA Joints-6.1
-1.521.526.1
Fz Joints0
38008900
Force and Moment - Carpet Plot
8000 N 7000 N6000 N
5000 N
4000 N
3000 N
2000 N
1000 N
0 N
6 deg
5 deg
4 deg
3 deg
2 deg
1 deg
0 deg0
1000
2000
3000
4000
5000
6000
Fy (N
)
Date Tested Apr-21-1998 12:38:31 PM Belt Speed 3.50 Wheel Dia. Tire Size P205/65R15Operator RLJ Avg IA 0.00 Rim Width Construction TR: 2stl 1 poly SW: 2 polyManufacturer Cooper Tire Inflation 180.0 Ref Load 5395 Adapter ID MTSTire Type Passenger Infl Control Ref 180.00 DOT Code
degkPa N
kPa
Test Data File Coordinates UsedTest Tire ID
Z:\FAM-SC_Cooper-Touring_015_21APR98-a.dataSTD GM 6 DEG
SAE15Break In FALSE
kph6.0 in15 in
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R20070307Proprietary 23
Example: G-Spline Analysis Report - MzMz vs SA and Fz
SA Joints-6.1
-1.521.526.1
Fz Joints0
38008900
Force and Moment - Carpet Plot
8000 N
7000 N
6000 N
5000 N
4000 N
3000 N2000 N
1000 N 0 N
6 deg5 deg
4 deg
3 deg
2 deg
1 deg
0 deg
-50
0
50
100
150
200
250
300
Mz
(N-m
)Date Tested Apr-21-1998 12:38:31 PM Belt Speed 3.50 Wheel Dia. Tire Size P205/65R15Operator RLJ Avg IA 0.00 Rim Width Construction TR: 2stl 1 poly SW: 2 polyManufacturer Cooper Tire Inflation 180.0 Ref Load 5395 Adapter ID MTSTire Type Passenger Infl Control Ref 180.00 DOT Code
degkPa N
kPa
Test Data File Coordinates UsedTest Tire ID
Z:\FAM-SC_Cooper-Touring_015_21APR98-a.dataSTD GM 6 DEG
SAE15Break In FALSE
kph6.0 in15 in
Mz vs SA and Fz
SA Joints-6.1
-1.521.526.1
Fz Joints0
38008900
Force and Moment - Carpet Plot
8000 N
7000 N
6000 N
5000 N
4000 N
3000 N2000 N
1000 N 0 N
6 deg5 deg
4 deg
3 deg
2 deg
1 deg
0 deg
-50
0
50
100
150
200
250
300
Mz
(N-m
)Date Tested Apr-21-1998 12:38:31 PM Belt Speed 3.50 Wheel Dia. Tire Size P205/65R15Operator RLJ Avg IA 0.00 Rim Width Construction TR: 2stl 1 poly SW: 2 polyManufacturer Cooper Tire Inflation 180.0 Ref Load 5395 Adapter ID MTSTire Type Passenger Infl Control Ref 180.00 DOT Code
degkPa N
kPa
Test Data File Coordinates UsedTest Tire ID
Z:\FAM-SC_Cooper-Touring_015_21APR98-a.dataSTD GM 6 DEG
SAE15Break In FALSE
kph6.0 in15 in
R20070307Proprietary 24
Example: Dynamic Sweep TestF y vs . S lip A n g le
-1 0 0 0 0
-8 0 0 0
-6 0 0 0
-4 0 0 0
-2 0 0 0
0
2 0 0 0
4 0 0 0
6 0 0 0
8 0 0 0
1 0 0 0 0
-3 0 -2 0 -1 0 0 1 0 2 0 3 0
S lip A n g le - d e g re e
Fy
- N
1 1 5 7 0 .3 39 2 5 6 .2 6 46 9 4 2 .1 9 84 6 2 8 .1 3 22 3 1 4 .0 6 6
In c lin a tio n A n g le = 6 d e g re e
T ire L o a d
P 2 0 5 /6 0 R 1 5
S p e e d = 8 8 .5
In f la t io n P re s s u re = 2 6 0 k P a
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R20070307Proprietary 25
Example: Dynamic Sweep Test
Mz vs. Slip Angle
-400
-300
-200
-100
0
100
200
300
400
500
-30 -20 -10 0 10 20 30
Slip Angle - degree
Mz
- N
m
11570.339256.2646942.1984628.1322314.066
Inclination Angle = 6 degree
Tire Load
P205/60R15
Speed = 88.5 km/hInflation Pressure = 260 kPa
R20070307Proprietary 26
Example: Combined Fx and Fy TestF ric tio n E lip s e F y vs F x
-5 0 0 0
-4 0 0 0
-3 0 0 0
-2 0 0 0
-1 0 0 0
0
1 0 0 0
2 0 0 0
3 0 0 0
4 0 0 0
-8 0 0 0 -6 0 0 0 -4 0 0 0 -2 0 0 0 0 2 0 0 0 4 0 0 0 6 0 0 0 8 0 0 0
F x - N
Fy
- N
T ire L o a d = 5 7 8 0 N S p e e d = 6 5 k m /h
In c lin a tio n A n g le = 0 d e g re eIn fla tio n P re s s u re = 2 6 0 k m /h
S lip A n g le = -2 d e g re e
S lip A n g le = 4 d e g re e
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R20070307Proprietary 27
Example: Slip Ratio TestFx vs SR
-6000
-4000
-2000
0
2000
4000
6000
-30 -20 -10 0 10 20 30
SR (%)
Fx
(N)
Condition 5 Condition 6
Cond. 5 SA 0 degFy 172 NFz -4338 NPt 261 kPaVr 65 kph
Cond. 6 SA 0 degFy 121 NFz -4347 NPt 260 kPaVr 65 kph
Condition Information
Flat-Trac ® LTRe» Located at the National Tire Research Center, owned and operated
by Virginia Tech, opening January 2013 in Southern Va.
– 200 mph, torque at full speed.
– ESC Maneuver simulation for improving stability control on vehicles.
– Advanced control improve Slip Ratio control and enable (mHil)
– Only test system that can test NASCAR tires at high speeds
MTS Proprietary Page 28
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Steering System Testing in Research and Product Development» Durability
» Characterization
– Vibration, noise
– Kinematics and Compliance (linearity, backlash, stiffness)
– Driver feedback
– Efficiency
– Steering tuning
» Comparison/Evaluation
– Testing to a Standard
– A:B comparison
– Benchmarking
– Characterization
– Specification, target setting
– New technology evaluation
– Cost reduction idea generation
» Performance, validation, fault testing
– Steering tuning
– Simulation
» Testing to real world responses
» Customer (or usage) correlated
– Evaluate safety issues29
New EPS Technology
» Rapidly evolving electronic steering systems (EPS) are replacing the hydraulic (HPS) technology.
» EPS systems enhance the overall driver experience by improving vehicle efficiency, handling, comfort and safety.
» Technology is more complex and presents new challenges as it continues to develop.
MTS Proprietary Page 30
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Component Test ExamplesSteering Column
Intermediate Shaft
EPAS Components
Steering Knuckle
31
Integrated CANbus 793.25
32
Integrated HIL Simulator
Vehicle Bus Interface Capability
MTS Proprietary
6/25/2015
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Maneuver
Vehicle Response
Road Surface
Real Vehicle System Simulated Vehicle System
Vehicle Model
Steer Hardware in anMTS Loading RigManeuver
Road Surface
Vehicle Response
Allows vehicle level evaluations with model of vehicle and real parts
Steering System: Mechanical Hardware-in-the-Loop (mHIL)
MTS Proprietary
6/25/2015Page 34
MTS Proprietary
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Hybrid Simulation
Physical components & Inputs
Virtual components & Inputs
Comprehensive and accurate simulation environment
+
=
MTS Proprietary Page 35
» Hybrid Simulation combines physical and virtual components, inputs, and constraints to create an integrated simulation system
Hybrid Simulation Benefits» Hybrid Simulation offers advantages for both
Analysis & Testing
– Analysis: Real physical parts can be substituted for difficult-to-model components when performing virtual simulations.
» Example: using actual vehicle dampers as part of a virtual handling simulation
– Testing: Generate correct test loads by surrounding physical test parts with virtual components and generic inputs.
» Example: using virtual tires and digital roads as part of a full-vehicle durability test
MTS Proprietary
6/25/2015
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Spindle Coupled Road Simulation
6/25/2015Page 37
MTS Proprietary
» Tire‐coupled suspension evaluation test system
– Floating or controlled sprung mass
» Applications
– Suspension development & validation
– Wheel control
– Ride Quality
– Isolation
– Road holding
– NVH
– Component Degradation
– Suspension Transmissibility
– Vertical Durability
¼‐Suspension Bi‐Axial Test System
MTS Proprietary Page 38
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Driving Simulation for Safety and Driver Response
6/25/2015Page 39
MTS Proprietary
Providing Solutions to Meet Changing Industry Needs
» Testing Electronic Stability Control (ESC) components and systems
» Tools to evaluate and design for advanced vehicle handling
» Pioneering advanced ride comfort testing solutions
» Systems for continued development of energy efficiency in vehicles
MTS Proprietary Page 40
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THANK YOU
6/25/2015Page 41
Rick L. ZiemanRegional Sales Manager Australia & Ground Vehicles India
m MTS Systems Corporation 14000 Technology Drive MS 210 Eden Prairie, MN 55344 (952) 937-4961 (612) 210-6859 Cell rick.zieman@mts.com