Post on 21-Apr-2018
Figure 1Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Simulation based
Power Steering Hose
Design and Optimization
Dr. Heiko Baum
FLUIDON GmbH
Jülicher Strasse 336
52070 Aachen
COMPETENCE IN FLUID POWER SYSTEMS SIMULATION
KOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEME
Figure 2Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Table of contents
Introduction1
Current situation of hydraulic pipe and hose simulation2
Development of a library for flexible hose elements3
A development methodology for automotive lines4
Presentation of example lines5
Summary6
Figure 3Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
FLUIDON a spin-off of the RWTH Aachen
Historical Highlights of IFAS - Institute for Fluid Power Drives and Controls
As nationally and internationally recognized research institution, the IFAS is and has been
pioneering many developments in Fluid Power technology.
60's: Beginnings of servo hydraulics, fluidics
70's: Basis of cavitation research, servo pneumatics, pump controlled systems
80's: Digital control, development of DSHplus (simulation tool), proportional / directional control
cartridge valves, secondary control
90's: Pre-compression chamber in piston pumps, fuzzy control, bio fluids, piezo technology,
sealing engineering (blow-by effect)
present: Coating technology, condition monitoring
The Institute's Development
1968: IFAS is founded as "Institut für hydraulische und pneumatische Antriebe und Steuerungen" -
IHP in short. Under Professor Backé's direction, two academic and six non-academic staff members are employed in the very beginning.
1977: The Institute now moves into its own large experimental hall with attached office building in the RWTH Expansion Area Seffent-Melaten. Now, there is room for about 50 test-stands,
workshops, laboratories, computer rooms and a library.
1994: Concurring with the succession to the direction of the Institute and to the professorship by Professor Murrenhoff is the change of the Institute's name. Today, about 25 academic staff
members, 20 non-academic employees and approx. 40 student assistants are working under the
grammalogue IFAS. Founding of FLUIDON as Spin-Off
1998: Opening of the expansion building which offers additional space for offices as well as computer, seminar and conference rooms thus giving more capacity for R&D tasks.
IFAS, Expansion Building and Conference Room
Areal View of IFAS
Figure 4Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
IFAS disposes two experimental laboratory buildings which are equipped with workshops and laboratories and give excellent opportunities to deal
effectively with R&D tasks. The newest measuring technology for all fluid power values is available.
• floor space about 1250 m² room for approx. 60 test rigs
• 2 clamping beds (5 x 3m), 70 ton foundation, 2 clamping beds (3 x 2.5m)
• 5 sound proof closets, 35 ton foundations
• anechoic room for sound measurements, (6.5 x 8m), drives 200 kW
• passable climatic test room (4.75 x 3.3 x 3m),
-70°C to +70°C, 20% to 95% relative humidity
• valve test stand max. 315 bar
• max. 500 1/min. ageing test rigs
for hydraulic fluids tribo tester
Laboratory and test rig recourses at IFAS
Laboratory Building 2
Laboratory Buildings 1
Figure 5Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Introduction1
Current situation of hydraulic pipe and hose simulation2
Development of a library for flexible hose elements3
A development methodology for automotive lines4
Presentation of example lines5
Summary6
Figure 6Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Thematic introduction
• The inside noise level of a vehicle represents an essential decision feature for the purchase decision of the customer. To satisfy this consumer expectation, it is nowadays extremely important that a potential source of noise, vibration or harshness (NVH) is identified and eliminated as early as possible in the development process.
• A known source for noise which can lead to NVH problems within the vehicle is the fluid-borne noise, issued by the pump of the hydraulic power steering. Currently the design and optimization of power steering hoses is mainly done by costly hardware tests.
• The adaptation of the automotive hose lines requires a high effort since hardware prototypes are optimized up to the desired maturity degree by means of test rig or vehicle tests. Without the amplified use of CAE tools a cost optimal development on schedule of new automotive hose lines in future can be only handled with difficulty.
• What was missing till now, for a time-domaine-based simulation, were suitable models for the flexible hose parts. As a result of the cooperation of FLUIDON GmbH and a manufacturer of automotive hoses these models are available now and a simulation-based development methodology for automotive lines can be presented.
Figure 7Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Simplified consideration of hose wall complianceVereinfachte Berücksichtigung der Schlauchwandnachgiebigkeit
1. The combination of rubber material and cord netting of the hose is responsible for a viscous-elastic behavior that determinates its damping characteristics (Figure 1).
2. The reinforcement material has either a more linear (steel braiding) or viscous-elastic (polyamid yarn) behavior. Due to the relative movement between the reinforcement layers there is moreover a static friction (coulomb friction) in the hose sleeve, which affects the damping characteristics as well. Some literature sources propose linear/viscoelastic damper models that are in a series connection to represent the reinforcement layers (Figure 2).
3. Up to now there is no physical model available that describes such behavior. However there are some approaches available that use measured material properties for simplified replacement models (Figure 3).
mm
Dia
me
ter
d
20.51
20.61
20.71
20.3
20.4
20.5
20.44
20.54
20.64
f = 1Hz f = 2 Hz f = 30 Hz
10 bar0 20 30 40 50 10 bar0 20 30 40 50 10 bar0 20 30 40 50
Pressure p
Hose Wall Dynamic at 1Hz, 2Hz, and 30 Hz(Diss Sänger, IHP, Aachen, 1985)
mm
mm
Figure 1
Figure 2
kvisc
dvisc
yvisc
ppp
Figure 3
Figure 8Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Pressure variation of an one-chamber hose line at 60 °CDruckvariation einer Ein-Kammer-Schlauchleitung bei 60 °C
10 bar60 bar100 bar
10 bar60 bar100 bar
10 bar60 bar100 bar
10 bar
60 bar100 bar
Figure 9Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Temperature variation of an one-chamber hose line at 50 barTemperaturvariation einer Ein-Kammer-Schlauchleitung bei 50 bar
40 °C60 °C80 °C
40 °C60 °C80 °C
40 °C60 °C80 °C
40 °C
60 °C80 °C
Figure 10Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Fingerprint of an one-chamber line at 50 bar – 60 °CVergleich zweier Ein-Kammer-Leitungen bei 50 bar – 60 °C
Hose 1
Hose 2
Hose 1
Hose 2
Hose 1
Hose 2
Hose 1
Hose 2
Figure 11Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Fingerprint of a two-chamber line at 10 bar - 40 °CVergleich zweier Zwei-Kammer-Leitungen bei 10 bar und 40 °C
Hose 1
Hose 2
Hose 1
Hose 2
Hose 1
Hose 2
Hose 1
Hose 2
Figure 12Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Introduction1
Current situation of hydraulic pipe and hose simulation2
Development of a library for flexible hose elements3
A development methodology for automotive lines4
Presentation of example lines5
Summary6
Figure 13Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Identification of hose material characteristicIdentifikation der Schlauchleitungscharakteristik
1. Structural resonance lHose. = 500 mm
l = 200 mm
l = 300 mm
l = 400 mm
l = 500 mm
P1P2
P3
P4
K1
K2
Hose
1. Test rig measurements:
Variation of hose length
from 100 mm to 500 mm.
Each hose at 40, 60, 80°C
and at 10, 50, 100 barPrüfstandsmessungen: Variation der
Schlauchlänge von 100 mm bis 500 mm. Jeder Schlauch bei 40, 60, 80 °C
und bei 10, 50, 100 bar
2. Identification of Hose Material Characteristic
Identifikation der Schlauchmaterialcharakteristik
40 °C
60 °C
80 °C
3. Structural resonance lHose. = 500 mm
System pressure = 10 bar
System pressure = 50 bar
System pressure = 100 bar
2. Structural resonance lHose. = 500 mm
3. Calculation of material characteristicsBerechnung der Materialcharakteristik
Figure 14Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Example of a steering system model with complex feed lineBeispiel eines Lenksystemmodells mit komplexer Versorgungsleitung
Source:
DELPHI productdata sheet to power
steering hoses
Helmholtz resonatorHelmholtzresonator
Pipe resonatorPfeifenresonator
Basic resonator typesBasistypen für Resonatoren
Figure 15Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Examples for fittings and flexible hose elementsBeispiele für Installationen und flexible Schlauchelemente
Figure 16Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Flexible hose library and simulation model of a two-chamber lineDehnschlauchbibliothek und Simulationsmodell einer Zwei-Kammerdehnschlauchleitung
Leitungspruefstand
P1 P2 P3 P4
FLUIDONLeitungsprüfstand
k2_c17
k2_c18k2_RV7
k2_Hohlschraube1
c18RV7
c17Hohlschraube1
k2_c16
k2_c15k2_c14k2_RV6
k2_Hohlschraube
k2_c13k2_c12k2_RV5 k2_Wendel
k2_c11k2_c10k2_RV4 k2_Verschraubung
k2_c9k2_c8k2_RV3 k2_Schlauch2
R1
k2_c7k2_RV2 k2_Mittelrohrk2_Schlauch1
R1
k2_SchlauchTuner_k1
R1
k2_c4k2_c5k2_RV1
k2_c1 k2_c2k2_RVk2_Rohr_ein
k2_c6k2_c3
c16
c15c14RV6
Hohlschraube
c13c12RV5 Wendel
c11c10RV4 Verschraubung
c9c8RV3 Schlauch2
R1
c7RV2 MittelrohrSchlauch1
R1
SchlauchTuner_k1
R1
c4c5RV1
c1 c2RVRohr_ein
p1_K1
p3_K2
p3_K1
p2_K2
p1_K2
p2_K1
p4_K1
p4_K2
c6c3
Figure 17Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Usage of hose material characteristicAnwendung der Schlauchleitungscharakteristik
1. Assignment of geometric parametersZuweisung von geometrischen Parametern
Figure 18Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Introduction1
Current situation of hydraulic pipe and hose simulation2
Development of a library for flexible hose elements3
A development methodology for automotive lines4
Presentation of example lines5
Summary6
Figure 19Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Development methodology for automotive hose assembliesEntwicklungsmethodik für automobile Dehnschlauchleitungen
Start
Define Power SteeringHose Design
Assemble Hose Model fromDSHplus Hose Component Library
Assign FluidProperties fromDSHplus Fluid
Data Base
Assign MaterialSpecific Properties
from DSHplusHose Material
Data BasePrepare Parameter Setsfor Batch Processing
Obtain CAD Data and Packaging Space Informations
Start
Define Power SteeringHose Design
Assemble Hose Model from
DSHplus Hose Component LibraryAssign Fluid
Properties from
DSHplus Fluid Data Base
Assign MaterialSpecific Properties
from DSHplusHose Material
Data BasePrepare Parameter Setsfor Batch Processing
Conduct Simulation Analysis(Single PC or Simultaneously on Multiple PC-Systems)
Compute Transfer Matrixes(If Hose Optimization, Compare with Hardware Measurements)
Review Results
Is Design Criterion Met?
Use Design
Modify Design
End
Obtain CAD Data and Packaging Space Informations
Figure 20Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Development methodology for automotive hose assembliesEntwicklungsmethodik für automobile Dehnschlauchleitungen
Start
Define Power SteeringHose Design
Assemble Hose Model from
DSHplus Hose Component LibraryAssign Fluid
Properties from
DSHplus Fluid Data Base
Assign MaterialSpecific Properties
from DSHplusHose Material
Data BasePrepare Parameter Setsfor Batch Processing
Conduct Simulation Analysis(Single PC or Simultaneously on Multiple PC-Systems)
Compute Transfer Matrixes(If Hose Optimization, Compare with Hardware Measurements)
Review Results
Is Design Criterion Met?
Use Design
Modify Design
End
Obtain CAD Data and Packaging Space Informations
Conduct Simulation Analysis(Single PC or Simultaneously on Multiple PC-Systems)
Compute Transfer Matrixes(If Hose Optimization, Compare with Hardware Measurements)
Review Results
Is Design Criterion Met?
Use Design
Modify Design
End
Figure 21Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Introduction1
Current situation of hydraulic pipe and hose simulation2
Development of a library for flexible hose elements3
A development methodology for automotive lines4
Presentation of example lines5
Summary6
Figure 22Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Simulation model of a two-chamber lineSimulationsmodell einer Zwei-Kammer-Leitung
Figure 23Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Example for an optimization of a two-chamber lineBeispiel für die Optimierung einer Zwei-Kammer-Leitung
T11
T12
T11
T12
Configuration A Configuration B
Frequency in Hz
Frequency in Hz Frequency in Hz
Frequency in Hz
Measurement
SimulationMeasurement
Simulation
Measurement
Simulation
Measurement
Simulation
Figure 24Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Simulation model of a one-chamber line with steel tunerSimulationsmodell einer Ein-Kammer-Leitung Stahltuner
Figure 25Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Example for a robustness analysis of the steel tuner lineBeispiel für eine Robustheitsanalyse der Stahltunerleitung
T11 represents the transfer
function of pressure input
(pump side) to pressure
output (steering gear side)
Blue: Measured transfer
function
Red: Simulation with exact
geometrical values
Grey: Simulation with
tolerated geometrical values
494,5 385386241238
120
4142
10
6,4
3 4
Figure 26Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Sensitivity analysis of the tuner lengthSensitivitätsanalyse der Tunerlänge
T 11
T 21
T 12
T 22
238494,5 385386241
1704142
10
6,4
3 4
lTuner = 170 mm (+50 mm)
Figure 27Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Sensitivity analysis of hose and pipe lengthSensitivitätsanalyse der Schlauch- und Rohrlänge
238194,5 185386241
17041542
10
6,4
3 4
T 11
T 21
T 12
T 22
lTuner = 170 mm, lHose.1a = + 500 mm, Σ lPipe 1, 2 = – 500mm
Figure 28Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Sensitivity analysis of hose and pipe lengthSensitivitätsanalyse der Schlauch- und Rohrlänge
738194,5 185386241
1704142
10
6,4
3 4
T 11
T 21
T 12
T 22
lTuner = 170 mm, lHose.1b = + 500 mm, Σ lPipe 1, 2 = – 500mm
Figure 29Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Sensitivity analysis of hose and pipe lengthSensitivitätsanalyse der Schlauch- und Rohrlänge
238194,5 1853856241
1704142
10
6,4
3 4
T 11
T 21
T 12
T 22
lTuner = 170 mm, lHose.1c = + 500 mm, Σ lPipe 1, 2 = – 500mm
Figure 30Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Sensitivity analysis of throttle diameterSensitivitätsanalyse des Drosseldurchmessers
238494,5 385386241
1704142
10
6,4
5 4
T 11
T 21
T 12
T 22
lTuner = 170 mm, dThrottle = 5 mm
Figure 31Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Sensitivity analysis of throttle positionSensitivitätsanalyse des Drosselposition
188494,5 385386241
1704192
10
6,4
3 4
T 11
T 21
T 12
T 22
lTuner = 170 mm, lHose.1a = + 50 mm, lHose.1b = - 50 mm,
Figure 32Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Introduction1
Current situation of hydraulic pipe and hose simulation2
Development of a library for flexible hose elements3
A development methodology for automotive lines4
Presentation of example lines5
Summary6
Figure 33Vehicle Dynamics 2008
© 2008 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Summary
• By means of the new DSHplus automotive hose library it is now possible to start the design of automotive lines using a virtual prototype. Based on a set of basic line elements the optimization of such lines can be automated using computer simulation.
• About variations of the geometry parameters a sensitivity and robustness analysis can very comfortably be carried out for the line design, e.g. by means of Doe techniques. The custom-designed application of automotive hose lines is not only accelerated by this, effort and costs for final tests with hardware prototypes are also reduced considerably.