Automotive mechatronics: operational and practical issues Volume I

Automotive Mechatronics: Operational

and Practical Issues

International Series on

INTELLIGENT SYSTEMS, CONTROL, AND AUTOMATION:

SCIENCE AND ENGINEERING

VOLUME 4

Editor:

Professor S.G. Tzafestas, National Technical University of Athens, Athens, Greece

Editorial Advisory Board

Professor P. Antsaklis, University of Notre Dame, Notre Dame, IN, USA

Professor P. Borne, Ecole Centrale de Lille, Lille, France

Professor D.G. Caldwell, University of Salford, Salford, UK

Professor C.S. Chen, University of Akron, Akron, Ohio, USA

Professor T. Fukuda, Nagoya University, Nagoya, Japan

Professor S. Monaco, University La Sapienza, Rome, Italy

Professor G. Schmidt, Technical University of Munich, Munich, Germany

Professor S.G. Tzafestas, National Technical University of Athens, Athens, Greece

Professor F. Harashima, University of Tokyo, Tokyo, Japan

Professor N.K. Sinha, McMaster University, Hamilton, Ontario, Canada

Professor D. Tabak, George Mason University, Fairfax, Virginia, USA

Professor K. Valavanis, University of Denver, Denver, Colorado, USA

For other titles published in this series, go to

www.springer.com/series/6259

7

B.T. Fijalkowski

Automotive Mechatronics:

Operational and Practical

Issues

Volume I

123

B.T. Fijalkowski

Cracow University of Technology

Dept. Mechanical Engineering

Al. Jana Pawla II 37

31-864 Krakow

Poland

[email protected]

ISBN 978-94-007-0408-4 e-ISBN 978-94-007-0409-1

DOI 10.1007/978-94-007-0409-1

Springer Heidelberg Dordrecht London New York

c Springer Science+Business Media B.V. 2011

No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by

any means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written

permission from the Publisher, with the exception of any material supplied specifically for the purpose

of being entered and executed on a computer system, for exclusive use by the purchaser of the work.

Printed on acid-free paper

Springer is part of Springer Science+Business Media (www.springer.com)

For my daughter Madeleine

Preface

The purpose of this book is to present operational and practical issues

of automotive mechatronics with special emphasis on the heterogeneous auto￾motive vehicle systems approach.

The book is intended as a graduate text as well as a reference for scientists and

engineers involved in the design of automotive mechatronic control systems.

As the complexity of automotive vehicles increases, so does the dearth of high

competence, multi-disciplined automotive scientists and engineers. This book pro￾vides a discussion into the type of mechatronic control systems found in modern

vehicles and the skills required by automotive scientists and engineers working

in this environment.

Divided into two volumes and five parts, Automotive Mechatronics aims

at improving automotive mechatronics education and emphasises the training

of students’ experimental hands-on abilities. The author hopes that this can stimu￾late and promote the education programme in students’ experimental hands-on

experience among high education institutes and produce more automotive mecha￾tronics and automation engineers.

Contents

™ VOLUME I

¾ Part 1 - RBW or XBW unibody or chassis-motion mechatronic control

hypersystems;

Part 2 - DBW AWD propulsion mechatronic control systems;

¾ Part 3 - BBW AWB dispulsion mechatronic control systems;

™ VOLUME II

¾ Part 4 - SBW AWS diversion mechatronic control systems;

¾ Part 5 - ABW AWA suspension mechatronic control systems.

The book was developed for undergraduate and postgraduate students as well

as for professionals involved in all disciplines related to the design or research and

development of automotive vehicle dynamics, powertrains, brakes, steering, and

shock absorbers (dampers). A basic knowledge of college mathematics, college

physics, and knowledge of the functionality of automotive vehicle basic propul￾sion, dispulsion, conversion and suspension systems is required.

viii

Individuals new to the subject matter of RBW or XBW unibody, space￾chassis, skateboard-chassis or body-over-chassis-motion motion mechatronic con￾trol systems, will have most advantage most the material. This manual is not com￾pulsory for individuals with a basic background in, or knowledge of DBW AWD

propulsion, BBW AWB dispulsion, SBW AWS diversion and ABW AWA sus￾pension mechatronic control systems. Into the bargain, please notice that because

of proprietary considerations, this book does not present details of algorithm

design, algorithm performance, or algorithm application.

I am the sole author of the book and all text contained herein is of my own

conception unless otherwise indicated. Any text, figures, theories, results, or de￾signs that are not of my own devising are appropriately referenced in order to give

acknowledgement to the original authors. All sources of assistance have been

assigned due acknowledgement.

All information in this book has been obtained and presented in accordance

with academic rules and ethical conduct. I also wish to state declare that, as re￾quired by these rules and conduct, I have fully cited and referenced all material

and results that are not original to this book.

I wish to express my sincere gratitude to Professor Spiros Tzafestas for his

interest in the preparation of this book in the Intelligent Systems, Control, Auto￾mation (ISCA), Science and Engineering book series. My gratitude is also due

to Ms Nathalie Jacobs and Ms Johanna F. A. Pot of Springer for their persistence

in making this book a reality.

I am grateful to the many authors referenced in this book from whom, during

the course of writing, I learnt so much on the subjects which appear in the book.

I am also indebted to my national and international colleagues who indirectly con￾tributed to this book.

Most of all I wish to express thanks the following consortia and institutions:

ABIresearch, ABResearch, ACURE Dynamics, ADAMS, ADVISOR, ADwin,

AEG, Air Force Research Lab. (AFRL), AIRMATIC, AirRock, AKA Bose Corp.,

AMESim, AMI Semiconductor, AMT, AMTIAC, AR&C, AROQ Ltd., Audi AG,

AUDIAG, AutoPro, AUTOSAR, AUTOTECH, Avio Pro, AVL, Bertone,

BizWire, Bobbs-Merril Co., BMW, BOSCH GmbH, Bridgestone Corp., Cadillac,

CAFS, California Linear Devices, Carnegie Mellon, Centro Richerche FIAT,

CFC, Challenge Bibendum, Chalmers University of Technology, Climatronic,

Cleveland State University, Cracow University of Technology, Continental

TEVES Inc., Cosc/Psych, Cracow University of Technology, CRL, Chrysler,

Daimler-Benz, DaimlerChrysler AG, D&R, DAS, DECOMSYS, Delco Electron￾ics, Delco-Remy, Delphi, Delft Center for Systems and Control, DJH, DLR

RoboDrive, DRDC, dSPACE GmbH, Dynamic Structures & Materials LLC,

Energen Inc., ERFD, ER Fluid Developments Ltd. UK, eSTOP GmbH, FAA

US DoT, FACE International Corp., FHWA-MC Fiat, Fichtel & Sachs, FlexRay

Consortium, FMA, FortuneCity, FPDA, US DoT, Ford Europe, Ford Motor Co.,

Ford SRL, Freescale Semiconductor Inc., FUJI Microelectronics Inc. (FMA),

FUJITSU, GM Chevrolet, GM Opel, General Motors Corp., German Aerospace

Centre (DLE e.V.), Gothorum Carolinae Sigillium Universita, Graz University

Preface

ix

of Technology (TUG), Haskell, Hitachi Co., Honda, How Stuff Works, Hunter,

I-CAR, IEC, IEEE, IMechE, Intel, Institute of Robotics and Mechatronics,

Intelligent Transportation Society (ITS), ISO, IPC website, IPG Automotive

GmbH, Istanbul Technical University, Jäger GmbH, JB, JUST-AUTO.COM,

Kalmar, Kinetic Suspension Technology, Lexus, Kungl. Tekniska Högskolan

(KTH), Land Rover, Lord, Lotus Engineering, Lund Institute of Technology,

MagnetiMarelli, Magnet Motor, Mazda, McCormick, Mechanical Dynamics, Inc.,

Mecel, Messier-Bugatti, MICHELIN, MILLENWORKS, MIT Hatsoupulos

Microfluid Lab., Mitsubishi Corporate, MOST Net-services, MOTOROLA, NI,

NASA Langley Research Center, National Highway Traffic Administration

(NHTSA), Nissan, Office of Naval Research (ONR), Norwegian University

of Science and Technology, Oldhams Ltd., OSEK-WORKS, Packard, PACIFICA

Group Technologies Pty Ltd., PEIT, PHILIPS, PITechnology, Polski FIAT,

Porsche, PSA PEUGEOT CITROËN , Purdue School of Engineering and

Technology, SAAB, SAE, Scania, Sensormag, Siemens VDO Automotive, SKF,

Star, Studebaker, Subaru, Radatec Inc., Southwest Research Institute (SwRI),

Racelogic, Radatec Inc., Renault, Research Team for Technology (CARAMELS),

Ricardo, RMSV, Robert Bosch GmbH, Rodmillen, SCANIA, Seoul National

University, TACOM TARDEC, Technische Universität Darmstadt, Universität

Koblenz, Universität Regensburg, TENNECO Automotive, The Motor Industry

Research Association (MIRA), The New York Times, The University of Michi￾gan, Toyota, TRIDEC, Triumph, TRW Automotive Inc., TTPbuild, TTPnode,

TTTech Computertechnik AG, Universita ‘di Bologna, Universität Salzburg,

University of California Berkeley, University of Leicester, University of Limerick,

University of Pennsylvania, University of Queensland, University of Sussex,

University of Texas at Austin, University of York (UK), Uppsala University,

US Army Research Office, US DLA, US DoD, US DoE, UT-CEM, Valentin

Technologies Inc., Valeo, Van Doorne Transmissie BV, VCT, Vienna Institute

of Technology, VOLKSWAGEN (VW), VOLVO, Wongkwang University,

ZF Sachs AG, and XILINX for their text, figures, or designs included in this book

in order to give them due credit and acknowledgement as well as to present their

contemporary achievements in automotive mechatronics.

The book is full of advanced statements and information on the technology

development of the automotive industry. These statements can be written and may

be recognizable by terms such as ‘may be’, ‘will’, ‘estimates’, ‘intends’, ‘antici￾pated, ‘expects’ or terms with analogous sense. These statements are derived from

presuppositions with reference to the developments of the technology of Europe,

Americas and Asia-Pacific countries, and in particular of their automotive indus￾try, which I have prepared on account of the information accessible to me and

I think to be realistic at the time of going to press.

The estimates specified implicate a degree of risk, and the actual development

may differ from those forecasts. If the presuppositions underlying any of these

statements prove incorrect, the actual results may noticeably differ from those

expressed or embedded by such statements.

Automotive Mechatronics

x

I do not update advanced statements retrospectively. Such statements are

valuable on the date of publication and can be superseded.

Whoever has attempted to write such a book in their spare time knows how

many weekends and vacation days go into it. I want to dedicate this book to my

family for their continual encouragement, constant care, and assistance and

infinite patience in making the writing of this book possible, as well as the gener￾ous understanding they have always shown me.

Cracow, September 2010 BOGDAN THADDEUS. FIJALKOWSKI

Preface

Contents

PART 1 RBW or XBW Integrated Unibody or Chassis Motion

Mechatronic Control Hypersystems ....................................................................... 1

1.1 Introduction .................................................................................................. 3

1.2 Integrated Unibody or Chassis Motion

Advanced Technology Roadmap ................................................................ 21

1.3 RBW or XBW Philosophy ......................................................................... 25

1.4 Harnessing Energy and Information Networks .......................................... 49

1.4.1 Foreword ........................................................................................... 49

1.4.2 SAE In-Vehicle Energy-and-Information Network Classes .............. 51

1.4.3 Scalable Modular Architecture .......................................................... 53

1.4.4 Optical Fibre Technology .................................................................. 54

1.4.5 Wireless Technologies ...................................................................... 54

1.4.6 Conclusion ......................................................................................... 55

1.5 Local Interconnect Networking .................................................................. 57

1.6 SAE J1850 Protocol ................................................................................... 61

1.7 IEEE 1394 Protocol .................................................................................... 63

1.8 Controller Area Networking ....................................................................... 65

1.8.1 Foreword ........................................................................................... 65

1.8.2 CAN Arbitration ................................................................................ 66

1.8.3 CAN Error Detection ......................................................................... 66

1.8.4 CAN Architecture .............................................................................. 66

xii Contents

1.9 Time Triggered Controller Area Networking ............................................. 69

1.10 Media Oriented System Transport (MOST) Networking ........................... 73

1.11 FLEXRAY™

RBW or XBW Networking ..................................................... 75

1.12 DSPACE RBW or XBW Networking ......................................................... 85

1.13 DBW 4WD × BBW 4WB × SBW 4WS × ABW 4WA

Intelligent Vehicles ..................................................................................... 89

1.14 Purpose of RBW or XBW Integrated Unibody or Chassis Motion

Mechatronic Control Between Individual DBW AWD, BBW AWB,

SBW AWS and ABW AWA Mechatronic Controls .................................. 95

1.14.1 Foreword ......................................................................................... 95

1.14.2 Three-Mode Hybrid SBW 4WS Conversion

Mechatronic Control System .......................................................... 98

1.14.3 Predictive and Adaptive, Semi-Active ABW 4WA Suspension

Mechatronic Control System ........................................................ 101

1.14.4 Series Hybrid-Electric DBW 4WD Propulsion

Mechatronic Control System ........................................................ 104

1.14.5 Anti-Wheel-Lock and Anti-Wheel-Spin BBW 4WB Dispulsion

Mechatronic Control System ........................................................ 107

1.14.6 Conclusion ..................................................................................... 109

1.15 Discussion and Conclusions ..................................................................... 111

Glossary .............................................................................................................. 119

References and Bibliography ............................................................................. 125

PART 2 DBW AWD Propulsion Mechatronic Control Systems ....................... 143

2.1 Introduction .............................................................................................. 145

2.1.1 Engine Management Control ........................................................... 162

2.1.2 Active Engine Management Control ............................................... 175

Automotive Mechatronics xiii

2.2 Automotive Vehicle Driving Performance ............................................... 209

2.2.1 Foreword ......................................................................................... 209

2.2.2 Lumped Mass .................................................................................. 209

2.2.3 Euler Angles .................................................................................... 210

2.2.4 Forces and Rotational Moments of Inertia ...................................... 210

2.2.5 Automotive Vehicle Fixed Coordinate System ................................ 210

2.2.6 Motion Variables ............................................................................. 211

2.2.7 On/Off-Road Surface Fixed Coordinate System ............................. 211

2.2.8 Newton’s Second Law ..................................................................... 212

2.2.9 Dynamic Axle Loads ....................................................................... 213

2.2.10 Forces Affecting Wheel Traction .................................................... 215

2.3 M-M DBW AWD Propulsion Mechatronic Control Systems for

Conventional Automotive Vehicles ............................................................ 219

2.3.1 Classical Mechano-Mechanical (M-M) Powertrains for M-M

DBW AWD Propulsion Mechatronic Control Systems .................... 219

2.4 M-M Transmission Arrangement Requirements for Conventional

Automotive Vehicles .................................................................................. 233

2.4.1 Foreword ........................................................................................... 233

2.4.2 Classical M-M Transmission Arrangement Requirements for

the M-M DBW AWD Propulsion Mechatronic Control System ...... 241

2.4.3 M-M Clutches ................................................................................... 245

2.4.4 M-M Transmissions .......................................................................... 246

2.4.5 Front ECE or ICE, M-M Clutch, MT or SAT or FAT or CVT

and Live-Axle M-M Transmission Arrangement for the M-M

DBW 2WD Propulsion Mechatronic Control System ...................... 249

xiv Contents

2.4.6 Front ECE or ICE, M-M Clutch, MT or SAT or FAT or CVT

and Live-Axle M-M Transmission Arrangement for the M-M

DBW 4WD Propulsion Mechatronic Control System ...................... 251

2.4.7 Rear ECE or ICE, M-M Clutch, MT or SAT or FAT or CVT

and Live-Axle M-M Transmission Arrangements for the M-M

DBW 2WD Propulsion Mechatronic Control System ...................... 257

2.4.8 Dead Axle and Axleless M-M Transmission Arrangements for

the M-M DBW 2WD Propulsion Mechatronic Control System ....... 259

2.5 F-M DBW AWD Propulsion Mechatronic Control Systems for

All-Fluidic Vehicles ......................................................................... 265

2.5.1 Foreword ........................................................................................... 265

2.5.2 Fluidostatic F-M Transmission Arrangement for the F-M

DBW AWD Propulsion Mechatronic Control System ..................... 268

2.5.3 Conclusion ......................................................................................... 272

2.6 ECE/ICE HF DBW AWD Propulsion Mechatronic Control Systems

for Hybrid-Fluidic Vehicles ....................................................................... 275

2.6.1 Foreword ........................................................................................... 275

2.6.2 Conclusion ......................................................................................... 283

2.7 E-M DBW AWD Propulsion Mechatronic Control Systems for

Battery Electric Vehicles ............................................................................ 285

2.7.1 Foreword ........................................................................................... 285

2.7.2 E-M Transmission Arrangements for the E-M DBW 2WD

Propulsion Mechatronic Control System .......................................... 289

2.7.3 E-M Transmission Arrangements for the E-M DBW 2WD

and/or 4WD Propulsion Mechatronic Control System ..................... 291

2.7.4 Conclusion ......................................................................................... 307

2.8 ECE/ICE HE DBW AWD Propulsion

Mechatronic Control Systems for Hybrid-Electric Vehicles ...................... 309