Automotive Mechatronics: Operational and Practical Issues Volume II

Automotive Mechatronics: Operational and Practical

Issues

For other titles published in this series, go to

International Series on

SCIENCE AND ENGINEERING

Editor

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

VOLUME 52

INTELLIGENT SYSTEMS, CONTROL AND AUTOMATION:

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

www.springer.com/series/6259

B.T. Fijalkowski

Volume II

Operational and Practical Issues

Automotive Mechatronics:

e-ISBN

Springer Dordrecht Heidelberg London New York

Printed on acid-free paper

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

B.T. Fijalkowski

Cracow University of Technology

Al. Jana Pawla II 37

31-864 Krakow

Poland

ISBN 978-94-007-1182-2 978-94-007-1183-9

DOI 10.1007/978-94-007-1183-9

© Springer Science+Business Media B.V. 2011

Cover design: SPi Publisher Services

Department of Mechanical Engineering

Library of Congress Control Number: 2011922911

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

pmfijalk@cyf-kr.edu.pl

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 automo￾tive 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 of 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

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

hypersystems;

Part 2 - DBW AWD propulsion mechatronic control systems;

 Part 3 - BBW AWB dispulsion mechatronic control systems;

 VOLUME II

 Part 4 - SBW AWS conversion mechatronic control systems;

 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 Preface

Individuals new to the subject matter of RBW or XBW unibody, space￾chassis, skateboard-chassis or body-over-chassis motion mechatronic control sys￾tems, will benefit most from the material. This manual is not compulsory for indi￾viduals with a basic background in, or knowledge of DBW AWD propulsion,

BBW AWB dispulsion, SBW AWS conversion and ABW AWA suspension

mechatronic control systems. Into the bargain, please notice that because of pro￾prietary considerations, this book does not present details of algorithm design, al￾gorithm 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, Science and Engineering book series (ISCA). 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 learned 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

Preface ix

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

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

I-CAR, IEC, IEEE, IMechE, Intel, Institute of Robotics and Mechatronics, Intelli￾gent 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, Magneti

Marelli, 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 Tech￾nologies 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 Michigan, 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 Pennsyl￾vania, 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 technology de￾velopments 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,

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

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.

x Preface

If the presuppositions underlying any of these statements prove incorrect, the

actual results may noticeably differ from those expressed by or embedded in such

statements.

I do not update advanced statements retrospectively. Such statements are

of most value on the date of publication and can be superseded.

Anyone who has attempted to write such a book in their spare time knows

how many weekends and vacation days go into it. I dedicate this book to my fam￾ily for their continual encouragement, constant care, and assistance and infinite

patience in making the writing of this book possible, as well as the generous

understanding they have always shown me.

Cracow, November 2010 BOGDAN THADDEUS FIJALKOWSKI

Contents

PART 4 …………………………………………………………………………... 1

4 SBW AWS Conversion Mechatronic Control System ……...…………...….. 3

4.1 Introduction ………………………………………………………....……... 3

4.2 Variable-Assist SBW 2WS Conversion

Mechatronic Control Systems ………………………………...…………. 39

4.2.1 Essentials of SBW 2WS Conversion

Mechatronic Control Systems …….………………………………...39

4.2.2 Categories of the SBW 2WS Conversion

Mechatronic Control Systems ……..………………………………..44

4.2.3 Description of SBW 2WS Conversion

Mechatronic Control Systems ...…………………………………….44

4.2.4 Hybrid E-M-F-M EPFS SBW 2WS Conversion

Mechatronic Control System ...…………………………………….. 50

4.2.5 E-M EPS SBW 2WS Conversion

Mechatronic Control System ...…………………………………….. 55

4.3 Energy-Saving Effectiveness …………………………………………….. 69

4.3.1 Foreword ……………………………………………………………69

4.3.2 Tendency in Research and Development (R&D)…………...………69

4.4 Steer-By-Wire (SBW) Four-Wheel Steering (4WS) Conversion

Mechatronic Control Systems.…………………………………….……... 73

4.4.1 Foreword…………………………………………………………….73

4.4.2 Philosophy of SBW 4WS Conversion

Mechatronic Control Systems ……………………………………....75

4.4.3 Dynamic Analysis of SBW 4WS Conversion

Mechatronic Control Systems ……………………………………....78

4.4.4 Categories of SBW 4WS Conversion

Mechatronic Control Systems ……………………………………....82

4.4.5 Foreword to Each SBW 4WS Conversion

Mechatronic Control System ………………………………………. 83

4.4.6 E-M SBW 4WS Conversion

Mechatronic Control Systems ……………………………………....98

4.4.7 Tendency in Research and Development (R&D) ……………….... 110

4.5 Tri-Mode Hybrid SBW AWS Conversion

Mechatronic Control Systems for Future Automotive Vehicles ….......... 117

4.5.1 Foreword ………………..................................................................117

4.5.2 Philosophy of Tri-mode Hybrid SBW AWS Conversion

Mechatronic Control …………………………………………….... 121

4.5.3 EM SBW AWS Conversion Actuators …………………………....122

4.5.4 SBW 4WS Conversion Mechatronic Control ……………………..124

4.5.5 Conclusion .………………………………………………………. 136

xii Contents

4.6 SBW 4WS Conversion Mechatronic Control System

for Automotive Vehicle Lane Keeping .………………………………... 139

4.6.1 Foreword …………………………………………………………..139

4.6.2 Automotive Vehicle Physical and Mathematical Models ............... 140

4.6.3 SBW 4WS Conversion Mechatronic Control System Design …… 141

4.6.4 4WS Automotive Vehicle Lane-Keeping Simulation ……………. 148

4.6.5 Conclusion ....................................................................................... 152

4.7 Model-Based Design with Production Code Generation for SBW

AWS Conversion Mechatronic Control System Development ............... 153

4.7.1 Foreword …………………………………………………………..153

4.7.2 Model-Based Design with Production Code Generation ................ 153

4.7.3 Behavioural Modelling ……………………………………………154

4.7.4 Simulation and Analysis …………………………………………..154

4.7.5 Rapid Prototyping …………………………………………………156

4.7.6 Detailed Software Design …………………………………………156

4.7.7 Physical Model Testing …………………………………………... 156

4.7.9 Production Code Generation ........................................................... 159

4.7.10 In-the-Loop Testing .......................................................................159

4.7.11 Integration Components ………………………………………… 159

4.7.12 Additional Resources …………………………………………….160

4.8 SBW AWS Conversion Mechatronic Control System

Using Fault-Silent Units ………….…………………………………….. 161

4.8.1 Foreword ..........................................................................................161

4.8.2 Time-Triggered Architectures for SBW AWS Conversion

Mechatronic Control Systems ……………………………………..164

4.8.3 Structure of Possible Four-Wheel-Steered (4WS)

Steer-By-Wire (SBW) Conversion Architecture …………………. 165

4.8.4 Conclusion ………………………………………………………... 169

4.9 Discussion and Conclusions …………………………………………….. 171

Glossary ……………………………………………………………………...175

References and Bibliography ………………………………………….......... 181

PART 5 ……………………………………………………………………....... 213

5 ABW AWA Suspension Mechatronic Control Systems …………………. 215

5.1 Introduction ……………………………………………………………... 215

5.2 Vehicular Suspension ………………………………………………........ 235

5.2.1 Vehicular Suspension Categories ………………………………… 236

5.2.2 Vehicular Suspension Functions ..................................................... 249

5.2.3 Vehicular Suspension Performance .................................................251

5.3 Passive Suspension ………………………………………………………255

5.3.1 Foreword ……………………………………………………….......255

5.3.2 Passive F-M or P-M Shock Absorber Suspension

Mechatronic Control System ……………………………………... 264

5.3.3 Passive F-P-M Suspension Mechatronic Control System …………277

5.4 Self-Levelling Suspension ........................................................................ 281

5.4.1 Foreword ……………………………………………………...........281

4.7.8 Distributed Architecture Design ………………………………….. 159

Contents xiii

5.4.2 Self-Levelling Suspension Mechatronic Control System

Arrangement ……………………………………………………… 283

Components ………………………………………………………. 284

5.4.4 Self-Levelling Suspension Mechatronic Control System

Function …………………………………………………………... 284

5.5 Semi-Active Suspensions ………………………………………………..289

5.5.1 Foreword …………………………………………………………..289

5.5.2 Shock Absorber Suspension Mechatronic Control

System Arrangement ……………………………………………..295

5.5.3 Shock Absorber Suspension Mechatronic Control

System Function ………………………………………………….. 296

5.5.4 Types of Semi-Active Devices ……………………………............ 298

5.5.5 Semi-Active ABW AWA Suspension Design Challenges ……......299

5.5.6 Semi-Active F-M ABW AWA Suspension Solution …………...... 300

5.5.7 Semi-Active P-M ABW AWA Suspension Solution …………...... 310

5.5.8 Semi-Active E-M ABW AWA Suspension Solution …………...... 313

5.5.9 Semi-Active MR ABW AWA Suspension Solution ……………... 315

5.5.10 Semi-Active ER ABW AWA Suspension Solution …………...... 333

5.6 Active Suspensions …………………………………………………....... 351

5.6.1 Foreword …………………………………………………………..351

5.6.2 Active F-M ABW AWA Suspension

Mechatronic Control Systems ……………………………………..367

5.6.3 Active F-P-M ABW AWA Suspension

Mechatronic Control Systems ……………………………………..389

5.6.4 Active P-M ABW AWA Suspension

Mechatronic Control Systems ……………………………………..401

5.6.5 Active E-M ABW AWA Suspension

Mechatronic Control Systems ……………………………………..408

5.6.6 Active E-P-M ABW AWA Suspension

Mechatronic Control Systems ……………………………………..422

5.6.7 Active E-M-M ABW AWA Suspension

Mechatronic Control Systems ……………………………………..434

5.7 Hybrid ABW AWA Suspension Mechatronic Control Systems ……...... 441

5.8 Discussion and Conclusions ……………………………………………..443

Glossary ...……………………………………………………………………451

References and Bibliography ……………………………………………...... 461

Acronyms ……………………………………………………………………… 505

513

Index ……………………………………………………………....................... 517

Nomenclature . …………………………………………………………………

5.4.3 Self-Levelling Suspension Mechatronic Control System

5.5.11 Semi-Active PF ABW AWA Suspension Solutions …………..... 342