An advanced physical modeling approach for brake s

CopyrightLMSInternational–2011-LMSCONFIDENTIAL1AnadvancedphysicalmodelingapproachforbrakesystemperformanceanalysisLionelBrogliaProductManagerFluids&ElectricalsolutionsVehicleDynamicsExpo2011MesseStuttgart,Germany17-19May2011CopyrightLMSInternational–2011-LMSCONFIDENTIAL2Presentation:TableofContentBrakesystemmodelingforvehicleperformanceevaluationsI.ProjectContextandPositioningII.ModelingApproachandTechnicalDetailsIII.SimulatedmaneuversinnormalandemergencyconditionsIV.SimulatedmaneuverswithsystemfailuresV.ConclusionsandpossiblemodelextensionsCopyrightLMSInternational–2011-LMSCONFIDENTIAL3Presentation:TableofContentBrakesystemmodelingforvehicleperformanceevaluationsI.ProjectContextandPositioningII.ModelingApproachandTechnicalDetailsIII.SimulatedmaneuversinnormalandemergencyconditionsIV.SimulatedmaneuverswithsystemfailuresV.ConclusionsandpossiblemodelextensionsCopyrightLMSInternational–2011-LMSCONFIDENTIAL4APG-PresentationoftheCompanyAPG,ZhejiangAsiaPacificMechanical&ElectronicCompanyOneofthemajorsupplierofBrakeSystemsinChina.Thissupplierisspecializedinresearch,development&manufacturingof:•Brakedisc/drumassemblies•Vacuumpump•MasterCylinder•BrakeBooster•ABS/ASRsystems.•ESPsystemsMaincustomers:FAW-Volkswagen,Dongfeng-PSA,Chery,Chang’anAutomotive,…HistoricalViewCopyrightLMSInternational–2011-LMSCONFIDENTIAL5APG,ZhejiangAsiaPacificMechanical&ElectronicCompanyThecurrentR&DprocessofthecompanyismainlybasedonintensivetestcampaignsAPGisnowlookingfornewR&Dprocessesrelyingonsimulation:-Improvetheunderstandingoftheirsystems-Decreasethetestingeffort-Acceleratedevelopmenttime/reducetimetoproduction-AssistthedevelopmentandvalidationofelectroniccontrollerssuchasABS/ASR/ESPcontrolunitsAPG–R&DProgramCopyrightLMSInternational–2011-LMSCONFIDENTIAL6Presentation:TableofContentBrakesystemmodelingforvehicleperformanceevaluationsI.ProjectContextandPositioningII.ModelingApproachandTechnicalDetailsIII.SimulatedmaneuversinnormalandemergencyconditionsIV.SimulatedmaneuverswithsystemfailuresV.ConclusionsandpossiblemodelextensionsCopyrightLMSInternational–2011-LMSCONFIDENTIAL7ProjectGlobalOverviewBrakesystemmodelingforvehicleperformanceevaluations1.Componentmodelingandbehaviorvalidation(oneafterone)-DualBrakeBooster-MasterCylinder-FrontfloatingCaliper-RearfloatingCaliperwithparkbrakeassembly2.Hydraulicpiping&hoses:modelingaccordingtothefrequencyrangeofinterest3.CompleteBrakeSystemassembly:parameteradaptationandvalidation4.FinalvalidationoftheBrakeSystemModelingPlatformMODELINGPROCESSCopyrightLMSInternational–2011-LMSCONFIDENTIAL8ComponentModelingandUnitaryValidationsVacuumDualBrakeBoosterFunctionalsprings&bodyrelativeendstops(MechanicalDomain).Vacuumvs.atmo.pressure:functionalassistancewithtypicalactivesurfaces(Pneumaticdomain)CopyrightLMSInternational–2011-LMSCONFIDENTIAL9ComponentUnitaryValidationVacuumDualBrakeBoosterTheboosterbehavesaccordingto4mainphases:1.Springpreloadsovercome2.Closingofvalveswithcontactflexibilities3.Amplificationduetovacuumassistance4.Saturatedassistanceratio=input/output=1Boundaries:“Quasi-StaticActuation”ValidationofboosteralonewithanArtificialMasterCylindermodeledbymeansofanequivalentstiffnessPedalForceIncreasePedalForceDecrease1234Patm(barA)Pvacuum(barA)CopyrightLMSInternational–2011-LMSCONFIDENTIAL10ComponentAnimationVacuumDualBrakeBoosterPedalForceIncreasePedalForceDecrease1234Patm(barA)Pvacuum(barA)CopyrightLMSInternational–2011-LMSCONFIDENTIAL11ComponentModelingandUnitaryValidationsMaster-CylinderFunctionalsprings&bodyrelativeendstops(Mechanicaldomain).Brakevs.atmo.pressure:functionalprimary&secondarychamberswithtypicalactivesurfaces(Hydraulicdomain)CopyrightLMSInternational–2011-LMSCONFIDENTIAL12ComponentModelingandUnitaryValidationsMaster-CylinderTheMaster-Cyl.behavesaccordingto4mainphases:1.Deadstroke(Valvesareopened).2.Closingof2ndand1stvalvewithcontactflexibilities.Fluidcompressionandairgascontentdissolution(quadraticshape).3.Pressureriseupaccordingtohydraulicclosedvolumeandspringloads(linearbehavior“Kstiff”).Boundaries:“Quasi-StaticActuation”1stand2ndHydraulicchambersoutletsinclosedcondition321Kstiff(hydChamber)CopyrightLMSInternational–2011-LMSCONFIDENTIAL13ComponentAnimationMaster-Cylinder:Behaviorsof1stValve(PrimaryChamber)and2ndValve(SecondaryChamber)PrimaryChamberValveCopyrightLMSInternational–2011-LMSCONFIDENTIAL14ComponentModelingandUnitaryValidationsFrontFloatingCaliperFunctionalsprings&bodyrelativeendstopsHydraulicpressure:functionalfrontcaliperchamberwithtypicalactivesurfacesCoolingofthebrakedisc:1DcompromisetoidentifythebraketemperatureandthenthefrictioncoefficientCopyrightLMSInternational–2011-LMSCONFIDENTIAL15ComponentModelingandUnitaryValidationsRearFloatingCaliperwithparkbrakesystemSpring&bodyrelativeendstops,CamFollowerfortheparkbrakesystemHydraulicpressure:functionalrearcaliperchamberwithtypicalactivesurfacesCoolingofthebrakedisc:1DcompromisetoidentifythebraketemperatureandthenthefrictioncoefficientCopyrightLMSInternational–2011-LMSCONFIDENTIAL16Internalvol