汽车底盘开发

目录一底盘概述二底盘的开发流程三底盘的系统设计与标定四底盘的性能调校五底盘的验证优化第一单元底盘系统概述底盘的定义底盘是指汽车上由传动系统、悬架系统、转向系统和制动系统等部分组成的组合，支承、安装汽车车身，发动机及其它各部件、总成，形成汽车的整体造型，承受发动机动力，保证正常行驶。底盘的组成悬置系统转向系统制动系统悬架系统操纵系统驱动系统燃油系统标准件第二单元底盘的开发流程整车与底盘系统开发流程项目开发节点生产生产工艺验证ProductStratege&PlanningProgramInitiationConceptApproveProgramApproveEngineeringPrototypeProduct&ProcessValidationPre-StartofPilotPilotProductionPSPPICAPAEPPPVPPPSOP-208-170-142-103-80-36-26-130产品规划项目启动概念批准项目批准工程样车产品与预试试生产批量生产TG1TG2完成50%的整车性能标定完成80%的整车性能标定完成100%的整车性能标定EP软模/DV硬模底盘性能开发Calibration/ValidationEngin’gPrototype/IntegrationVehicleESOEngineeringSign-Off工程认可骡子车MuleCarTuning工程样车EPTuning前期开发AVD底盘架构件开发数据发布TG0概念数模TG1TG2软模硬模TG0概念数模造型及车身开发底盘系统开发流程-悬架系统ProductStrategicProgramConceptProgramEngin’gProduct&ProcessPre-StartofPlanningInitiationApproveApprovePrototypeValidat’nPilotPilotProductionPSPPICAPAEPPPVPPPSOP-208-170-142-103-80-36-26-130产品规划项目启动概念批准项目批准工程样车产品与预试试生批量生产工生产产生产艺验证硬件开发软件开发Release1：仅EBD功能；Mule装车；场地试验Release2：ABS/TCS/ESC基本性能；Release3：ABS/TCS/ESC性能优化；Release4：全功能软件；PP装车；公共道路试验Release5：量产软件；量产装车；SOPProduct&StrategicPlanningProgramInitiationConceptApproveProgramApproveEngin’gPrototypeProcessValidat’nPre-PilotPilotStartofProductiPSPPICAPAEPPPVPPPSOP-208-170-142-103-80-36-26-130Produ底ct盘系统开发流程-制动系统第三单元底盘的系统设计底盘的系统开发明确各开发要素控制，依据开发体系，实现各系统及零部件正向开发整车性能VTS子系统设计SSTS零件设计/分析零件/系统台架试验DV整车调校验证底盘架构底盘架构开发240013701700428044804432460014301500A-级车系统方案：前悬架-麦弗逊，后悬架-扭转梁电助力转向-C-EPSA级车系统方案：前悬架-麦弗逊，后悬架-四连杆、扭转梁电助力转向-DP-EPS、C-EPSB级车系统方案：前悬架-麦弗逊，后悬架-四连杆，电助力转向DP-EPS整车长度（mm）4900整备质量（kg）平台共用：麦弗逊前悬架、四连杆后悬架、DP-EPS转向平台共用：麦弗逊前悬架、扭转梁后悬架、C-EPS转向麦弗逊四连杆DP-EPS麦弗逊四连杆DP-EPS扭转梁C-EPS麦弗逊扭转梁C-EPS底盘系统选型规划•Handling•Roll-OverResistanceWeightTireLateralForceTireVerticalForceCorneringInertiaForce•RideRandomRoadMotion•Braking&AccelerationBrakingInertiaForceTireFore/AftForceTireFore/AftForceWhatisVehicleDynamics?Comprisedof4primaryareas:•Steering•Ride平顺性•Handling操纵稳定/转向•Braking制动性能•Traction驱动性能HandlingRequirementsSource:T.GillespieFundamentalsofVehicleDynamics,SAEBooksHandlingLinearHandlingNon-LinearHandlingLimitHandlingUndersteerGradientRollGainYawResponseStabilityParkingEffortTurningDiameterMaxLateralAccelerationNonlinearUndersteerOnCenterDoubleLaneChange稳态回转LateralAccelerationResponseTimeSteeringSensitivity稳态回转稳态回转阶跃和扫频阶跃0.4g稳态回转稳态回转静态/动态转向中心感最小转弯直径RolloverStability双移线整车性能VTS子系统设计SSTS零件设计/分析零件/系统台架试验DV整车调校验证底盘架构整车（底盘）性能开发竞争车研究及性能目标设定-RideandHandlingCar1Car2Car3客观测试目标设定底盘性能开发–BrakeVTSExample–GovernmentRegulations–Stoppingdistancerequirements–Pedalfeelrequirements–Brakesystemresponse–Brakebalancerequirements–Thermalrequirements–Liftanddiveperformancerequirements–Combinedcorneringandbrakingperformance基础制动性能标杆A标杆B标杆CMule制动踏板总成真空助力器带主缸总成ABS/ESP总成前制动卡钳总成手制动操纵机构总成前制动盘轮速传感器制动系统竞争车研究及性能目标设定-BrakeSystem底盘性能开发ADAMS特点•结构化软件，可建立任何机械系统的虚拟样机•可进行悬架KC特性仿真及整车仿真建模思路首先确定硬点——建立运动部件——用约束将它们连接——通过装配成为系统——利用外力或运动驱动虚拟仿真分析---ADAMS--CAR利用ADAMS对悬架及整车操稳性能进行虚拟仿真分析FrequencyResponseDoubleLaneChangeRideStepResponseRideandHandlingSimulationMaxPotholeRoughRoadCrossDitchLoadPredictionSteeringAxis(KingpinAxis)CastAngleCasterOffsetatWCCasterOffsetatGroudSAInclinationAngleSAOffsetatWCSAOffsetatGroudSpindleLength5.5.2.15.5.2.25.5.2.35.5.2.45.5.2.55.5.2.65.5.2.75.5.2.81.SteeringandCamberAngle102.SteeringAxisGeometry85.6SuspensionMotion65.7.1RideKinematics175.7.2RollKinematics115.7.3SteeringKinematics115.7.4Anti-Characteristics55.8RideandRollStiffness61.CamberandSteerCompliance42.OtherCompliances5SSTSSuspensionK&C(SAEJ670)SuspensionRollCamber5.7.2.1SuspensionRollCamberGradient5.7.2.2SuspensionRollInclination5.7.2.3SuspensionRollInclinationGradient5.7.2.4SuspensionRollCaster5.7.2.5SuspensionRollCasterGradient5.7.2.6SuspensionRollSteer5.7.2.7SuspensionRollSteerGradient5.7.2.8RollCenter5.7.2.9RollCenterHeight5.7.2.10RollAxis5.7.2.11ComplianceCamber5.9.1.1CamberCompliance5.9.1.2ComplianceSteer5.9.1.3SteerCompliance5.9.1.4-LateralForceSteer-LongForceSteer-AligningTorqueSteerTotal=83整车性能VTS子系统设计SSTS零件设计/分析零件/系统台架试验DV整车调校验证底盘架构FrontSprungMassRearSprungMassTargetF/RRideFrequencyRideRateSpringRateSpringLinkageRatioTireRateRidef=1/2(k/m)1/2Ks=r2KwFlatRideFronttoRearRideFrequencyBalanceRearridefrequencyhigherthanfrontHopeFrequencyDampingRatioSpringRequirements:1.Load2.RideFrequency3.Travel(atvariousloads)/MEJatCurbatCurb+2atGVW(GroundClearance)Ridefreq1.1~1.3HzHopFreq10~13HzmsKsuspmus长直线85kph悬架系统设计SuspensionK&CKtireRightturnshownRollRollGain(deg/g)RollCenter(mm)F/RRollStiffness(Nm/deg)CGHeight(mm)TireLateralLoadTransferDistribution(TLLTD)FrontView悬架系统设计SuspensionK&C5mm5mm7mmTopMount12mmRollCenterLFrontViewInstantCenterLCABushingLBJStrutMountKingpinRollCenterCHeightRollCenterHeightExampleLBJLCABushingOriginalWC(-11mm)LBJ(+7mm)TireSize(-30mm)LCABushing(-5mm)RCH42mmAdditionalWC(-12mm)92mm63mmTireEnvelop轮胎包络LoadCaseADAMSWheelCenterDisp.CATIATireEnvelopLoadCaseExampleTotalRackForceAnalysis整车性能VTS子系统设计SSTS零件设计/分析零件/系统台架试验DV整车调校验证底盘架构转向系统设计SSTSI-ShaftBalancingGearRatio方向盘力矩波动EPSSizing转向系统设计SSTSMaxLoadEPSControl转向系统EPSControl底盘零件开发•整车操稳/平顺•转向性能•制动性能•系统开发•零部件开发•数据发布零部件数据设计工程分析性能调校•CAE分析•DMU分析•工艺分