The use of Simulink and SimMechanics in the development of vehicle test systems

cuckootrainMechanics

Oct 31, 2013 (4 years and 9 days ago)

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The use of

Simulink and SimMechanics

in the development of

vehicle test systems

Andrew Plummer

Instron Ltd, UK


andrew_plummer@instron.com

Materials & component

testing machines

Overview


Hydraulic catapult for vehicle crash testing


Control using an inverse dynamic model



Full vehicle test rigs for road/track simulation


Modelling for performance verification


Real
-
time models for control

Crash testing catapult

Actuator

Accumulator

Sledge

Hydrostatic Bearing

4th Valve Stage

Longitudinal Accelerometer

Rail

3
-
Stage Servovalve

Hydraulic Oil

Modelling system dynamics


Forward model

Simulink Model

Longitudinal car

acceleration

Valve command

signal

Calculating command signal

Inverse Dynamic Model

Target

acceleration

Valve

command signal

Calculating command signal

Inverse Dynamic Model

Target

acceleration

Valve

command signal

Results

Full vehicle test rigs

F1 track simulation

To minimise lap time by assessing alternative designs and set
-
ups.

Test rig control concept

Car and rig

Up to 28 hydraulic actuators

















Control System


Standard digital controller

(8800)

Valve

drives

Sensors


Specialised control functions

via Simulink Real
-
Time Code





Virtual systems,
e.g. aero model

Performance simulation

-

Simulink and SimMechanics

Car and rig


















Control System


Standard digital controller

SIMULINK MODEL

Valve

drives

Sensors


Specialised control functions

SIMULINK MODEL






Virtual systems,
e.g. aero model

Hydraulic system

SIMULINK MODEL

Rig mechanics

SimMECHANICS MODEL

Car mechanics

SimMECHANICS MODEL

Results

Kinematics
-

e.g. joint angles

Forces (joints, actuators etc.)

Control performance

Benefits of simulation


Obtaining mechanical design information


loads, displacements (clashes)


System performance prediction


comparison with specification


perform virtual acceptance tests


assess and refine controller, hydraulic and
mechanical design


Avoid expensive re
-
work !!

Advantages of Simulink for rig
simulation


Control system and mechanical multi
-
body
simulation in a unified environment


Increased simulation speed


Some parts of control system already
designed using Simulink ready for code
-
generation