Search Results

ADAMS, SIMULINK, and ADAMS-SIMULINK co-simulation models of component test systems, Multi-Axis-Simulation-Table (MAST) systems, and spindle-coupled vehicle testing system (MTS 329) were created. In the ADAMS models, the mechanical parts, joints, and bushings were modeled. Hydraulic and control elements were absent. The SIMULINK models modeled control and hydraulic elements including actuator dynamics, servo valve dynamics, closed loop control, three-variable control, matrix control, and coordinate transformation. However, the specimen had to be simplified due to the limitation of SIMULINK software. The ADAMS-SIMULINK co-simulation models considered hydraulic and control components in the SIMULINK portion and mechanical components in ADAMS portion. The interaction between the ADAMS and SIMULINK portions was achieved using ADAMS/Control.

Hybrid vehicle simulation methods combine physical test articles (vehicles, suspensions, etc.) with complementary virtual vehicle components and virtual road and driver inputs to simulate the actual vehicle operating environment. Using appropriate components, hybrid simulation offers the possibility to develop more accurate physical tests earlier, and at lower cost, than possible with conventional test methods. MTS Systems has developed Hybrid System Response Convergence (HSRC), a hybrid simulation method that can utilize existing durability test systems and detailed non-real-time virtual component models to create an accurate full-vehicle simulation test without requiring road load data acquisition. MTS Systems and Audi AG have recently completed a joint evaluation project for the HSRC hybrid simulation method using an MTS 329 road simulator at the Audi facility in Ingolstadt, Germany.

Wheel force and moment transducers (WFT) are widely used in vehicle testing and analysis [1], [2], [3]. There are many benefits of using these sensors. To install the transducer, vehicle wheel has to be modified. Transducer mounting adaptors are required to interface the sensor with the modified wheel rim. To study the effect of added mass with wheel force transducers, three vehicles, two types of passenger cars, and one SUV, were instrumented with an MTS spindle wheel force transducer (SWIFT 30A) as well as with regular wheels. The instrumented vehicles were driven on multiple proving ground surfaces with three passes for each vehicle. This experimental data was analyzed using RPC Pro software to assess both per pass variation and data trends from 3 passes without WFT (baseline) and 3 passes with WFT added mass. A validated ADAMS model of a production passenger vehicle, with and without added weight of the wheel force transducers, was also used to assess the added weight effect.

Virtual testing is a method that simulates lab testing using multi-body dynamic analysis software. The main advantages of this approach include that the design can be evaluated before a prototype is available and virtual testing results can be easily validated by subsequent physical testing. The disadvantage is that accurate specimen models are sometimes hard to obtain since nonlinear components such as tires, bushings, dampers, and engine mounts are hard to model. Therefore, virtual testing accuracy varies significantly. The typical virtual rigs include tire and spindle coupled test rigs for full vehicle tests and multi-axis shaker tables for component tests. Hybrid simulation combines physical and virtual components, inputs and constraints to create a composite simulation system. Hybrid simulation enables the hard to model components to be tested in the lab.

Two-poster rig plays a very important role in accelerated durability evaluation in a motorcycle industry, similar to what a four-poster rig does in a car industry. The rig simulates the exact road conditions in the vertical direction through tire coupling by applying feedback control on displacement. On account of its ability to simulate to the exact customer usage conditions, it reproduces the failures realistically as it happens on the field. However, as complete vehicle is required for testing on the rig, the testing happens mostly in the advanced stages of product development. Any failures beyond the concept stage have a huge impact on the development time and cost and the same should be avoided. Therefore, in this paper, a virtual testing methodology is proposed, based on which potential failures on the vehicles can be captured at the concept design stage itself. An ADAMS model of a motorcycle was created.

A test engineer faces a series of considerations (decisions) when designing a test program to conduct service history simulation testing of full scale vehicles (structures) in the laboratory. This paper proposes a logical decision path, with pertinent discussion of tradeoffs, which is intended to serve as a design guide in this process. A good deal of the authors’ subjective opinion is included. The paper begins by presenting a model of how a test facility should interface to the total engineering process. This is important in establishing a proper division of responsibility for the validity and usefulness of test results. This is followed by a specific discussion of service history simulation testing for durability evaluation.