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This study was performed to showcase the possible applications of the Hardware-in-the-loop (HIL) simulation environment developed by the National Highway Traffic Safety Administration (NHTSA), to test heavy truck crash avoidance safety systems. In this study, the HIL simulation environment was used to recreate a simulation of an actual accident scenario involving a single tractor semi-trailer combination. The scenario was then simulated with and without an antilock brake system (ABS) and electronic stability control (ESC) system to investigate the crash avoidance potential afforded by the tractor equipped with the safety systems. The crash scenario was interpreted as a path-following problem, and three possible driver intended paths were developed from the accident scene data.

A Software-in-the-Loop (SIL) simulation is presented here wherein control algorithms for the Anti-lock Braking System (ABS) and Roll Stability Control (RSC) system were developed in Simulink. Vehicle dynamics models of a 6×4 cab-over tractor and two trailer combinations were developed in TruckSim and were used for control system design. Model validation was performed by doing various dynamic maneuvers like J-Turn, double lane change, decreasing radius curve, high dynamic steer input and constant radius test with increasing speed and comparing the vehicle responses obtained from TruckSim against field test data. A commercial ESC ECU contains two modules: Roll Stability Control (RSC) and Yaw Stability Control (YSC). In this research, only the RSC has been modeled. The ABS system was developed based on the results obtained from a HIL setup that was developed as a part of this research.

There have been many articles published in the last decade or so concerning the components of an electronic stability control (ESC) system, as well as numerous statistical studies that attempt to predict the effectiveness of such systems relative to crash involvement. The literature however is free from papers that discuss how engineers might develop such systems in order to achieve desired steering, handling, and stability performance. This task is complicated by the fact that stability control systems are very complex and their designs and what they can do have changed considerably over the years. These systems also differ from manufacturer to manufacturer and from vehicle to vehicle in a given maker of automobiles. In terms of ESC hardware, differences can include all the components as well as the addition or absence of roll rate sensors or active steering gears to name a few.

The tractor trailer models discussed in this paper were for a real-time hardware-in-the-loop (HIL) simulation to test heavy truck electronic stability control (ESC) systems [1]. The accuracy of the simulation results relies on the fidelity and accuracy of the vehicle parameters used. However in this case where hardware components are part of the simulation, their accuracy also affects the proper working of the simulation and ESC unit. Hence both the software and hardware components have to be validated. The validation process discussed in this paper is divided into two sections. The first section deals with the validation of the TruckSim vehicle model, where experimental data is compared with simulation results from TruckSim. Once the vehicle models are validated, they are incorporated in the HIL simulation and the second section discusses the validation of the whole HIL system with ESC.

According to NHTSA's 2011 Traffic Safety Facts [1], passenger vehicle occupant fatalities continued the strong decline that has been occurring recently. In 2011, there were 21,253 passenger vehicles fatalities compared to 22,273 in 2010, and that was a 4.6% decrease. However; large-truck occupant fatalities increased from 530 in 2010 to 635 in 2011, which is a 20% increase. This was a second consecutive year in which large truck fatalities have increased (9% increase from 2009 to 2010). There was also a 15% increase in large truck occupant injuries from 2010. Moreover, the fatal crashes involving large trucks increased by 1.9%, in contrast to other-vehicle-occupant fatalities that declined by 3.6% from 2010. The 2010 accident statistics NHTSA's report reveals that large trucks have a fatal accident involvement rate of 1.22 vehicles per 100 million vehicle miles traveled compared to 1.53 for light trucks and 1.18 for passenger cars.

Vehicle dynamics models employed in heavy truck simulation often treat the semitrailer as a torsionally rigid member, assuming zero deflection along its longitudinal axis as a moment is applied to its frame. Experimental testing, however, reveals that semitrailers do twist, sometimes enough to precipitate rollover when a rigid trailer may have remained upright. Improving the model by incorporating realistic trailer roll stiffness values can improve assessment of heavy truck dynamics, as well as an increased understanding of the effectiveness of stability control systems in limit handling maneuvers. Torsional stiffness measurements were conducted by the National Highway Traffic Safety Administration (NHTSA) for eight semitrailers of different types, including different length box vans, traditional and spread axle flat beds, and a tanker.

Heavy trucks are involved in many accidents every year and Electronic Stability Control (ESC) is viewed as a means to help mitigate this problem. ESC systems are designed to reduce the incidence of single vehicle loss of control, which might lead to rollover or jackknife. As the working details and control strategies of commercially available ESC systems are proprietary, a generic model of an ESC system that mimics the basic logical functionality of commercial systems was developed. This paper deals with the study of the working of a commercial ESC system equipped on an actual tractor trailer vehicle. The particular ESC system found on the test vehicle contained both roll stability control (RSC) and yaw stability control (YSC) features. This work focused on the development of a reliable RSC software model, and the integration of it into a full vehicle simulation (TruckSim) of a heavy truck.

The paper discusses the development of a model for the 2006 BMW 330i for the National Advanced Driving Simulator's (NADS) vehicle dynamics simulation, NADSdyna. The front and rear suspensions are independent strut and link type suspensions modeled using recursive rigid-body dynamics formulations. The suspension springs and shock absorbers are modeled as force elements. The paper includes parameters for front and rear semi-empirical tire models used with NADSdyna. Longitudinal and lateral tire force plots are also included. The NADSdyna model provides state-of-the-art high-fidelity handling dynamics for real-time hardware-in-the-loop simulation. The realism of a particular model depends heavily on how the parameters are obtained from the actual physical system. Complex models do not guarantee high fidelity if the parameters used were not properly measured. Methodologies for determining the parameters are detailed in this paper.

This paper describes the design and development of the hardware, electronics, and software components of a state-of-the-art automated steering controller, the SEA, Ltd. ASC. The function of the ASC is to input to a vehicle virtually any steering profile with both high accuracy and repeatability. The ASC is designed to input profiles having steering rates and timing that are in excess of the limits of a human driver. The ASC software allows the user to specify steering profiles and select controller settings, including motor controller gains, through user-interface windows. This makes it possible for the test driver to change steering profiles and settings immediately after running any test maneuver. The motor controller used in the ASC offers self-contained signal input, output, and data storage capabilities. Thus, the ASC can operate as a standalone steering machine or it can be incorporated into typical existing, on-vehicle data acquisition systems.