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Approach for the Development of Suspensions with Integrated Approach for the Development of Suspensions with Integrated Electric Motors Von der Fakultät Konstruktions-, Produktions- und Fahrzeugtechnik der Universität Stuttgart zur Erlangung der Würde eines Doktors der Ingenieurwissenschaften (Dr.-Ing.) genehmigte Abhandlung Vorgelegt von Meng Wang aus Hebei, China Hauptberichter: Prof. Dr. -Ing. Horst E. Friedrich Mitberichter: Prof. Dr. -Ing. Eckhard Kirchner Tag der mündlichen Prüfung: 06. May 2020 Institut für Verbrennungsmotoren und Kraftfahrwesen, Universität Stuttgart Angefertigt am Institut für Fahrzeugkonzepte, Deutsches Zentrum für Luft- und Raumfahrt (DLR) e.V. Stuttgart 2020 D93 (Dissertation Universität Stuttgart) Acknowledgments The author would like to thank his supervisors Prof. Dr. -Ing. Friedrich and Prof. Dr. - Ing. Kirchner for their consistent support and patience to his Ph.D study. The author is sincerely thankful to his advisor Dr. Elmar Beeh for his encouragement and guidance with his professional knowledge. Without their support, this thesis would not be completed. I am grateful to have these colleagues, who provided me honest communication and exchange of learning experience: Dr. Zhou Ping, Dr. Andreas Höfer, Dr. Diego Schierle, Dr. Jens König, Dr. Gerhard Kopp and so on. I wish to thank the support of colleagues in laboratory of DLR FK, who helped me to complete the test and acquired the useful data in this work: Michael Kriescher, Philipp Straßburger, Cedric Rieger and so on. I wish to thank these friendly colleagues: David Krüger, Lucia Areces Fernandez, Marco Münster, Erik Chowson, Thomas Grünheid and so on, who let me enjoy the work in DLR FK. You are already my best friends in Germany. I want to mention Moritz Fisher, Dr. Bernd Propfe, Dr. Martin Redelbach who help me quickly accommodate the living and work in Germany. In my daily work I have been blessed with a friendly and cheerful group: DLR FK. I wish to thank all the colleagues who have given me help and encouragement. Finally, I would like to thank my family member for supporting and understanding me throughout my study at university. Kurzfassung Das Konzeptdesign ist eine innovative und strategische Phase in der Produktentwicklung. In dieser Phase sind die Konzepterstellung und Entscheidung entscheidend für die folgende Produktentwicklung. Jedoch sind die realisierbaren Designkonzepte zu generieren und dann eine richtige Entscheidung zu treffen eine Herausforderung, da es sich um ein multidisziplinäres Design und unzureichende Informationen handelt. In der Konzeptionsphase von Elektrofahrzeugen ist Leichtbau ein Thema, dass nicht ignoriert werden kann und von hoher Priorität ist. Die Kombination der Antriebseinheit in den Lenker ist eine effektive technische Lösung, um den Systemleichtbau zu erreichen und gleichzeitig die geringe Zunahme der ungefederten Masse zu realisieren. Allerdings sind hier folgende Fragen zu untersuchen: Wie die mit Elektromotoren integrierten Fahrwerkskonzepte unter Berücksichtigung der komplexen Funktionen, mehreren Designparameter und komplizierten Beziehungen systematisch generiert und bewertet werden können? Wie eine Strukturleichtbau der Achse für dieses kombinierte Konzept gestaltet werden kann? Wie die Fahrdynamik des Fahrzeugs mit diesem Fahrwerk bewertet wird? In dieser Arbeit wird eine Design Methodik für die Entwicklung von mit Elektromotoren integierten Fahrwerkskonzept vorgestellt. Zunächst wird ein neuer Ansatz für die Funktionen Integration auf der Basis der Axiomatic Design vorgeschlagen. Bei diesem Ansatz wird die Funktion Integration formelhaft und explizit durch Matrixgleichungen beschrieben. Die Systemfunktionen, entsprechenden Parameter und ihre Beziehungen können in den Designmatrizen untersucht werden. Dieser Ansatz wird dann auf die Entwicklung von Fahrwerkskonzepten angewendet, die die Funktionen von Elektromotoren integrieren. Die generierten Konzepte werden durch die Vergleiche ihren Matrizen nach den Axiomen in Axiomatic Design bewertet und ausgewählt. Anschließend wird ein Referenzfahrwerk getestet und die Parameter als Benchmark für die Entwicklung des Fahrwerkskonzepts verwendet. Die Designmatrix des Fahrwerkskonzept dient als Anleitung für nachfolgende Entwicklungen. Die Designsvariablen in der Matrix werden in der Reihenfolge bestimmt, in der die mathematischen Matrixgleichungen gelöst werden. Um die Systemmasse weiter zu reduzieren, wird die Topologieoptimierung für das Design der Fahrwerkstruktur unter der Berücksichtigung von kinematischen und elastokinematischen Zielen eingesetzt. Auf Basis von der Strukturtopologie wird eine aus Stahlrohren mit unterschiedlichen Dicken bestehende Leichtbaustruktur ausgelegt. Die Eigenschaften des Fahrwerkskonzeptes werden mit dem Referenzfahrwerk verglichen. Um die Vertikal- und Rolldynamik des Fahrwerkskonzeptes zu untersuchen, werden ein analytisches Modell für die Fahrdynamik der Hinterachse und ein Straßenmodell für zweispurige Unregelmäßigkeiten gemäß den Straßenoberflächenprofile von ISO-8608 entwickelt. Diese Modelle können auf die Simulation der Fahr- und Rolldynamik des Zielfahrzeugs mit dem Konzept der Hinterachse angewendet werden. Die Fahrdynamik des Fahrzeugs mit dem neuen Fahrwerk wird mit dem Referenzfahrwerk verglichen. Abstract Conceptual design is an innovative and strategic phase in the process of product development. In this phase the concept generation and decision-making are critical to the following product development. However, it is a challenge to generate the realizable design concepts and then make a right decision because of involved multidisciplinary design and insufficient information. Lightweight design is a non- negligible and high priority subject in the concept design phase of electric vehicles. Combining the drive unit into suspension links is an effective engineering solution to achieve system lightweight while realizing the low increase of the unsprung mass. However, these questions arise from this idea: how the suspension concepts with integrated electric motors can be systematically generated and evaluated with consideration of complex functions, multiple design parameters and their intricate relationships? How an axle structure can be designed to be lightweight and suit this combined concept? How the ride dynamics of the vehicle with this suspension is evaluated? This thesis presents a design methodology for the development of suspension concepts in which links are combined with electric motors. Firstly, a new approach for concept design to integrating the functions based on the Axiomatic Design is proposed. In this approach, the integration process is formulaically and explicitly expressed by matrix equations. The system functions, corresponding parameters and their relationships can be investigated in the design matrices. This approach is then applied to the design of suspension concepts which integrate the functions of electric motors. The generated concepts are evaluated and selected by comparing their design matrices according to the Axioms introduced in Axiomatic Design. Subsequently, a reference suspension is tested and the parameters are used as the benchmark for the development of the suspension concept. The design matrix of the suspension concept is further to guide the subsequent engineering development. The design variables in the matrix are determined in the order in which the mathematical matrix equations are solved. To further reduce the system mass, a topological design approach considering the suspension kinematics and compliance is proposed for the design of suspension structure. On the basis of the structure topology, a lightweight linkage consisting of steel tubes with different thickness is achieved. The characteristics of the suspension concept are compared with the reference suspension. In order to investigate the vertical and roll dynamics of the concept suspension, an analytical model for the rear-axle vehicle dynamics and a road model for double lane irregularities in accordance with the ISO road standards are developed. These models can simulate the ride and roll dynamics of the target vehicle with the concept rear-axle on the ISO standard road surface. The ride dynamics with the new suspension is compared with the reference suspension. Contents ix Contents Acknowledgments ................................................................................................................................... iv Kurzfassung ................................................................................................................................................ v Abstract ...................................................................................................................................................... vii Contents ...................................................................................................................................................... ix List of Tables ............................................................................................................................................. xv List of Figures .........................................................................................................................................xvii Introduction ........................................................................................................................................1 Background ................................................................................................................................1 Overview of suspensions with integrated electric
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