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Model Based Suspension Calibration for Hybrid Vehicle Ride and Handling Recovery

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Model Based Suspension Calibration for Hybrid Vehicle Ride and Handling Recovery Model Based Suspension Calibration for Hybrid Vehicle Ride and Handling Recovery THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Matthew Joseph Organiscak, B.S. Graduate Program in Mechanical Engineering The Ohio State University 2014 Thesis Committee: Dr. Giorgio Rizzoni, Advisor Dr. Shawn Midlam-Mohler Dr. Jeffrey Chrstos Copyright by Matthew Joseph Organiscak 2014 ABSTRACT Automotive manufacturers spend many years designing, developing, and manufacturing each new model to the best of their ability. The push to shorten the time of a design cycle is motivated by reducing development costs and creating a more competitive advantage. Model based design and computer simulations have an increasing presence in the automotive industry for this reason. In the automotive industry, current ride and handling tuning methods are subjective in nature. There are few, if any, objective evaluations of the vehicle ride and handling performance. EcoCAR 2 is a three year collegiate design competition, in which 15 teams compete to develop a vehicle with lower petroleum consumption and fewer emissions. The teams begin the task with a 2013 Chevrolet Malibu and are challenged with maintaining consumer acceptability. The stock vehicle has been modified greatly by removal of the stock powertrain and battery system. Nearly 900 lbs of batteries and supporting components have been added to the trunk of the car along with an electric motor and single speed transmission. This change in vehicle mass has led to issues with poor ride and handling performance. Model based calibration of the suspension dampers can be seen as a method to recover some of the lost performance. A CarSIM Model of the vehicle was developed after numerous measurements involving a vehicle inertial measurement facility as well as a kinematics and compliance test from a ii suspension parameter measurement device. The CarSIM model was validated using experimental testing data. The vehicle was subjected to several different tests including a steady state handling test, transient handling test, and a ride test. To understand how different damper curve parameters would affect the performance of the vehicle, a design of experiments was developed using CarSIM to obtain the outputs. The seven objective metrics based on passenger comfort were used to create seven response surface equations based on the results of the DOE. Once the response surface equations are validated and considered to be accurate enough to be useful, a minimization optimization was performed to determine what inputs will return the lowest output value from each response surface. The individual response surface equation minimization showed that it was able to decrease uncomfortable accelerations and pitch motions while maintaining a vehicle that is easy to drive through transient handling maneuvers. iii DEDICATION To my loving parents who have dedicated most of their lives to me, let all my accomplishments also be yours iv ACKNOWLEDGEMENTS I would like to thank, Dr. Shawn Midlam-Mohler, Dr. Rizzoni, and Dr. Jeff Christos for their guidance and patience throughout this project and other EcoCAR related projects throughout my career at The Ohio State University. Their support through these projects was crucial to the success of many students like myself at the Center for Automotive Research. I would like to thank David Emerling for setting me up with many industry sponsors that have made this project possible. I would like to thank everyone on the EcoCAR 2 team for their camaraderie, support, and drive to compete at a high level I would like to thank Gary Heydinger, Anmol Sidhu, Jonathan Coyle, and Hank Jebode at SEA Limited for their help in measuring the EcoCAR 2 vehicle. This is an enormous task and few students are able to have such strong resources dedicated to them I would like to thank Tom Mallin and Craig Jennings at Tenneco for their support and professional knowledge on the subject of dampers and damper tuning. v I would like to thank Nick Stucky, Pat Majors, Seewoo Lee, Tim Donley and Adam Homan for their support of the EcoCAR 2 program and the tire data measured for the sole purpose of my project. I would like to thank Mike Neal, Mike Leduk and Ed Argalas for providing me with professional inside on ride and handling tuning as well as important vehicle data used in my model development I would like to thank my friends from the racing world: Shawn MacNealy, Patrick Moro, and David Stacy for providing me with help when I needed it the most. Lastly, I would like thank my friends and family for their patience and support during the most stressful times in my life. vi VITA June 2008 ..........................................................Dublin Coffman High School December 2012 .................................................B.S. Mechanical Engineering, The Ohio State University January 2013 to Present ...................................Graduate Research Associate, Department of Mechanical Engineering, The Ohio State University PUBLICATIONS K. Bovee, A. Hyde, M. Yard, M. Organiscak, E. Gallo, A. Huster, A. Garcia, M. Yatsko, J. Ward, S. Midlam-Mohler and G. Rizzoni, "Fabrication of a Parallel-Series PHEV for the EcoCAR 2 Competition," SAE, 2013-01-2491. K. Bovee, A. Hyde, M. Yard, T. Trippel, M. Organiscak, A. Garcia, E. Gallo, M. Hornak, A. Palmer, J. Hendricks, S. Midlam-Mohler and G. Rizzoni, "Design of a Parallel- Series PHEV for the EcoCAR 2 Competition," SAE, 2012-01-1762. FIELDS OF STUDY Major Field: Mechanical Engineering vii TABLE OF CONTENTS ABSTRACT ...................................................................................................................... II DEDICATION................................................................................................................. IV ACKNOWLEDGEMENTS ............................................................................................ V VITA............................................................................................................................... VII TABLE OF CONTENTS ............................................................................................ VIII LIST OF TABLES ....................................................................................................... XIII LIST OF FIGURES ..................................................................................................... XIV CHAPTER 1: INTRODUCTION .................................................................................... 1 1.1 Introduction ................................................................................................................. 1 1.2 EcoCAR 2 Competition .............................................................................................. 1 1.3 EcoCAR 2 Architecture .............................................................................................. 4 viii 1.4 Motivation .................................................................................................................... 5 CHAPTER 2: LITERATURE REVIEW AND BACKGROUND.............................. 10 2.1 Introduction ............................................................................................................... 10 2.1.1 Un-damped Ride Theory...................................................................................... 11 2.1.2 Damped Ride Theory ........................................................................................... 12 2.2 Subjective Handling Tuning .................................................................................... 13 2.3 Objective Handling Tuning Combined Approach ................................................. 15 2.4 Objective Ride Quality ............................................................................................. 15 2.5 Simulated Objective Transient Handling ............................................................... 16 CHAPTER 3: VEHICLE MEASUREMENT AND CHARATERIZATION ........... 17 3.1 Purpose of Vehicle Measurement ............................................................................ 17 3.2 Vehicle Inertial Measurement ................................................................................. 17 3.3 Suspension Parameter Measurement ...................................................................... 19 3.4 Auxiliary Wheel Rate Measurement ....................................................................... 21 3.5 Tire Measurement ..................................................................................................... 25 3.6 CarSIM ...................................................................................................................... 27 ix 3.7 Vehicle Testing .......................................................................................................... 28 3.7.1 Steady State Turn Testing .................................................................................... 32 3.7.2 Transient Testing ................................................................................................. 34 3.7.3 Ride Testing ......................................................................................................... 35 3.8 Damper Tuning ......................................................................................................... 37 CHAPTER 4: INITIAL VEHICLE ASSEMENT ....................................................... 41 4.1 Baseline Vehicle Assessment
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