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Objective Tyre Development Band 57 Quantification of Their Conflicts of Tyre Characteristics and Analysis and Definition Objective Tyre Development Peckelsen Ulrico 57 Band 57 Ulrico Peckelsen Objective Tyre Development Definition and Analysis of Tyre Characteristics and Quantification of their Conflicts Objective Tyre DevelopmentObjective Tyre U. Peckelsen U. Ulrico Peckelsen Objective Tyre Development Definition and Analysis of Tyre Characteristics and Quantification of their Conflicts Karlsruher Schriftenreihe Fahrzeugsystemtechnik Band 57 Herausgeber FAST Institut für Fahrzeugsystemtechnik Prof. Dr. rer. nat. Frank Gauterin Prof. Dr.-Ing. Marcus Geimer Prof. Dr.-Ing. Peter Gratzfeld Prof. Dr.-Ing. Frank Henning Das Institut für Fahrzeugsystemtechnik besteht aus den Teilinstituten Bahnsystemtechnik, Fahrzeugtechnik, Leichtbautechnologie und Mobile Arbeitsmaschinen. Eine Übersicht aller bisher in dieser Schriftenreihe erschienenen Bände finden Sie am Ende des Buchs. Objective Tyre Development Definition and Analysis of Tyre Characteristics and Quantification of their Conflicts by Ulrico Peckelsen Dissertation, Karlsruher Institut für Technologie KIT-Fakultät für Maschinenbau Tag der mündlichen Prüfung: 15. Mai 2017 Referenten: Prof. Dr. rer. nat. F. Gauterin, Prof. Dr. M. Gobbi Impressum Karlsruher Institut für Technologie (KIT) KIT Scientific Publishing Straße am Forum 2 D-76131 Karlsruhe KIT Scientific Publishing is a registered trademark of Karlsruhe Institute of Technology. Reprint using the book cover is not allowed. www.ksp.kit.edu This document – excluding the cover, pictures and graphs – is licensed under a Creative Commons Attribution-Share Alike 4.0 International License (CC BY-SA 4.0): https://creativecommons.org/licenses/by-sa/4.0/deed.en The cover page is licensed under a Creative Commons Attribution-No Derivatives 4.0 International License (CC BY-ND 4.0): https://creativecommons.org/licenses/by-nd/4.0/deed.en Print on Demand 2017 – Gedruckt auf FSC-zertifiziertem Papier ISSN 1869-6058 ISBN 978-3-7315-0713-0 DOI 10.5445/KSP/1000073428 Vorwort des Herausgebers Die Fahrzeugtechnik ist gegenwärtig großen Veränderungen unterwor- fen. Klimawandel, die Verknappung einiger für Fahrzeugbau und –betrieb benötigter Rohstoffe, globaler Wettbewerb, gesellschaftlicher Wandel und das rapide Wachstum großer Städte erfordern neue Mobilitätslösun- gen, die vielfach eine Neudefinition des Fahrzeugs erforderlich machen. Die Forderungen nach Steigerung der Energieeffizienz, Emissionsreduk- tion, erhöhter Fahr- und Arbeitssicherheit, Benutzerfreundlichkeit und angemessenen Kosten finden ihre Antworten nicht aus der singulären Verbesserung einzelner technischer Elemente, sondern benötigen Sys- temverständnis und eine domänenübergreifende Optimierung der Lösun- gen. Hierzu will die Karlsruher Schriftenreihe für Fahrzeugsystemtechnik ei- nen Beitrag leisten. Für die Fahrzeuggattungen Pkw, Nfz, Mobile Arbeits- maschinen und Bahnfahrzeuge werden Forschungsarbeiten vorgestellt, die Fahrzeugsystemtechnik auf vier Ebenen beleuchten: das Fahrzeug als komplexes mechatronisches System, die Fahrer-Fahrzeug-Interaktion, das Fahrzeug in Verkehr und Infrastruktur sowie das Fahrzeug in Gesell- schaft und Umwelt. Die Fahrzeugentwicklung nutzt immer stärker virtuelle Prototypen um schneller, flexibler und kostengünstiger auf die Anforderungen des Markts reagieren zu können. Bei dem Bauteil Reifen, der einen erhebli- chen Einfluss auf viele Gebrauchseigenschaften des Fahrzeugs hat, ist dies bislang noch nicht so gut gelungen, wie bei anderen Fahrzeugteilsyste- men. Dies hat seine Ursache vor allem in den komplexen Vorgängen im Rollkontakt, in dessen Einfluss auf die Dynamik der Reifenstruktur und des Luftraums im Reifeninneren sowie in den von vielen Einflussgrößen abhängen Materialeigenschaften. Physikalische Reifenmodelle sind i Vorwort des Herausgebers dadurch sehr umfangreich und rechenintensiv. Ein FEM-Modell eines Rei- fens mit seinem kompletten mehrlagigen Aufbau kommt selbst in verein- fachter geometrischer Darstellung schnell auf 106 Freiheitsgrade. Dabei werden fast immer vereinfachte Materialgesetzte verwendet. Um die Modelle dennoch im Entwicklungsprozess nutzen zu können, sind sie vielfach auf die Beschreibung einzelner Reifen-Gebrauchseigenschaf- ten zuggeschnitten. Ein einfaches Modell für die Beschreibung aller Ge- brauchseigenschaften des Reifens existiert nicht. Dieses wäre aber hilfrei- che, um die zahlreichen Zielkonflikte quantifizieren zu können, die in der Reifenentwicklung aufgrund des starken Einflusses des Reifens auf viele Gebrauchseigenschaften des Fahrzeugs bestehen. Hier setzt die Arbeit von Herrn Peckelsen an, in der er die Kette von Kon- struktionsparametern des Reifens über Kenngrößen des Gesamtreifens bis hin zu im Fahrmanöver am Fahrzeug erfassbaren objektiven und sub- jektiven Größen des Fahrverhaltens einbezieht. Über ein vereinfachtes physikalisches Modell ermittelt er die Zusammenhänge zwischen Reifen- gestaltungsparametern und Reifenkenngrößen, den Einfluss der Reifen- kenngrößen auf das Fahrzeugverhalten bildet er über statistisch ermit- telte Zusammenhänge ab. Aus der Betrachtung der gesamten Kette heraus quantifiziert er die Zielkonflikte zwischen vier ausgewählten Gebrauchs- eigenschaften des Fahrzeugs hinsichtlich des Einflusses der Reifengestal- tung. Frank Gauterin Karlsruhe, 24.7.2017 ii Objective Tyre Development Definition and Analysis of Tyre Characteristics and Quantification of their Conflicts Zur Erlangung des akademischen Grades Doktor der Ingenieurwissenschaften Der Fakultät für Maschinenbau Karlsruher Institut für Technologie (KIT) genehmigte Dissertation von M. Sc. Ulrico Peckelsen Tag der mündlichen Prüfung: 15.05.2017 Hauptreferent: Prof. Dr. rer. nat. F. Gauterin Korreferent: Prof. Dr. M. Gobbi Abstract The present thesis focuses on the tyre, especially on its influence on four requirements of the vehicle development, namely power loss, lateral dy- namics, ride comfort and interior noise. The objective of the thesis is the quantification of conflicts between four selected requirements consider- ing the physical constraints given by the tyre. The method proposed in the present thesis is based on a set of functional tyre characteristics (FTCs), a physical tyre model and a procedure for identifying and quantifying the conflicts. The FTCs are objective quantities that can be derived from tyre simulation or tyre measurement (e.g. verti- cal stiffness); they are a “common language” for communicating tyre char- acteristics. The physical tyre model and the proposed procedure allow to evaluate conflicts as a function of geometrical and material properties of the tyre. The method contributes in reducing time and costs of the tyre develop- ment; moreover, the know-how generated through the performed objec- tivation studies and sensitivity analyses supports decision-making during the virtual design of tyres as well as vehicle architecture, axle kinematics and wheel-suspension system characteristics. v Kurzfassung Der Fokus der vorliegenden Dissertation liegt auf dem Reifen, insbeson- dere auf seinem Einfluss auf vier Anforderungen in der Fahrzeugentwick- lung, nämlich der Rollwiderstandsverlustleistung, der Querdynamik, der Vertikaldynamik und dem Innengeräusch des Fahrzeugs. Ziel der Disser- tation ist die Quantifizierung der Zielkonflikte zwischen den Anforderun- gen. Diese Zielkonflikte entstehen aufgrund der durch den Reifen gegebe- nen physikalischen Randbedingungen. Die vorgestellte Methode fußt auf einem Set an funktionalen Reifeneigen- schaften (functional tyre characteristics, FTCs), einem physikalischen Rei- fenmodell und einem Prozess zur Identifizierung und Quantifizierung der Zielkonflikte. Die FTCs sind objektive Eigenschaften, deren Werte von ei- nem virtuellen Reifenmodell oder einer Reifenmessung abgeleitet werden können (z. B. eine Vertikalsteifigkeit); sie stellen folglich eine „gemein- same Sprache“ für die Kommunikation der Reifeneigenschaften dar. Das physikalische Reifenmodell und der vorgestellte Prozess ermöglichen es die Zielkonflikte und deren Abhängigkeit von geometrischen und Materi- aleigenschaften des Reifens zu berechnen und visualisieren. Die Methode trägt dazu bei, Zeit und Kosten der Reifenentwicklung zu re- duzieren. Darüber hinaus unterstützen die durch Objektivierungsstudien und Sensitivitätsanalysen gewonnen Erkenntnisse die Konzeptauswahl und –gestaltung von Reifen, sowie die virtuelle Grundauslegung der Fahr- zeug-, Achs, und Federdämpfungsarchitektur in der frühen Entwicklungs- phase. vii Acknowledgement The present thesis addresses several topics and different requirements of the tyre: from statistic methods for DoE to physical modelling of tyres, from power loss and lateral dynamics to ride comfort and interior noise phenomena. Therefore, strong collaborations with different departments and experts were needed. In the following, I would like to thank all those colleagues and friends who played an important role during the thesis pe- riod, well-knowing that a lot more contributed in shaping it. First of all, I would like to thank the colleagues of the tyre development department, especially those who participated in long-lasting studies at the test track and at the driving simulator: C. Vogt, T. Beck, G. Mülbl, H. Dreier, P. Wagner and R. Rapp as well as D. Bode and R. Högl. The oppor- tunity to share knowledge and skills concerning vehicle dynamics and tyre development was of great help! Furthermore, a big thank goes to the colleagues of the simulation and the NVH departments. Dr. F. Niedermeier and Dr. M. Zimmermann had been perfect feedback partners concerning virtual tyre development; N. Reissig, T. Heinker,
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