Bicycle Hardware in the Loop Simulator for Braking Dynamics - - PowerPoint PPT Presentation

Bicycle Hardware‐in‐the‐Loop Simulator for Braking Dynamics Assistance System

IPG Apply & Innovate 2016 Conference Session: Off‐Highway Cornelius Bott, Martin Pfeiffer, Oliver Maier, Jürgen Wrede 21.09.2016

Outline Introduction to BikeSafe Motivation Vision Methodology HIL Testbench Structure and Components Usage in Development Results Conclusion

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Motivation for Active Safety Systems on Bicycles

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• Low wheel moment of inertia
• Risk of overbraking
• Mainly on roads with low

friction coefficient & in curves

Front wheel lockup

• High centre of gravity
• Emergency or shock braking
• Mainly on roads with high

friction coefficient & downhill

Nose over

(falling over the handlebars)

• Properly adjusted:

always very powerful

• Modern hydraulic technology:

stronger and more robust

• High risk of falling due to

users’ mistakes

Bicycle braking systems

• Availability of electric energy
• Favourable mass & cost ratio

Electrified bicycles

Sources: Gustav Magenwirth GmbH, Robert Bosch GmbH

Vision Functional Prototype

• Purpose: algorithm development
• Rapid‐control‐prototyping system
• Purpose: brake pressure modulation
• Hydraulic unit of motorcycle ABS
• Measurands: 1) longitudinal and vertical accelerations

2) pitch rate

• Micromechanical sensor unit

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Control unit Actuator

• Measurand: front wheel speed
• Active sensor based on Hall Effect

Sensors

Mechatronic Structure of the Braking Dynamics Assistance System (BDA)

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Environment Plant Actuators Controller Driver Sensors u y x r z uD

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Methodology of Development

Proof of Concept Functional model evaluation System integration and testing ④ Requirements Profile Accident research and respective applications ① Requirements identification and quantification ② ⑤ System design and implementation ③ Validation Validation

Structure of HiL‐Testbench

User‐PC dSPACE MAB

Sensor Signals Brake Actuation Parameters, Stimuli Measurement Values Simulation BDA‐ Function Measure‐ ment Values Brake System Control Signals HU Measurement Values Experiment

Hardware‐ Installation

Bosch HU Hydraulic Brake Pneumatic System

Xeno Realtime‐ Computer

CarMaker I/O Modules Bicycle Model

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Simulation Model

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• Software: SimHydraulics/ SimMechanics
• Extensions:
• Dynamic effects of brake hydraulic
• Repeated rear‐wheel lift‐off
• Movement of driver during brake process
• Code generation and cross compilation supported

except for tyre model

• Software: Simulink
• Features:
• Static effects of hydraulic brake system
• Plain movement (longitudinal and vertical)
• Driver is modeled as a point mass
• Code generation and cross compilation fully

supported 13 DoF

Physical Multi‐Body Model

4 DoF

Equation‐based Model with three Bodies

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Real‐Time Computer & M‐Modules

M400 WheelSpeed M62N Analog Outputs M36N00 Analog Inputs M51 4x CAN

• Front‐ and

Rear‐Wheel

• 60 Teeths
• Measurement

Trigger

• Lift‐Off Sensor
• Brake force

Measurement

• Brake lever Sensor
• Pressure sensors
• Acceleration sensors

HiL‐Testbench

Real time computer RCP System Brake force sensor Charge amplifier Brake lever Battery

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Video of automated braking system

Pressure: 100bar Gradient: 1000bar/s Controllable movement Conditions can be reproduced

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Usage in Development

MiL HiL Real Experiment

• Wheel Speed Signal Analysis

under real conditions

• Investigation of hydraulic brake

system (especially HU)

• Cover a wider parameter space
• Reproducibility

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Results – BDA‐Function not engaged

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Results – BDA‐Function engaged

Conclusion – Usage of HIL for development of a BDA function

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 Requirements for BikeSafe function development were met  Very useful for investigation of Brake System and HU  Good validation of BDA function before real experiments  Limitations of BDA function could be accessed  Transfer of known method to a new domain

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Thank you for your attention!