Implementation of a Control Concept for the Car-in-the-Loop Test Rig - - PowerPoint PPT Presentation

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Implementation of a Control Concept for the Car-in-the-Loop Test Rig - - PowerPoint PPT Presentation

Dec 19, 2022 212 likes •490 views

Implementation of a Control Concept for the Car-in-the-Loop Test Rig on the IPG Xpack4 Real-Time Target Kevin Engleson Control Concepts for the Car-in-the-Loop Test Rig | Institut fr Mechatronische Systeme im Maschinenbau | Kevin Engleson

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 1

Implementation of a Control Concept for the Car-in-the-Loop Test Rig on the IPG Xpack4 Real-Time Target

Kevin Engleson

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 2

Overview 1. Introduction 2. Car-in-the-Loop Test Rig 3. IPG Xpack4 Real-Time Target 4. Controller Concepts

  • Wheel Speed Controller
  • Steering Angle Controller

5. C-Code Generation and IPG CarMaker Implementation 6. Results 7. Conclusion 8. Questions

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 3

Introduction

  • Numerous advancements in regards to safety and efficiency of a

vehicle’s powertrain and suspension components

  • Many of these new developments incorporate mechatronic systems [1]
  • The implementation of mechatronic

systems is resulting in much higher complexity

  • Hardware-in-the-Loop (HiL) systems

allow automotive manufactures to test and validate the electrical, mechanical, and control concepts [3] [2]

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 4

Car-in-the-Loop Test Rig

  • Car-in-the-Loop (CiL) Test Rig built by the Institute for Mechatronic

Systems (IMS) at the Technische Universität Darmstadt [4]

  • Quarter-car section of a Mini Countryman provided by BMW
  • Validate driving forces from test track data or computer simulations
  • Advantages:
  • Elimination of

safety concerns during prototype testing

  • Independence

from weather conditions

  • Higher test

repeatability

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 5

Xpack4 Real-Time Target

  • The Xpack4 Real-Time Target provided by IPG
  • Test platform with multiple processor cores for increased performance
  • Compact PCI terminals for increased flexibility with interchangeable

modules based on test requirements [7]

  • Embedded coder implementation
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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 6

Controller Concepts

  • Overall goal is the implementation of controller concepts which regulate

the wheel speed and steering angle of the CiL in real-time

  • Physical system must be modeled within a closed control loop
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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 7

Wheel Speed Controller

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 8

Wheel Speed Controller (Continued)

− = 1 −1 − Ꝋ − − Ꝋ

  • Ꝋ
  • Ꝋ
  • Ꝋ

(−−) Ꝋ − + 1 Ꝋ 1 Ꝋ

  • +
  • Ꝋ

−1 Ꝋ − Ꝋ

  • = 0

1 −

  • ẋ = Ax + Bu (Linear)

Ez (Non-linear) y = Cx

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 9

Wheel Speed Controller (Continued)

  • Pole locations on the Pole-Zero Map suggest border stability for the linear

component of the state-space representation

  • Controller must increase the stability margins of the poles to compensate for the

non-linear influences, as well as disturbances from the AM

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 10

Wheel Speed Controller (Continued)

  • Non-collocated system

suggests need for observer and pole placement controller [5]

  • Matrices A, B, C, and E are

direct substitutions from the state-space representation

  • Matrices V, K, and L are

left to be calculated based

  • n the desired

performance of the system

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 11

Steering Angle Controller

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 12

Steering Angle Controller (Continued)

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 13

Steering Angle Controller (Continued)

  • P cascade controller is effective at combating instability caused by double

poles at the origin [6]

  • Simple system dynamics allow a linear

assumption

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 14

Sensors

  • Vehicle states are measured to provide

valuable input information into the mechatronic systems

  • Further measured states for analysis of

controller implementation

  • Optical Encoder located at wheel hub
  • Torque Sensor located on side shaft
  • Load Cell in-line with tie-rod
  • Load Cell in-line with vertical adjustment
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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 15

C-Code Generation and IPG CarMaker Implementation

  • Implementation of the control concepts into the IPG CarMaker software is

dependent on the generation of C-code from the developed Simulink control models

  • C-code generation is completed within the Simulink Model Configurator
  • Important that the code generation parameters coincide with the implementation

target, in this case the Xpack4

  • Interchangeable modules known as M-Modules for Xpack4 [7]
  • M401

(Encoder Signals)

  • M62

(Analog Outputs)

  • M36N

(Analog Inputs)

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 16

C-Code Generation and IPG CarMaker Implementation (Continued)

  • Within IPG CarMaker there are two user accessible modules of interest
  • User.c
  • Additional program functionality
  • IO.c
  • Communication with HiL components
  • Individual code sections called at different

times within the overall CarMaker simulation execution

  • Global Parameters at beginning of code
  • IO_Init() function for initialization of modules
  • IO_Out() function for HiL communication

[7]

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 17

Results (Video)

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 18

Results (Wheel Speed Controller)

  • Goal of control is a

deviation of no more than 5% from CarMaker setpoint

  • Measured deviation is

consistent around 5%

  • Area of concern within

the first 2 seconds of the simulation

  • Wheel Slip occurs

during acceleration resulting in deviation peak

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 19

Results (Wheel Speed Controller Continued)

  • Goal of control is a

torque with scaled magnitude but follows CarMaker trend

  • After applying a re-

scaling factor, the results almost perfectly overlay

  • Further support wheel

speed controller performance

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 20

Results (Wheel Speed Controller Continued)

  • Goal of control is a

torque with scaled magnitude but follows CarMaker trend

  • After applying a re-

scaling factor, the results almost perfectly overlay

  • Further support wheel

speed controller performance

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 21

Results (Steering Angle Controller)

  • Goal of control is a

deviation of no more than 5% from CarMaker setpoint

  • Measured deviation is

consistent around 3%

  • Wheel slip does not

affect steering angle, therefore no peaks within deviation

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 22

Results (Steering Angle Controller Continued)

  • Goal of control is a

scaled force which follows CarMaker trend

  • Trending of the

measured data does not correlate with CarMaker values

  • Suggests further

tuning is required for desired steering angle controller performance

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 23

Conclusion

  • In conclusion, the wheel speed controller operates within the 5%

deviation threshold

  • Side shaft torque value, after re-scaling, replicates almost exactly the

CarMaker calculated value

  • Steering angle controller operates within the 5% deviation threshold at a

more accurate 3% deviation

  • Tie-rod force value suggests further tuning of AML performance from the

steering angle controller in order to exhibit correctly trending data

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 24

Questions

Thank you for your attention. Questions?

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 25

Sources [1]

  • Prof. Dr. H. Winner. Kraftfahrtzeugtechnik, Winter 2015.

(Technische Universität Darmstadt). Print. [2] "ZF Technology for Cars." Cars. http://www.zf.com/corporate/en_de/products/product_range/cars/c ars_7_speed_dual_clutch_transmission.shtml Web. 25 Aug. 2016. [3] National Instruments. "Hardware-in-the-Loop (HIL)." Hardware-in- the-Loop (HIL) - National Instruments. Web. 25 Aug. 2016. [4] Fietzek, Rafael. "Modellbildung, Regelung und Realisierung eines neuartigen Konzepts für einen Gesamtfahrzeugprüfstand." Technische Universität Darmstadt, Diss, 2014. Print. [5] Fietzek, Rafael, and Stephan Rinderknecht. "Observer Validation and Model Based Control of a Two Mass Oscillator with Backlash." 2013 IEEE International Conference on Mechatronics and Automation, 2013. Web.

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Control Concepts for the Car-in-the-Loop Test Rig | Institut für Mechatronische Systeme im Maschinenbau | Kevin Engleson | 26

Sources (Continued) [6]

  • Prof. Dr.-Ing. U. Klingauf. Systemtheorie und Regelungstechnik,

Summer 2016. (Technische Universität Darmstadt). Print. [7] IPG Automotive GmbH. Programmer's Guide. Version 5.0.1, 2015. Print.