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 2

Motivation for Active Safety Systems on Bicycles Front wheel lockup • Low wheel moment of inertia Bicycle braking • Risk of overbraking systems Electrified • Mainly on roads with low • Properly adjusted: bicycles friction coefficient & in curves always very powerful • Modern hydraulic technology: • Availability of electric energy Nose over stronger and more robust • Favourable mass & cost ratio (falling over the handlebars) • High risk of falling due to • High centre of gravity users’ mistakes • Emergency or shock braking • Mainly on roads with high friction coefficient & downhill 3 Sources: Gustav Magenwirth GmbH, Robert Bosch GmbH

Vision Functional Prototype Actuator • Purpose: brake pressure modulation • Hydraulic unit of motorcycle ABS Control unit • Purpose: algorithm development • Rapid ‐ control ‐ prototyping system Sensors • Measurand: front wheel speed • Active sensor based on Hall Effect • Measurands: 1) longitudinal and vertical accelerations 2) pitch rate • Micromechanical sensor unit 4

Mechatronic Structure of the Braking Dynamics Assistance System (BDA) Driver Environment u D z u y x r Controller Actuators Plant Sensors 5

Methodology of Development Requirements Profile Proof of Concept ① ⑤ Validation Accident research and Functional model respective applications evaluation ② ④ Validation Requirements System integration identification and and testing quantification ③ System design and implementation 6

Structure of HiL ‐ Testbench Xeno Realtime ‐ User ‐ PC Computer Parameters, Stimuli Measurement Values Simulation Bicycle CarMaker Model Measurement Sensor Signals BDA ‐ Values Experiment Function I/O Modules Measure ‐ Brake ment Actuation Hardware ‐ Values dSPACE MAB Installation Brake System Bosch Hydraulic Pneumatic Control Brake HU System 7 Signals HU

Simulation Model Equation ‐ based Physical Multi ‐ Body 4 DoF 13 DoF Model with three Model Bodies  Software: Simulink  Software: SimHydraulics/ SimMechanics  Features:  Extensions:  Static effects of hydraulic brake system  Dynamic effects of brake hydraulic  Plain movement (longitudinal and vertical)  Repeated rear ‐ wheel lift ‐ off  Driver is modeled as a point mass  Movement of driver during brake process  Code generation and cross compilation fully  Code generation and cross compilation supported supported except for tyre model 8

Real ‐ Time Computer & M ‐ Modules M400 M62N M36N00 M51 WheelSpeed Analog Outputs Analog Inputs 4x CAN  Pressure sensors  Front ‐ and  Measurement  Brake force  Acceleration sensors Rear ‐ Wheel Trigger Measurement  60 Teeths  Brake lever Sensor  Lift ‐ Off Sensor 9

HiL ‐ Testbench Battery Charge amplifier Brake force sensor Real time computer RCP System Brake lever 10

Video of automated braking system Pressure: 100bar Gradient: 1000bar/s Controllable movement Conditions can be reproduced 11

Usage in Development Real Experiment MiL HiL • • Wheel Speed Signal Analysis Cover a wider parameter space • under real conditions Reproducibility • Investigation of hydraulic brake system (especially HU) 12

Results – BDA ‐ Function not engaged 13

Results – BDA ‐ Function engaged 14

Conclusion – Usage of HIL for development of a BDA function  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 15

Thank you for your attention! 16