mechatronische systeme fÜr kraftfahrzeuge · mechatronische systeme fÜr kraftfahrzeuge...

R. I.TU Darmstadt 2005

MECHATRONISCHE SYSTEME MECHATRONISCHE SYSTEME FÜR KRAFTFAHRZEUGEFÜR KRAFTFAHRZEUGE

(Automotive (Automotive MechatronicsMechatronics ))

Prof. Dr.Prof. Dr.--IngIng. R. . R. IsermannIsermann

Institut für AutomatisierungstechnikTechnische Universität Darmstadt

R. I.TU Darmstadt

AUTOMOTIVE MECHATRONICSAUTOMOTIVE MECHATRONICS

• INTRODUCTION

• DESIGN PROCEDURE

• HISTORICAL DEVELOPMENT

• MECHATRONIC SUSPENSIONS

• MECHATRONIC BRAKE SYSTEMS

• MECHATRONIC STEERING SYSTEMS

• ACTIVE FRONT STEERING CONTROL

• CONCLUSIONS

2005

R. I.TU Darmstadt

Mechatronics: Synergetic integration of different d isciplines

MECHATRONICS

informationtechnology

system theorymodelingautomation technologysoftwarecomputational intelligence

electronics

micro electronicspower electronicssensorsactuators

mechanics

mechanical elementsmachinesprecision mechanics

R. I.TU Darmstadt

sensors

measuredvariables

Mechanical process and information processing devel op towards mechatronic systems

mechanics &energy converter

mechanicalhydraulicthermal

electrical

energy flow

energysupply

energycon-

sumer

monitoredvariables

referencevariables

manipulatedvariables information flow

man/machineinterface

informationprocessing

actua-tors

auxiliaryenergysupply

R. I.TU Darmstadt

o Definition

• Many technical processes and products show an increasingintegration of MECHAnics with elecTRONICS and informationprocessing

• The integration is between the components (hardware) and theinformation-driven functions (software)

• Their development involves finding– an optimal balance between the basic mechanical structure, sensor and

actuator implementation– automatic digital information processing– overall control

• This synergy results in innovative solutionsIFAC T.C. Mechatronic Systems (2000)

R. I.TU Darmstadt

MechatronicSystems

Mechatronicmotion

generators

- integratedelectricalservo drives

- integratedhydraulicservo drives

- integratedpneumaticservo drives

- robots(multi-axis,mobile)

Mechatronicmachine

components

- semi-activehydraulicdampers

- magneticbearings

- automaticgears

Mechatronicpower

producingmachines

- brushless DCmotors

- integrated ACdrives

- mechatroniccombustionengines

machine tools

- integratedmulti-axis

- integratedhydraulicpumps

Mechatronicpower

consumingmachines

Mechatronicautomobiles

- antilock brake(ABS)

- electro-hydraulicbrake (EHB)

- activesuspension

- active frontsteering

Mechatronictrains

- tilting trains- active boogie- magnetic

levitated

(MAGLEV)trains

Examples for mechatronic systems

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o Functions and integration of mechatronic systems

• Distribution of functions• Operating properties• New functions• Integration forms

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• New functions– Control of nonmeasurable variables

• Tire slip• Slip angle and ground speed of vehicles• Internal temperatures or tensions• Damping parameters

– Advanced supervision and fault diagnosis– Fault-tolerant systems with redundancy– Teleservice functions

• monitoring, maintenance, repair

– Programmable functions• flexible adaptation through software change• changes during design, commissioning, after-sales• shorter time-to-market

R. I.TU Darmstadt

• Integration forms- consideration of integrated overall systemgeneration of synergetic effects→ classical mechanical-electronic system :

“addition of available components”

micro-computer actuators process sensors

integration of components

R. I.TU Darmstadt

Spatial integration (integration of the components)

“Integration of the components at different places”

� actuator and microcomputer� smart actuator

� process and microcomputer� sensor and microcomputer

� smart sensor

micro-computer

actuators process sensors


Hardware-Integration

R. I.TU Darmstadt Mechatronic overall integration

supervisiondiagnosis

adaptationoptimizationcontrol

online information processing

knowledge baseintegration by information processing

mathematicalprocess models

performancecriteria

information gaining- identification- state observer

design methods- control- supervision- optimization

software-integration

micro-computer

actuators process sensors


hardware-integration

R. I.TU Darmstadt

Runge, ATZ 2000

Mechatronic control module for a 6-gear-automatic tr ansmission(ZF 6HP26)

R. I.TU Darmstadt

128k

Byt

e

ABS 2ABS 2

6,2 kg

ABS 5.0ABS 5.0

3,8 kg

ABS 5.3ABS 5.3

2,6 kg

ABSR 5.7ABSR 5.7

2,5 kg

ABS 8ABS 8

1,8 kg

Tend

enz

stei

gend

!

48kB

yte

24kB

yte

16kB

yte

8kB

yte

1989 1992 1995 1998 2001

3

6

kg kByte200

100

History of ABS Systems

Rob. Bosch GmbH

Anti-lock braking systems (ABS)

R. I.TU Darmstadt

Quelle:ATZ/MTZ Extra „Der Neue Golf“ Oktober2003

Direct automatic shift gear box with double clutch (2003)

Volkswagen

R. I.TU Darmstadt


Electro-hydraulic control system for DSG

Volkswagen

R. I.TU Darmstadt

AUTOMOTIVE MECHATRONIC SYSTEMSAUTOMOTIVE MECHATRONIC SYSTEMS

• INTRODUCTION







• CONCLUSIONS

2005

R. I.TU Darmstadt

DESIGN PROCEDURE FOR MECHATRONICSYSTEMS

o Mechatronic engineeringo Modelling and simulationo Software tools

R. I.TU Darmstadt

Design procedure for mechatronic systems (iterationa l steps not indicated )

systemdefinition

requirementsengineering

(specification)

mechanical& electricalengineering

electronicengineering

information& control

engineeringoperating

engineering

process/component

design

electronichardware

design

inform. proc-cessing & soft-

ware design

human-ma-chine inter-face design

traditionalengineering

integration of components(hardware)

integration by informationprocessing (software)

integrated(concurrent)engineering

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reliability &safety

engineering

manufacturingengineering

mechatronicsystem

Design procedure for mechatronic systems (iterationa l steps not indicated)

integrated(concurrent)engineering

integration of components(hardware)

integration by informationprocessing (software)

integrated mechan.electronic systemgeneration of

synergeticeffects

R. I.TU Darmstadt

o Modelling and Simulation for design and integratio n:

– Software-in-the-loop simulation (SiL)• Process and controller (ECU) simulated (not real-time)

– Rapid-control-prototyping (RCP)• Real process and high-performance prototyping computer (real-time)

– Hardware-in-the-loop simulation (HiL)• Simulated process and real ECU (real-time)

R. IsermannTU Darmstadt

real process real ECU + real actuator

RCP

SiL

integratedmechatronic

system

HiL

process-model

simulation tool

θFW

nengT2,stat T2

p2,stat p2

ECU-model

high performancereal-time computer

(full pass, by pass)

θFW

neng

p 2,Setpoint

p 2

controlalgorithm

u pwm

Simulations for mechatronic development

real-time

real-time

R. I.TU Darmstadt

Diesel engines

Truck engine Passenger car engine

R. I.TU Darmstadt

Hardware-in-the-Loop Simulator für truck engine controlHardware-in-the-Loop Simulator für truck engine control

HiL-Simulator, dSpace DSP & Power PC

IAT/DC1992-1999

R. I.TU Darmstadt HiL-simulation of a single injection pump valve cut off

R. I.TU Darmstadt HiL-simulation of a full power acceleration of a 40 tons truck

1 gear shifts

2 drive train oscillations

3 soot limitation

4 speed limitation

5 turbo charger inertness

R. I.TU Darmstadt


• INTRODUCTION







• CONCLUSIONS

2005

R. I.TU Darmstadt

Anti-skid control (1993)Acceleration sensor

Anti-lock brake system(1979)

Wheel speed sensor

Electronic stability progr.(1995)Yaw rate sensor

Active Body Control(2000)

Susp.deflect.

Adaptive Cruise Control(1999)

Radar sensor

Steer-by-Wire(20??)

Figures: Continental Teves AG & Co. oHGCollision Avoidance

(20??)

Brake assist(1996)

EMB-force sensor

Brake-by-Wire (EHB )(2001)

Active front steering (2003 )

EHB-pressure

Pedal position

Brake-by wire (20??)

Vehicle dynamics control systems

R. I.TU Darmstadt

Sensors and Sensors and actuatorsactuators forfor gasolinegasoline enginesengines

� Electronic fuel injection(1967, D-Jetronic)

� Microelectroniccontrolled ignition and injection(1979, Motronic)

� Exhaust gas valve

� Tank vent valve

� Secundary air valve(1994)

� Variable geometrymanifold

� Electronic throttle (1997)

� Variable camshafttiming

� Variable valve lift(2001)

Actuators� Engine speed (1967),

camshaft phase

� Engine temperature (1967)

� Manifold pressuremanifold temperature (1967)

� Knock sensor (1969)

� Airmass flap (1973)

� Oxygen (lambda) (1976)

� Airmass hot-film (1981)

� Ambient pressure

� Throttle- and pedal-position(1997, E-Gas)

� Tank pressure

� Ion current (20??)

� Combustion pressure (20??)

Sensors

Abbildung: Adam Opel AG

�ca. 15-25 measurements

�ca. 6-8 manipulation variables

�ca. 80-120 look-up-tables

Sensors and actuators for gasoline engines

R. I.TU Darmstadt

Mechatronicautomobiles

Mechatroniccombustion

engines

- electricalthrottle

- mechatronicfuel injection

- mechatronicvalve trains

- variable geo-metry turbo-charger (VGT)

- emission control- evaporative

emission control- electrical pumps

& fans

Mechatronicdrivetrains

- automatichydrodynamictransmission

- automaticmechanicshift transm.

- continuouslyvariable trans-mission (CVT)

- automatic tractioncontrol (ATC)

- automatic speedand distance control (ACC)

Mechatronicsteering

- parameter-izable power-assistedsteering

- electro-mechanical power-assistedsteering (EPS)

- active frontsteering (AFS)

Mechatronicbrakes

- hydraulic anti-lock braking (ABS)

- electronic stabilityprogram (ESP)

- electro-hydraulicbrake (EHB)

- electro-mechanicalbrake (EMB)

- electrical parkingbrake

Mechatronicsuspensions

- semi-activeshock-absorbers

- active hydraulicsuspension(ABC)

- active pneumatic suspension

- active anti-roll bars (dynamic drive control (DDC) or roll-control)

R. I.TU Darmstadt Control units and data exchange

40 - 75 Electronic Control Units30 - 150 electrical motors2- 4 km cables (harness): 40 - 80 kg4 bussystems2500 signals

Source: VDA 2001

R. I.TU Darmstadt

Bordnetz des VW Phaeton

Quelle: ATZ Sonderheft VW Phaeton

VW Phaeton: Elektrisches Bordnetz

R. I.TU Darmstadt


• INTRODUCTION







• CONCLUSIONS

2005

R. I.TU Darmstadt

Stabilisation through single wheel braking with ESP

VDA 2001

R. I.TU Darmstadt

Electro-Hydraulic Brake System

VDA 2001

R. I.TU Darmstadt

EHB1 Hydraulic Unit Components

Suction connectionSealings for pressure sensor modul

Contact springPressure sensor modul

ECU

Sealing for ECUMagnet group

Valve

Medium separatorPump element

Accumulator withmultilayer diaphragm

Electric motor

Rob. Bosch GmbH

Electrohydraulic brake

R. I.TU Darmstadt

Chassis SystemsElectro Hydraulic Brake System EHB1

Rob. Bosch GmbH

R. I.TU Darmstadt

Continental Teves (2003)

Electro-mechanical brake (prototype)

R. I.TU Darmstadt


• INTRODUCTION







• CONCLUSIONS

2005

R. I.TU Darmstadt

ElectricalPower Steering

(EPS)

Electrical PowerAssisted Steering

(HPS + EPS)

Active FrontSteering

(AFS)

Mechatronic steering systems

HydraulicPower Steering

(HPS)

hydraulicactuator

hydraulicpump

hydraulicvalve

HydraulicPower Steering

(HPS)

ElectricalPower Steering

(EPS)

electricalactuator

electricalactuator

in steering column

Electrical PowerAssisted Steering

(HPS + EPS)(larger vehicles)

hydraulicactuator

hydraulicactuator

Active FrontSteering

(AFS)

electricalactuator

generates additionalsteering angles

electricalsteering

torque motorfor hapticfeedback

Steer-by-Wire

(SbW)

electricalactuator

R. I.TU Darmstadt

Servomotor

ECU

Steer pinion

Torque sensor

Torsion rodServo pinion


Electrical Power Steering (EPS)

VW

R. I.TU Darmstadt

Superposition of a steering angle

BMW (2003)

Active front steering

R. I.TU Darmstadt

Development of driver assistance systemsDevelopment of driver assistance systems

R. I.TU Darmstadt

Automotive surrounding sensors

1. Close range: ultra sonic, radar

2. Medium range: lidar, radar, camera

3. Remote area: radar, camera

R. I.TU Darmstadt FG Regelungstechnik u. Prozessautomatisierung

Gemeinschaftsforschung mit der IndustrieArbeitskreise begleiten Forschungsvorhaben: 2-3 Jahre

Finanzierung: 50% Industrie – 50% BMBF oder BMWiAuftragsumfang: 65.000 € pro Jahr und Vorhaben

Dieselmotoren-Regelung (1992-1995)

Nebenaggregate-Management (1995-2000)Fehlerdiagnose an Dieselmotoren (1999-2002)Fehlerdiagnose an Ottomotoren (1999-2002)

Dieselmotoren-Steuerung (1995-1997)

Verbrennungsmotoren

ForschungsvereinigungVerbrennungskraftmaschinenFVV

Modellbasierte Telediagnose elektrischer Antriebe und Textilmaschinen

TeleserviceForschungszentrum KarlsruheProjektträger des BMBFVerbundprojekt OKTEL

Intelligente dezentraleelektromechanische Komponenten (1996-1999)

Störungsfrüherkennung an oszillierendenVerdrängerpumpen (2002-2004)

Mechatronische Systeme

Mechatronische Pumpen

Deutsche Forschungsgesellschaft fürdie Anwendung der MikroelektronikDFAM

Fachgemeinschaft Pumpen VDMA

Einfach anwendbare Diagnoseverfahren fürmechatronische Komponenten (2001-2003)

DFAM

R. I.TU Darmstadt

Forschungskooperationen mit FirmenForschungverträge: 1-3 Jahre, Finanzierung: 100% In dustrie

Auftragsumsatz: ca. € 700.000 pro Jahr

FG Regelungstechnik u. Prozessautomatisierung

MedizintechnikDialysesysteme (seit 1998)

ModellbildungOptimale RegelungPatientenadaption

�

��

Ottomotoren (seit 1996)

Regelung

Regelung

Brennraumdruck-

Abgasrückführungs-

�

�

Verbrennungsmotoren

Verbrennungsaussetzer-Erkennung (1996-2001)

AbgasstrangDruckanalyse im

Ionenstrommessung

�

�

Dieselmotoren (seit 1992)Modellbildung�

Echtzeit-SimulationRegelung

��

Energie-/Produktionstechnik

Zementproduktion (1992-1997)Modellbildung, SimulationStrukturvariable Regelung von Mahlanlagen

�

�

W1

W2

Heizungssysteme (seit 1986)Modellbildung, SimulationAdaptive RegelungFuzzy-Regelung

�

��

KraftfahrzeugeBrake-by-Wire (seit 1995)

Regelung und Rekonstruktionder Bremskraft einer EMBIntelligentes BremspedalRegelung der Horizontaldynamikmit BbW-Aktuatoren (ABS/ESP)

�

��

Personenkraftwagen (seit 1990)

Geschwindigkeitsregelung

On-line Simulationsmodelle Automatische Abstands- und

automatischesParkassistenzsystem

�

�

�

Aktive Fahrwerke (seit 2001)Zustandserkennung für aktiveFahrwerke

�

Ottomotoren (seit 2001)Optimierung der Verbrennungbeim Direkteinspritzer

�

R. I.TU Darmstadt

In Kooperation mit

Sensorik

Radar Lidar

Regelung

Notlenken Notbremsen

Aktorik

Steer-By-Wire

Brake-By-Wire

Elektronische Fahrerassistenz für einunfallvermeidendes FahrzeugPRORETA

R. I.TU Darmstadt

CONCLUSIONS

• Mechanical, hydraulic and pneumatic components areintegrated with microelectronics

• Software determines functions• Mechatronic components improve functionality, safety,

economy and comfort• Modelling and simulation tools allow simultaneous

engineering and fewer prototypes• Same mechatronic development for combustion engines,

transmissions

→ Mechatronic components change the design of automobiles

→ Mechatronics: emerging area of innovative engineering

R. I.TU Darmstadt

AUTOREG 2006-Steuerung und Regelung von Fahrzeugen und Motoren-

Wiesloch, 7. und 8. März 2006

Veranstalter: VDI/VDE-GMA und VDI-FVTAusschuss “Steuerung und Regelung von Kraftfahrzeugen

und Verbrennungsmotoren-GMA 7.62”

AUTOREG 2006 (3.Tagung)– 2 Plenarvorträge

– 64 Einzelvorträge in 3 parallelen Sitzungen

– 15 Posterbeiträge

FVT

GMA

Steuerung und Regelung von Fahrzeugen undMotoren - AUTOREG 2004

Aufruf zur Einreichung von Beiträgen

FVTGMAwww.vdi.de/gma/autoreg2006

R. I.TU Darmstadt

END

80 Folien: 65 min effektiv benötigt.... Seoul ICCAS: 0.8 min/Folie.

R. I.TU Darmstadt

CONCLUSIONS

• Mechanical, hydraulic and pneumatic components are integrated withmicroelectronics

• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions• Mechatronic components improve functionality, safety, economy and comfort• Mechatronic design allows parallel development of hardware , electronics

and software• Modelling and simulation tools allow simultaneous engineering and fewer

prototypes• Same mechatronic development for combustion engines, transmissions• Next steps: surrounding sensors, collision avoidance, drive-by-wire• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)



R. I.TU Darmstadt

CONCLUSIONS


• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions

R. I.TU Darmstadt

CONCLUSIONS


• Integrated components comprise hardware and software• Hardware is partially simplified, software determines functions

• Mechatronic components improve functionality, safety, economy and comfort• Mechatronic design allows parallel development of hardware , electronics


prototypes

R. I.TU Darmstadt

CONCLUSIONS




prototypes

• Same mechatronic development for combustion engines, transmissions• Next steps: surrounding sensors, collision avoidance, drive-by-wire• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)

R. I.TU Darmstadt

CONCLUSIONS




prototypes• Same mechatronic development for combustion engines, transmissions• Next steps: surrounding sensors, collision avoidance, drive-by-wire• Open issues: steer-by-wire (fault-tolerance? costs? advantages?)



R. I.TU Darmstadt

OUTLOOK

- Intelligent mechatronic systems� adaptation, learning, decision making � sensors, actuators, devices (optics, office, medicine)

R. I.TU Darmstadt

OUTLOOK

- Intelligent mechatronic systems� adaptation, learning, decision making � sensors, actuators, devices (optics, office, medicine)

- Fault- tolerant mechatronic systems� highly reliable and safe systems (vehicles,

engines, drive systems, production machinery)� Medical devices (operation robots, implants)� Aero-space systems

R. I.TU Darmstadt

OUTLOOK

- Intelligent mechatronic systems� adaptation, learning, decision making� sensors, actuators, devices (optics,office, medicine)

- Fault- tolerant mechatronic systems� highly reliable and safe systems (vehicles,

engines, drive systems, production machinery)� Medical devices (operation robots, implants)� Aero-space systems

- x-by-wire mobile systems� brake-by wire, steer-by wire, drive-by wire� autopilot-driver assistance, auto-navigation� mobile robots (agriculture, production, home)

R. I.TU Darmstadt

Six-legged walking forest machine (Finland)

(S.Niilola,Tekes)

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