Mts Systems Corporation

Ford Global Technolgoies, LLC

Ford Motor Company Limited

David M Fricke

Rakan C Chabaan

Mark D Hansen

Lawrence Andrew Mianzo

Byron John Saari

Jodi L Sommerfeld

Bruce Howard Whittle

Arthur J Page

Fayyaz Saleem

James Alanoly

Nabih Wassef Elsenety

David W Olson

A test system and method for testing a coupled hybrid dynamic system in simulated motion along a path includes a physical test rig configured to test a physical component. A processor is configured with modeled test data, a first virtual model portion and a second virtual model portion of the coupled hybrid dynamic system, the first virtual model portion, the second virtual model portion and the physical component comprising the coupled hybrid dynamic system. The processor is configured to control the test rig such that the component under test responds to the second virtual model portion, that in turn receives a first input comprising the modeled test data, a second input being motion of the first virtual model portion of the coupled hybrid dynamic system, a third input being a control mode response from the test rig having the physical component under test and a fourth input comprising guidance controls for the coupled hybrid dynamic system.

Methods and systems for testing coupled hybrid dynamic systems

A test system and method for testing a coupled hybrid dynamic system in simulated motion along a path () includes a physical test rig () configured to test a physical component (). A processor () is configured with modeled test data (), a first virtual model portion and a second virtual model portion of the coupled hybrid dynamic system, the first virtual model portion (), the second virtual model () portion and the physical component () comprising the coupled hybrid dynamic system. The processor () is configured to control the test rig () such that the component under test () responds to the second virtual model portion (), that in turn receives a first input () comprising the modeled test data (), a second input () being motion of the first virtual model portion () of the coupled hybrid dynamic system, a third input () being a control mode response from the test rig having () the physical component () under test and a fourth input () comprising guidance controls for the coupled hybrid dynamic system.

Systems and methods are provided for controlling the simulation of a coupled hybrid dynamic system. A physical test rig configured to drive the physical structure component of the system and to generate a test rig response as a result of applying a test rig drive signal. A processor is configured with a virtual model of a complementary system to the physical structure component. The processor receives the test rig response and generates a response of the complementary system based on a received test rig response. The system can be driven with a random input. The processor compares the test rig response with the response of the complementary system, the difference being used to form a system dynamic response model.

Method and systems for off-line control for simulation of coupled hybrid dynamic systems

A method and an arrangement of controlling simulation of a coupled hybrid dynamic system comprising a component under test and a virtual model includes driving the physical component under test of the system on a test rig over a period of time to conduct a test by applying an initial test drive signal input to the test rig to generate a test rig response. At least a portion of the test rig response is inputted into the virtual model of the system to obtain a model response of the system. A condition of the physical component under test is assessed during at least a portion of the period of time to conduct the test based on comparing another portion of the test rig response with the model response where an output relating to the assessment is recorded or rendered.

Method of off-line hybrid system assessment for test monitoring and modification

A test system configured to impart a body disturbance to a test specimen and measure motion or displacement of the test specimen in response to the input body disturbance. The system includes one or more actuator devices configured to replicate motion or displacement of the body imparted through the original input body disturbance utilizing the measured motion or displacement. As disclosed, the system includes algorithms or instructions to generate control parameters utilizing the measured motion or displacement to control operation of the one or more actuator devices. The force applied through the one or more actuator devices to replicate the measured motion or displacement is used to determine the force or load applied to the body via the input disturbance.

Test system for measuring and evaluating dynamic body forces

Systems and methods are provided for controlling the simulation of a coupled hybrid dynamic system. A physical test rig configured to drive the physical structure component of the system and to generate a test rig response as a result of applying a test rig drive signal. A processor is configured with a virtual model of the system. The processor receives the test rig response and generates a model response of the system based on the received test rig response and a virtual drive input. The system is driven with a random input. The processor compares the test rig response with the model response, the difference being used to form a system dynamic response model for generating the test drive signal. An inverse of the system dynamic response model is used to iteratively reduce the difference between the model response and the test rig response below a defined threshold.

Methods and systems for off-line control for simulation of coupled hybrid dynamic systems

A process for removing a modulation sinusoidal error from signals of a rotating load cell measuring forces and/or moments with respect to a non-rotating orthogonal coordinate system includes mounting the load cell to the rotating object and obtaining a first set of signals from the load cell, wherein at least one signal of the first set of signals is indicative of a load as the object rotates. A characterization of a modulation error is obtained from the first set of signals. The modulation error is a periodic signal having a frequency greater than and proportional to a frequency of revolution of the load cell. A second set of signals is obtained from the load cell pursuant to object loading. A modulation error in the second set of signals is calculated as a function of the characterization of the modulation error from the first set. The calculated modulation error in the second set of signals is subtracted from the second set of signals.

Modulation error compensation for a rotating load cell

A method and system are provided for generating engine attachment control boundary conditions and corresponding control signals for an exhaust system laboratory test fixture which accurately reproduce both the dynamic behavior of a vehicle powertrain during operation, and the dynamic behavior of the vehicle frame during operation in the area where the exhaust system is attached to the vehicle frame. Road load data is collected in vertical, lateral, and longitudinal directions on the vehicle frame during vehicle operation at each of the locations where the exhaust system attaches. In addition, temperature and thermal cycling data are also collected during operation of the vehicle. The road load data is used to determine a best fit rigid body model. Accelerometer locations and directions are determined from statistical analysis and ranking to find the measures best fitting the determined rigid body. This information is then used to generate the test boundary conditions and control signals to be input to the test fixture. Thermal profiles are generated based on the collected temperature data to form input control signals to control heating of the exhaust system during testing. The generated thermal profiles allow simulation of real-world thermal stresses caused by hot exhaust gases.

Method and system for dynamic testing of a vehicle exhaust system in a rigid frame test fixture

A method for developing a tire model for use with an effective road profile in testing an automotive vehicle on a spindle-coupled road simulator defines a flat surface road plane in a multiple coordinate reference system to represent the effective road profile. The coordinates comprise at least four of a plane vertical deflection, a plane radial contact angle, a plane lateral contact angle, a steer contact angle, a lateral displacement and a longitudinal displacement. A tire is excited over a predetermined range while on a tire test apparatus for developing the tire model. The tire test apparatus includes an articulated running flat belt platform moveable so as to contact the tire, the flat tire contact plane defining a coordinate reference system to represent the effective road profile in multiple degrees-of-freedom.

Multiple degree-of-freedom tire modeling method and system for use with

A method and system for controlling an automotive vehicle spindle-coupled road simulator with a predetermined effective road profile for a road surface uses tire loss-of-contact compensation to modify the tracking parameter in a control loop to avoid incorrectly loading a test vehicle. Tire deflection obtained during measurement of a vehicle's tire profile calculation is used to detect and flag regions where the tire profile is not a function of the road input so that the tire profile motion is governed only by the free dynamic response of the suspension. A tire model is first developed for a vehicle. The vehicle is then coupled to the spindle-coupled simulator, and a set of control signals is generated in a control loop. The control signals are used for driving the spindle-coupled simulator with the vehicle attached thereto so that a response generated by the simulator is consistent with the predetermined effective tire profile. Determination of the set of control signals includes selection of a composite tracking response from a generated output representing a tire in contact with the road surface and a tire deflection output representing a tire having lost contact with the road surface.

Effective road profile simulation method and system with tires

A method for developing a tire model for use with an effective road profile in testing an automotive vehicle on a spindle-coupled road simulator defines a flat surface road plane in a three coordinate reference system to represent the effective road profile with the three coordinates comprising a plane vertical deflection, a plane radial contact angle, and a plane lateral contact angle. The tire is then excited over a predetermined range while on a tire test apparatus for developing the tire model. The tire test apparatus includes a flat tire contact plane moveable so as to contact the tire, the flat tire contact plane defining a three coordinate reference system to represent the effective road profile in the three coordinates.

Method and apparatus for modelling a tire for use with a vehicle

A method for testing an automotive vehicle on a vehicle spindle-coupled simulator comprises the steps of driving a first vehicle over a test road surface, collecting spindle dynamics data from at least one spindle of said first vehicle, developing a first tire model for the first vehicle, estimating a road profile for the road surface based upon the spindle dynamics data and the first tire model, developing a second tire model for a second vehicle, coupling the second vehicle to the spindle-coupled simulator, and generating a set of control signals for driving the spindle-coupled simulator with the second vehicle coupled thereto so that a road response generated by the spindle-coupled simulator is consistent with the road profile. The method allows accurate testing of the second vehicle without driving it over the test road. The tire model is developed using system identification techniques.

Growing community of inventors

Prior Lake, MN, United States of America

David M Fricke