Hardware-In-The-Loop Simulation for a Multiaxial Suspension Test Rig with a Nonlinear Spatial Vehicle Dynamics Model

Abstract

Hardware-in-the-Loop (HiL) simulations where a mechatronic system is used as the device under test (DUT), are established in the automotive sector for the design of active suspension components, e.g. roll-stabilizers. Usually, uniaxial actuator systems within the test rig are applied for the excitation of the DUT. However, in the context of mechatronic suspension systems incorporating multiple mechatronic subsystems, more sophisticated HiL test rigs / simulations with multiaxial excitation of the DUT are necessary. This contribution presents the model-based design of a HiL simulation for a multiaxial vehicle axle test rig. Within the HiL simulation a nonlinear spatial vehicle dynamics model with 36 states is used to reproduce the environment of the DUT in real-time. The implemented model and its requirements are described in detail. An appropriate HiL control framework is developed, which combines the vehicle dynamics model with the hybrid motion/force control of the manipulator systems. The primary actuator is a hydraulic hexapod. Simulation results and measurements obtained with the HiL system show the effectiveness of this approach. The potential for chassis control validation and design is highlighted in comparison to a highly detailed benchmark vehicle dynamics model.