Simulation can play an important role when aiming to streamline extensive and time-consuming tests. It has the potential to save time, money and energy. One of the testing methods used to test shock absorbers (SA), is accelerated life testing using a rolling road, CamDrum. It is therefore of great interest to examine the possibilities to streamline this testing method. This master thesis is conducted in co-operation with Öhlins Racing AB and the Machine Design department at KTH. The thesis project aims to look into the following: How can the use of simulation software aid in streamlining the test sequence used for shock absorbers in CamDrum? What limitations is there when simulating the CamDrum method using the selected simulation software? The goal was to develop an adequate model according to specified requirements, to facilitate early testing of new ideas and parameter changes. The delimitations includes, that the project only focuses the test-rig for MTB shock absorbers, the parts of the test-rig are assumed to be rigid and the simulation of the shock absorber is out of scope, since the aim of this thesis is to simulate the test-rig. To succeed with the project, a background research was conducted to gain knowledge about shock absorbers, test method and equipment, dynamics and useful software. The simulation model was verified against data obtained from tests. The tests were performed using the CamDrum with two different MTB shock absorbers and a stiff rod. The aim was to log and verify the change in position for the test-rig, shock absorbers and wheel. In addition the forces acting on the shock absorbers was investigated using strain gauges attached to the test-rig. The mean deviation in % for configuration 70-30-30 [mm] bump: SA MTBM1899, A4: 11.6% - 23.2%. SA MTB1691, A4: 15.8% - 28.1%. Stiff rod, A3: 0.9% - 4.9%, A5: 2.0% - 5.1%. SA Force, 16.1% - 24.0%. The deviation between the simulation and the test environment increases with the velocity. The use of stiff rod verifies the model against the CamDrum regarding the displacement. The resulting force from the use of strain gauges verifies the simulation models force regarding the shape. The Amesim model has the potential to be of great aid when designing tests. / Simulering kan vara en väg till att effektivisera tidskrävande och omfattande tester. Det finns potential att spara såväl energi som tid och pengar. En av metoderna för att testa stötdämpare är rullande landsväg, CamDrum. Det är därför intressant att undersöka hur den processen kan effektiviseras. Examensarbetet utförs i samarbete mellan Öhlins Racing AB och institutionen för Maskinkonstruktion på KTH. Det här examensarbetet avser att undersöka följande: Hur kan användandet av simuleringsprogram underlätta effektivisering av testmetoden som används för stötdämpare i CamDrum? Vilka avgränsningar finns vid användande av simulering för CamDrum-metoden med valt simuleringsprogram? Målet var att utveckla en modell som uppfyller givna krav och underlättar vid initieringsfasen för utveckling av tester för CamDrum. Projektets avgränsningar innebär att enbart riggen för MTBstötdämpare undersöks, alla ingående komponenter i testriggen antas styva och dämparmodellen som utvecklats är förenklad då målet är att simulera riggen för dämparen. För att lyckas med uppgiften har en förstudie genomförts för att samla nödvändig kunskap om stötdämpare, dynamik, testmetoden och lämplig mjukvara. Simuleringsmodellen verifieras mot data hämtat från utförda tester. Testerna utfördes i CamDrum med två olika MTB-stötdämpare och en rundstång med mål att logga och verifiera rörelser för riggen, stötdämpare och hjulet. Vidare har krafterna på stötdämparen undersökts med hjälp av trådtöjningsgivare monterade på testriggen. Medelavvikelsen i % för guppkonfigurationen 70-30-30 [mm]: SA MTBM1899, A4: 11.6% - 23.2%. SA MTB1691, A4: 15.8% - 28.1%. Rundstång, A3: 0.9% - 4.9%, A5: 2.0% - 5.1%. SA Force, 16.1% - 24.0%. Avvikelsen mellan simuleringen och testerna ökar med hastigheten. Användandet av rundstången verifierar modellen gentemot CamDrum med avseende på positionsförändring. Den resulterande kraften från användandet av trådtöjningsgivare verifierar simuleringsmodellen med avseende på form.  Amesim-modellen har en möjlighet att underlätta vid framtagning av tester.

En Power Transfer Unit (PTU) eller vinkelväxel i ett drivsystem för allhjulsdrift är enväxellåda med en hypoid-växel som drevsats. PTUn ar placerad mellan fordonets transmissionoch kardanaxel och används för att fördela momentet från drivsystemet mellanalla hjulen. De dynamiska egenskaperna hos vinkelväxeln är kopplade till de ljud ochvibrationer som uppfattas i bilen, speciellt tonalt ljud som växelvin. Källan till dennavibration kan relateras till transmissionsfelet i växeln. Transmissionsfelet beror pa faktorersom geometri, rotationshastighet och statiskt moment. Om faktorernas inverkankan identieras skapar det möjligheter att reducera felet genom designförändringar. 1D ellersystem-simulering ar en förenklad beskrivning av det dynamiska beteendet av systemet.Det är en flexibel metod som kan ge en uppskattning av systemets egenskaper iett tidigt skede och kan användas i såväl tids- som frekvensdomönen.Denna studie syftar till att bygga en 1-D system-modell av en PTU och studera dessdynamiska beteende. De typer av analyser och resultat som ar möjliga att få från en dynamisk1-D modell av en specic produkt har utvärderats. Befintliga komponenter frånmjukvarans bibliotek har används for att bygga en förenklad modell med lumpade massorav den fysiska systemet. Simuleringar har utförts både i tidsdomänen och frekvensdomänen.System-modellen är mycket användbar för modelling av hela system och av hur delarnaväxelverkar i ett tidigt skede av produktutvecklingen. Beräkningen av nivån på transmissionsfeletsgrundtonen stämmer väl med tillgängliga mätresultat. Rotationshastigheternasvariation då kopplingen kopplar i och ur vinkelväxeln illustrerar tydligt kopplingensinverkan på dynamiken i systemet. Det var dessutom möjligt att erhålla systemets torsionsegenfrekvenseroch modformer från den linjära frekvensanalysen. / A Power Transfer Unit (PTU) of an All-Wheel Drive system is a hypoid gearbox whichis a driveline component, used to distribute power from the powertrain to all the wheelsof a vehicle. The gearbox dynamics is closely related to the gearbox noise and vibration,especially tonal noise like gear whine. The source of this vibration is referred to as thetransmission error in the unit. Transmission error is attributed to various geometricaland operating conditions, which if mapped mathematically, allows the designer to reducethe error by varying the design parameters. The demand in the automotive industry toreduce time to market is high. A lot of time can be saved if system performance can beassessed at the concept stage, even before the detailed design. This is where system-levelsimulation plays a key role. 1-D or system simulation technique studies the dynamicbehaviour of the system in one dimension. This greatly simplies the model and allowsfor the exibility to get early estimates of the system behaviour with respect to time andfrequency. Here, such a system model is built for a hypoid gear based driveline system.This work aims to build a 1-D system model of the PTU and study the dynamic behaviourof the response. The evaluation helps in understanding the capabilities on 1-D systemmodel in simulating a specialised product dynamic characteristics. LMS AMESim wasthe commercial tool used in building the system model. Existing components from thesoftware library were used to build a sketch of a simplied, lumped mass model of thephysical system. The model was then simulated in both the time domain and frequencydomain through a temporal and linear analysis respectively.It is observed that the system model is very useful in early modelling of a system and itsinteractive eects. The fundamental harmonic of the transmission error is predicted wellin the system model. The clutch connect/disconnect behaviour can also be seen in therotary velocity response of the gear. The system eigenfrequencies and mode shapes wereobtained from the linear analysis.

This master thesis presents a novel methodology for the  development of simulation models  for hydraulic pumps and motors. In this work, a generic simulation model capable of representing multiple axial piston machines is presented, implemented and validated. Validation of the developed generic simulation model is done by comparing the results from the simulation model with experimental measurements. The development of the generic model is done using AMESim. Today simulation models are an integral part of any development process concerning hydraulic machines. An improved methodology for developing these simulation models will affect both the development cost and time in a positive manner. Traditionally, specific simulation models dedicated to a certain pump or motor are created. This implies that a complete rethinking of the model structure has to be done when modeling a new pump or motor. Therefore when dealing with a large number of pumps and motors, this traditional way of model development could lead to large development time and cost. This thesis work presents a unique way of simulation model development where a single model could represent multiple pumps and motors resulting in lower development time and cost. An automated routine for simulation model creation is developed and implemented. This routine uses the generic simulation model as a template to automatically create simulation models requested by the user. For this purpose a user interface has been created through the use of Visual Basic scripting. This interface communicates with the generic simulation model allowing the user to either change it parametrically or completely transform it into another pump or motor. To determine the level of accuracy offered by the generic simulation model, simulation results are compared with experimental data. Moreover, an optimization routine to automatically fine tune the simulation model is also presented.

<p>In the future, new challenges will occur during the product development in the vehicular industry when emission legislations getting tighter. This will also affect the truck cooling system and therefore increase needs for analysing the system at different levels of the product development. Volvo 3P wishes for these reasons to examine the possibility to use AMESim as a future 1D analysis tool. This tool can be used as a complement to existing analysis methods at Volvo 3P. It should be possible to simulate pressure, flow and heat transfer both steady state and transient.</p><p>In this thesis work a cooling system of a FH31 MD13 520hp truck with an engine driven coolant pump is studied. Further a model of the cooling system is built in AMESim together with necessary auxiliary system such as oil circuits. The model is validated using experimental data that have been produced by Volvo 3P at the Gothenburg facility.</p><p>The results from validation and other simulations show that the model gives a good picture of the cooling system. It also gives information about pressure, flow and heat transfer in steady state conditions. Further a design modification is done, showing how a change affects the flow in the cooling system.</p><p>The conclusion is that a truck cooling system can be built and simulated in AMESim. Further, it shows that AMESim meets the requirements Volvo 3P in Gothenburg has set up for the future 1D analysis tool and thereby AMESim is a good complement to the already existing analysis method.</p>

In the future, new challenges will occur during the product development in the vehicular industry when emission legislations getting tighter. This will also affect the truck cooling system and therefore increase needs for analysing the system at different levels of the product development. Volvo 3P wishes for these reasons to examine the possibility to use AMESim as a future 1D analysis tool. This tool can be used as a complement to existing analysis methods at Volvo 3P. It should be possible to simulate pressure, flow and heat transfer both steady state and transient. In this thesis work a cooling system of a FH31 MD13 520hp truck with an engine driven coolant pump is studied. Further a model of the cooling system is built in AMESim together with necessary auxiliary system such as oil circuits. The model is validated using experimental data that have been produced by Volvo 3P at the Gothenburg facility. The results from validation and other simulations show that the model gives a good picture of the cooling system. It also gives information about pressure, flow and heat transfer in steady state conditions. Further a design modification is done, showing how a change affects the flow in the cooling system. The conclusion is that a truck cooling system can be built and simulated in AMESim. Further, it shows that AMESim meets the requirements Volvo 3P in Gothenburg has set up for the future 1D analysis tool and thereby AMESim is a good complement to the already existing analysis method.

No / Braking system characteristics, brake system performance and brake system component design parameters that influence brake pedal ‘feel’ in a passenger car have been studied using the simulation modelling package AMESim, in particular to model the linear and nonlinear characteristics of internal components. A passenger car hydraulic brake system simulation model incorporating the brake pedal, booster, master cylinder, brake lines and calipers has been developed to predict brake system response to assist in the design of braking systems with the desired brake pedal force / travel characteristic characteristics to create good brake pedal ‘feel’. This has highlighted the importance of system components, in particular the master cylinder and caliper seal deformation, and the operating characteristics of the booster in determining the brake pedal force / travel characteristic. The potential contribution of these 3 components to brake pedal ‘feel’ improvement has been investigated, and the results of the AMESim model have been verified using experimental measurement data. The model can be used in the future to provide an accurate prediction of brake system response at the design stage thereby saving time and cost.

Computer simulation software’s are arguably some of the most convenient and utilized tools for an engineer as it lets them model real phenomena and observe different operations without having to perform the operation physically, thus saving both time and resources. Naturally these tools varies in design depending on their intended area of application and while a large number of them supports modeling of more than one physical domain, it is often cumbersome to attain a functional interaction between them. In spite of this there do exist simulation software that have been specifically developed for effectively integrating several physical domains known as system simulation software’s. One of these are Siemens Simcenter Amesim, a computer simulation software for modeling multi domain mechatronic systems. One company that has recently found an interest in potentially adapting the concept of system simulations into their workflow is BAE Systems Hägglunds, Örnsköldsvik, where a pre-study has previously been conducted in order to define a system requirement specification as well as narrow down the number of promising tools to only a few, with Simcenter Amesim being one of them. The aim of this study is then to evaluate and assess to what degree Simcenter Amesim complies with the requirements specified by the company. The primary source of information in which this analysis will be based upon is through the modeling of two different pilot cases in Simcenter Amesim, an electric driveline as well as the hydraulic component of the active suspension system affiliated with the CV90 vehicle. The electric driveline was developed as a general model featuring a few key functionalities in terms of power setup. This being that two electric motors were to be utilized, one for driving the vehicle forward and the other for steering the vehicle left and right. Powering these two was then an electric generator which by itself was to be powered by an internal combustion engine (ICE). The active suspension system was modeled based on existing schematics and information available through company resources with the ambition of realizing a certain behavior of the system as described by a couple of real tests made. Results from simulations made using the electric driveline model indicates that the model succeeds in fulfilling its fundamental functionality. Through plain throttle and steering inputs the corresponding vehicle is able to move about in a simple and predictable fashion with data also showcasing realistic behavior in terms of velocity evolution and power generation. The hydraulic model of the CV90 active suspension system furthermore appears to replicate the behavior of the actual suspension system fairly well based on the real test data available. Analogous with both models however is the fact that they are rather primitive in their current state. The electric driveline model lacks some of the finesses and functionalities that are included in modern driveline systems, mostly coupled to the component steering and feedback system which is more arbitrarily implemented in this model. As for the hydraulic suspension system it would be beneficial to continue develop the model through further evaluation using more real life test data.

Dans les dernierès années la politique des entreprises s'est concentrée sur la recherche de solutions industrielles plus écologiques pour réduire l'impact sur l'environnement et l'énergie consommée. La tendance s’est élargie aux machines stationnaires dans l'automatisation industrielle. Il inclut la technologie d’entraînement pour contrôler le mouvement séquentiel de plusieurs axes dans les presses à injecter. La conception des systèmes se focalise sur une approche conduisant à l’amélioration du rendement énergétique aussi bien que l’augmentation de la pression de service, la réduction de cycle de la machine et l’amélioration de sa répétabilité. Toutes ces exigences ont poussé la technologie d’entraînement à se développer en augmentant l'intérêt pour les modules électromécaniques et électro-hydrostatiques (EHM). Dans cette thèse, une solution innovatrice d'EHM est proposée qui associe un convertisseur, un servomoteur AC brushless et la pompe à palettes Parker. En détail, l'intérêt de recherche concerne le développement d'un modèle à niveau système de la pompe à palette. L'objectif principal est de permettre l'évaluation des pertes d'énergie de la pompe et la performance de module pendant des phases spécifiques du cycle de la machine : accélération, dépressurisation et phase de maintien de la pression. Premièrement analysée au moyen de l'approche analytique, la dynamique est alors évaluée par des modèles plus avancés basés sur le prototypage virtuel construit dans l'environnement LMS-AMESim. Les avantages concernant la prévision des performances du module EHM et sur l’évaluation des paramètres fondamentaux inconnus (comme la compressibilité du fluide et le contenu d’air dans le fluide) sont montrés par comparaison avec des résultats expérimentaux obtenus dans le laboratoire. Les phénomènes de la cavitation et d’aération sont aussi pris en compte pendant les phases d'accélération et des modèles sont ainsi développés pour prévoir les conditions de fonctionnement qui promeuvent ces phénomènes. La consommation d'énergie de l'EHM est alors analysée au moyen des modèles thermo-hydrauliques capables de déterminer les échanges de chaleur entre les composants de module et l'environnement. / In last years companies’ policy has been focusing on research of more eco-friendly solutions in order to reduce the environmental impact and the consumed energy. The trend has been affecting the stationary machinery in the industrial automation too. It includes the drive technology for motion control in the injection moulding machines. The design studies concern energy efficiency improvement, as well as increased service pressure, shorter cycle time and repeatability over a long period of time. All these requirements have led the drive technology to evolve by increasing the interest for the electro-mechanical and electro-hydrostatic modules (EHM). In this thesis an innovative solution of EHM is proposed that associates industrial inverter, AC brushless servo motor and fixed-displacement low-noise Parker vane pump. In detail, the research interest concerns the development of a system level model of the vane pump. The main objective is to enable assessing the pump energy losses and full module performance in specific phase of machine’s cycle: acceleration, depressurisation and holding pressure phases. Firstly analysed by means of analytical approach, dynamics are then evaluated through more advanced models based on virtual prototyping built in LMS-AMESim environment. The advantages on predicting the EHM performance and on estimating the unknown fundamental parameters (e.g. Bulk Modulus and fluid air content) are showed through comparison with experimental results obtained in laboratory. The cavitation/aeration phenomena are also taken into account during acceleration transients and models are thus developed in order to predict the operating conditions which promote these phenomena. Energy behaviour of the EHM is then analysed by means of thermal hydraulic models able to determine the heat exchanges between module components and environment.

Aujourd’hui, les constructeurs automobiles continuent de chercher les technologies renouvelables face à la pénurie d’énergie et les problèmes d’émission de polluants. Un moyen important pour optimiser l’économie de carburant et réduire les émissions polluantes des moteurs à allumage commandés est le concept ‘downsizing’. Cependant, ce concept est limité par le phénomène de cliquetis dû aux conditions de haute température et haut pression. Dans cette étude, le contrôle de la concentration d’oxygène dans l’air est proposé. Car d’une part, la combustion enrichie en oxygène permet d’améliorer la densité de puissance de moteur avec le même niveau de pression d’admission. Cela permet soit de ‘booster’ la combustion pour augmenter la puissance du moteur ou de l’activer lorsque le moteur fonctionne à faible charge ou dans des conditions de démarrage à froid. D’autre part, une faible concentration en oxygène dans l’air (ou dilution de N2) par un système membranaire peut être considérée comme une alternative à la recirculation des gaz d’échappement. Les expériences ont été effectuées dans un moteur monocylindre ‘downsizing’ avec différents taux d’oxygène et richesse. L’étude de l’impact du contrôle de la concentration d’oxygène sur les caractéristiques de combustion et d’émissions a été effectuée pour plusieurs charges en fonctionnement optimum pour limiter la consommation spécifique de carburant. L’effet de la concentration en oxygène sur les caractéristiques de combustion du moteur a été simulé en utilisant le logiciel commercial AMESim avec le modèle de combustion développé par IFP-EN. En mettant en oeuvre des corrélations de la vitesse de combustion laminaire, déterminées au préalable durant ce travail, et délai d’auto-inflammation, les pressions dans les cylindres sont parfaitement calibrés avec une erreur maximale inférieure à 2% et l’intensité du cliquetis a pu être prédite. / Nowadays, car manufacturers continue to lead researches on new technologies facing to the energy shortage and pollutant emission problems. A major way to optimise fuel economy and reduce pollutant emissions for Spark-Ignition (SI) engines is the downsizing concept. However, this concept is unfortunately limited by ‘knock’ phenomena (abnormal combustion) due to high temperature and high pressure in-cylinder conditions. In the present study, control the oxygen concentration in air is proposed. Indeed, on the one hand, oxygen-enriched combustion can improve engine power density with the same intake pressure level. Thus, oxygen-enriched combustion can be used either as a booster to increase engine output or as a combustion enhancer when the engine operates at low loads or in cold start conditions. On the other hand, low oxygen concentration in air (or N2 dilution) can be considered as an alternative to exhaust gas recirculation (EGR). The experiments were carried out in a downsized single-cylinder SI engine with different rates of oxygen and equivalence ratios. The study of the impact of controlling oxygen concentration on the combustion characteristics and emissions was performed at several loads by optimizing the spark advance and the intake pressure to maintain the load and obtain a minimum value of indicated Specific Fuel Consumption (SFC). The effect of oxygen concentration on the engine combustion characteristics was simulated by using the commercial software AMESim, with the combustion model developed by IFP-EN. By implementing correlations for the laminar burning velocity, determined previously during this study, and auto-ignition delay data base, the in-cylinder pressures were perfectly calibrated with a maximum pressure relative error less than 2%, and the knock intensity was predicted.

A Power Transfer Unit (PTU) of an All-Wheel Drive System is a hypoid gear transmission unit that distributes the power from the vehicle transmission to all wheels of the vehicle. This thesis aims at increasing the fidelity of the analytical power loss calculation methods through test data correlation and develop a 1D simulation model that can be used to evaluate the drag losses in the PTU at early design stages.  Firstly, the analytical methods to predict the frictional losses and oil churning losses due to the hypoid gearset, rolling bearings and seals immersed in oil are studied. Several drag loss tests with different combinations of internal components, bearing preloads and with/without the presence of oil were previously conducted on the PTU at different speeds and temperatures at zero torque. The power losses are computed in ROMAX Energy and Excel using different analytical methods available in the literature for each component in the PTU. Then the results from the drag loss tests are segregated component-wise for data correlation with the losses evaluated previously. Based on the data correlation, modification factors are introduced for all analytical methods to match the segregated test results.  The demand in the automotive industry to reduce time to market is high. Hence, system-level simulation was chosen as a solution to assess the system efficiency at early concept design stage, saving a lot of time and aid the detailed design. 1D simulation technique is used to study the total power loss of the PTU to optimize its design. The thesis is aimed at developing a 1D system model of the PTU in a commercial tool called LMS AMESim, to evaluate the total power loss of the unit. Inbuilt component models from the software library are used to build a sketch of a simplified lumped mass model of the physical system. The model is simulated in a time domain temporal analysis. The total power loss results simulated using AMESim are compared to the efficiency tests results conducted at different torque levels and ROMAX results.  Comparisons between the simulations and test data shows that the system model is accurate and can be used in predicting the power losses in the PTU in the early design stages. This model can also be used to study the influential factors through sensitivity analysis of different parameters which can be done as an extension to the current scope of this work. / En kraftöverföringsenhet (PTU) i ett fyrhjulsdriftsystem är en hypoidväxellådsöverföringsenhet som fördelar kraften från växellådan till alla hjul i fordonet. Det rapporterade arbetet syftar till att öka konfidensen i de analytiska beräkningsmetoderna för effektförlust genom testdatakorrelation och genom att utveckla en 1D-simuleringsmodell som kan användas för att utvärdera dragförlusterna i PTUn i tidiga designfaser.  För det första studeras analysmetoderna för att förutsäga friktionsförluster och plaskförluster på grund av hypoidväxeln, rullager och tätningar nedsänkta i olja. Flera ”Drag Loss”-tester med olika kombinationer av interna komponenter, lagerförspänningar och med / utan närvaro av olja utfördes tidigare på PTU vid olika hastigheter och temperaturer utan pålagt moment. Effektförlusterna beräknas i ROMAX Energy med olika analysmetoder tillgängliga i litteraturen för varje komponent i PTU. Sedan separeras resultaten från dragförlusttesterna komponentmässigt för datakorrelation med de tidigare utvärderade förlusterna. Baserat på datakorrelationen införs modifieringsfaktorer för alla analysmetoder för att matcha de segregerade testresultaten.  Efterfrågan inom fordonsindustrin att minska tiden till marknaden är hög. Därför väljs simulering på systemnivå som en lösning för att bedöma systemeffektiviteten i ett tidigt konceptdesignfas, vilket sparar mycket tid och underlättar den detaljerade designen. 1D-simuleringsteknik används för att studera PTUns totala effektförlust för att optimera dess design. Arbetet syftar till att utveckla en 1D-systemmodell av PTU i ett kommersiellt verktyg som heter LMS AMESim, för att utvärdera enhetens totala effektförlust. Inbyggda komponentmodeller från programvarubiblioteket används för att skapa en skiss av en förenklad modell av det fysiska systemet. De totala effektförlusterna beräknade med AMESim jämförs med effektivitetstestresultaten vid olika vridmomentnivåer och ROMAX-resultat.  Från korrelationen med testresultaten observeras att systemmodellen är korrekt och kan användas för att förutsäga effektförlusterna i PTU i de tidiga designstadierna. Denna modell kan också användas för att studera de viktigaste faktorerna genom känslighetsanalys av olika parametrar, vilket kan göras som en förlängning av detta arbete.