The electromechanical design and development of a sophisticated roller rig testing facility at the Railway Technologies Laboratory (RTL) of Virginia Polytechnic and State University (VT) is presented. The VT Roller Rig is intended for studying the complex dynamics and mechanics at the wheel-rail interface of railway vehicles in a controlled laboratory environment. Such measurements require excellent powering and driving architecture, high-performance motion control, accurate measurements, and relatively noise-free data acquisition systems. It is critical to accurately control the relative dynamics and positioning of rotating bodies to emulate field conditions. To measure the contact forces and moments, special care must be taken to ensure any noise, such as mechanical vibration, electrical crosstalk, and electromagnetic interference (EMI) are kept to a minimum. This document describes the steps towards design and development of all electromechanical subsystems of the VT Roller Rig, including the powertrain, power electronics, motion control systems, sensors, data acquisition units, safety and monitoring circuits, and general practices followed for satisfying the local and international codes of practice. The VT Roller Rig is comprised of a wheel and a roller in a vertical configuration that simulate the single-wheel/rail interaction in one-fourth scale. The roller is five times larger than the scaled wheel to keep the contact patch distortion that is inevitable with a roller rig to a minimum. This setup is driven by two independent AC servo motors that control the velocity of the wheel and roller using state-of-the-art motion control technologies. Six linear actuators allow for adjusting the simulated load, wheel angle of attack, rail cant, and lateral position of the wheel on the rail. All motion controls are performed using digital servo drives, manufactured by Kollmorgen, VA, USA. A number of sensors measure the contact patch parameters including force, torque, displacement, rotation, speed, acceleration, and contact patch geometry. A unified communication protocol between the actuators and sensors minimizes data conversion time, which allows for servo update rates of up to 48kHz. This provides an unmatched bandwidth for performing various dynamics, vibrations, and transient tests, as well as static steady-state conditions. The VT Roller Rig has been debugged and commissioned successfully. The hardware and software components are tested both individually and within the system. The VT Roller Rig can control the creepage within 0.3RPM of the commanded value, while actively controlling the relative position of the rotating bodies with an unprecedented level of accuracy, no more than 16nm of the target location. The contact force measurement dynamometers can dynamically capture the contact forces to within 13.6N accuracy, for up to 10kN. The instantaneous torque in each driveline can be measured with better than 6.1Nm resolution. The VT Roller Rig Motion Programming Interface (MPI) is highly flexible for both programmers and non-programmers. All common motion control algorithms in the servo motion industry have been successfully implemented on the Rig. The VT Roller Rig MPI accepts third party motion algorithms in C, C++, and any .Net language. It successfully communicates with other design and analytics software such as Matlab, Simulink, and LabVIEW for performing custom-designed routines. It also provides the infrastructure for linking the Rig's hardware with commercial multibody dynamics software such as Simpack, NUCARS, and Vampire, which is a milestone for hardware-in-the-loop testing of railroad systems. / Ph. D.

Standardisierte Mehrkörpersimulationsmodelle von Aggregatelagern erweisen sich bei Anregungen hoher Lasten bis zu 20 kN und gleichzeitig hoher Frequenzen bis 15 Hz als fehlerhaft. In dieser Arbeit mit dem Titel: „Entwurf einer Bewertungsmethodik von Elastomer- und Hydrolagermodellen zum Einsatz für die virtuelle Lastdatenermittlung“, wird ein Bewertungskriterium für die Charakterisierung von Aggregatelagermodellen für die Lastdatenermittlung entwickelt. Dieses ist in der Lage die Frequenz, den Verlustwinkel und die dynamische Steifigkeit stochastischer Signale zu bestimmen. Mit dem entwickelten Bewertungskriterium werden standardmäßig eingesetzte Modelle von Elastomerlagern mit Prüfstandsmessdaten verglichen und auf ihre Abbildungsgüte untersucht. Weiterhin werden die Messdaten mit dem Bewertungskriterium auf Effekte und Eigenschaften des untersuchten Aggregatelagers analysiert. Aus den gewonnen Erkenntnissen wird ein Messplan zur verbesserten Parametrierung und weiterführenden Erforschung der Eigenschaften des untersuchten Aggregatelagers abgeleitet. Es wird ein neues Lagermodell entwickelt und in Zusammenarbeit mit Liu parametriert (2018). Im letzten Schritt wird das entwickelte Lagermodell mit dem in dieser Arbeit entwickelten Bewertungskriterium bewertet und mit den Standardmodellen verglichen.:Abbildungsverzeichnis IV Tabellenverzeichnis VII Formelzeichenverzeichnis VIII Abkürzungsverzeichnis XI 1 Einleitung und Motivation 1 2 Grundlagen und Stand der Technik 4 2.1 Eigenschaften von Elastomer- und Hydrolagern 4 2.1.1 Elastomerlager 4 2.1.2 Hydrolager 11 2.2 Elastomerlagermodelle 12 2.2.1 Bushing (BUS) 13 2.2.2 Universal Bushing (UBS) 14 2.3 Lastdatenermittlung der Aggregatelager 15 2.4 Bewertung stochastischer Signale 19 3 Bewertungskriterien 24 3.1 Fehlerverteilung 24 3.2 Kriterium Ersatzgrößen 25 3.2.1 Ersatzfrequenz 27 3.2.2 Ersatzverlustwinkel 29 3.2.3 Ersatzsteifigkeit 31 3.2.4 Mittlere Kraft und Ersatzamplitude 32 4 Modellbewertung 34 4.1 Einaxiale Anregung 35 4.2 Mehraxiale Anregung 42 4.3 Modellbewertung auf Gesamtfahrzeugebene 45 4.3.1 Gesamtfahrzeugmodell und Fahrmanöver 46 4.3.2 Modellbewertung 47 4.4 Zusammenfassung Modellbewertung 49 5 Messdatenanalyse 51 5.1 Einaxiale Anregung 51 5.2 Mehraxiale Anregung 60 5.3 Zusammenfassung und Forschungsfragen 64 6 Messdatenauswertung 67 6.1 Einaxiale dynamische Messungen 67 6.2 Vorlast- und Amplitudensprung 68 6.3 Kopplung der Freiheitsgrade 71 7 Lagermodellentwicklung Extended Universal Bushing 74 7.1 Aufbau Extended Universal Bushing (EUB) 74 7.2 Parameteridentifikation 75 7.3 Modellbewertung 75 7.3.1 Einaxiale Anregung 76 7.3.2 Mehraxiale Anregung 78 8 Zusammenfassung 81 9 Ausblick 83 9.1 Bewertungskriterium Ersatzgrößen 83 9.2 Extended Universal Bushing 83 Literaturverzeichnis X Anhang XIII A Kennfelder zur Kopplung der Freiheitsgrade XIII B Messplan XV

The goal of this thesis work is to evaluate and quantify the advantages and disadvantages of Active Rear Steering (ARS). The evaluation is carried out through Multi-Body System (MBS) simulations. An analytical model has been developed to better understand the basic dynamics of vehicles equipped with rear steering. In parallel, a high fidelity MBS model is developed in Simpack. This model includes suspension kinematics and compliance, allowing for detailed analyses of steering hardware performance. Next, different control strategies aiming at improving manoeuvrability, stability and agility are implemented in Simulink. In order to assess their effectiveness, the high fidelity model is utilised by running co-simulation with Simulink. Manoeuvrability is assessed through constant steer, constant radius and ramp steer manoeuvres. Stability is assessed through transient manoeuvres such as step steer and sine with dwell. Agility is assessed through step steer and frequency response. Ultimately, also a subjective assessment is carried out by means of Volvo Cars' dynamic driving simulator. The conclusion from the assessment is that the drivers feel the all wheel steered vehicle more stable during evasive manoeuvres. It is concluded that for manoeuvrability the minimum turning radius is reduced by 19 % at low velocity; this implies that the steering angle request is reduced at low velocity, while it is increased at high velocity. A slightly higher steering angle request at high velocity might be beneficial since the driver would be able to control the vehicle in a wider range of steering wheel angles. For agility the results are contradicting: on the one hand, according to the step steer rise time difference between lateral acceleration and yaw rate, the controlled vehicles are performing worse than the passive vehicle; on the other hand, according to the frequency response analysis, both the delays between steering input and yaw rate and between lateral acceleration and yaw rate are reduced up to respectively 75 % and 46 % for the considered frequency range. Finally, for stability, the yaw rate overshoot from a step steer can be reduced up to 65 % at high velocity and the sideslip angle can always be reduced. The vehicle equipped with ARS outperforms the passive vehicle in the sine with dwell manoeuvre. / Målet med detta examensarbete är att utvärdera och kvantifiera fördelarna och nackdelarna med Active Rear Steer (ARS) för Volvo Cars. Utvärderingen utförs genom Multi-Body System (MBS) simuleringar. En analytisk modell har utvecklats för att bättre förstå den grundläggande dynamiken i fordon utrustade med bakhjulsstyrning. Parallelt utvecklades en MBS-modell med hög precision i Simpack. Denna modell inkluderar hjulupphängningens kinematik och eftergivlighet, vilket möjliggör detaljerade analyser av styrhårdvarans prestanda. Därefter implementeras olika kontrollstrategier som syftar till att förbättra manövrerbarhet, stabilitet och agilitet i Simulink. För att bedöma deras effektivitet används MBS-modellen för att köra co-simulering med Simulink.Manövrerbarhet bedöms genom konstant styrning, konstant radie och rampstyrning. Stabilitet bedöms genom transienta manövrar som stegstyrning och sinus med fördröjning. Agilitet bedöms genom stegstyrning och frekvensrespons. Slutligen görs också en subjektiv bedömning med hjälp av Volvo Cars dynamiska körsimulator. Slutsatsen från bedömningen är att förarna anser att fordonet upplevs vara mycket stabilare vid undanmanövrar. Vidare är slutsatsen att för manövrerbarhet minskar den minsta svängradien med 19 % vid mycket låg hastighet; detta innebär att styrvinkel reduceras vid låg hastighet, medan den ökar vid hög hastighet. En något högre styrvinkeln kan vara fördelaktig eftersom föraren skulle kunna styra fordonet i ett större rattvinkelområde. För agilitet är resultaten motsägelsefulla: å ena sidan, enligt stegstyrningstidsskillnaden mellan lateral acceleration och girhastighet, fungerar de aktiva fordonen sämre än det passiva fordonet; å andra sidan, enligt frekvensresponsanalysen, reduceras både fördröjningarna mellan girhastighet och styrvinkel och mellan lateral acceleration och girhastighet upp till ungefär 30 %. Slutligen, för stabilitet, kan girhastighetens översläng från en stegstyrning minskas upp till 65 % vid hög hastighet och avdriftsvinkeln kan alltid minskas. Fordonet som är utrustat med ARS överträffar det passiva fordonet i manövern sinus med fördröjning.

Vehicle Dynamics Control (VDC) systems (also known as Active Chassis systems) are mechatronic systems developed for improving vehicle comfort, handling and/or stability. Traditionally, most of these systems have been individually developed and manufactured by various suppliers and utilised by automotive manufacturers. These decentralised control systems usually improve one aspect of vehicle performance and in some cases even worsen some other features of the vehicle. Although the benefit of the stand-alone VDC systems has been proven, however, by increasing the number of the active systems in vehicles, the importance of controlling them in a coordinated and integrated manner to reduce the system complexity, eliminate the possible conflicts as well as expand the system operational envelope, has become predominant. The subject of Integrated Vehicle Dynamics Control (IVDC) for improving the overall vehicle performance in the existence of several VDC active systems has recently become the topic of many research and development activities in both academia and industries Several approaches have been proposed for integration of vehicle control systems, which range from the simple and obvious solution of networking the sensors, actuators and processors signals through different protocols like CAN or FlexRay, to some sort of complicated multi-layered, multi-variable control architectures. In fact, development of an integrated control system is a challenging multidisciplinary task and should be able to reduce the complexity, increase the flexibility and improve the overall performance of the vehicle. The aim of this thesis is to develop a low-cost control scheme for integration of Electric Power-Assisted Steering (EPAS) system with Enhanced Stability Program (ESP) system to improve driver comfort as well as vehicle safety. In this dissertation, a systematic approach toward a modular, flexible and reconfigurable control architecture for integrated vehicle dynamics control systems is proposed which can be implemented in real time environment with low computational cost. The proposed control architecture, so named “Integrated Vehicle Control System (IVCS)”, is customised for integration of EPAS and ESP control systems. IVCS architecture consists of three cascade control loops, including high-level vehicle control, low-level (steering torque and brake slip) control and smart actuator (EPAS and EHB) control systems. The controllers are designed based on Youla parameterisation (closed-loop shaping) method. A fast, adaptive and reconfigurable control allocation scheme is proposed to coordinate the control of EPAS and ESP systems. An integrated ESP & ESP HiL/RCP system including the real EPAS and Electro Hydraulic Brake (EHB) smart actuators integrated with a virtual vehicle model (using CarMaker/HiL®) with driver in the loop capability is designed and utilised as a rapid control development platform to verify and validate the developed control systems in real time environment. Integrated Vehicle Dynamic Control is one of the most promising and challenging research and development topics. A general architecture and control logic of the IVDC system based on a modular and reconfigurable control allocation scheme for redundant systems is presented in this research. The proposed fault tolerant configuration is applicable for not only integrated control of EPAS and ESP system but also for integration of other types of the vehicle active systems which could be the subject of future works.

An operating vehicle requires energy to oppose the subjected driving resistances. This energy is supplied via the fuel combustion in the engine. Decreasing the opposing driving resistances for an operating vehicle increases its fuel efficiency: an effect which is highly valued in today’s industry, both from an environmental and economical point of view. Therefore a lot of progress has been made during recent years in the area of fuel efficient vehicles, even though some driving resistances still rises perplexity. These resistances are the air drag Fd generated by the viscous air opposing the vehicles propulsion and the rolling resistance Frr generated mainly by the hysteresis caused by the deformation cycle of the viscoelastic pneumatic tires. The energy losses associated with the air drag and rolling resistance account for the majority of the driving resistances facing an operating vehicle, and depends on numerous stochastic and ambient parameters, some of which are highly correlated both within and between the two resistances. To increase the understanding of the driving mechanics behind the energy losses associated with the complexity that is rolling resistance, a set of complete vehicle tests has been carried out. These tests were carried out on the test track Malmby Fairground, using a Scania CV AB developed R440 truck equipped with various sensors connected in one measurement system. Under certain conditions, these parameters can allow for an investigation of the rolling resistance, and a separation of the rolling resistance and air drag via explicit subtraction of the air drag from the measured traction force. This method is possible since the aerodynamic property AHDVCd(β) to some extent can be generated from wind tunnel tests and CFD simulations. Two measurement series that enable the above formulated method of separation were designed and carried out, using two separate measurement methods. One which enables the investigation of the transient nature of rolling resistance as it strives for stationarity, where the vehicle is operated under constant velocities i.e. no acceleration, and one using the well established method of coastdown, where no driving torque is applied. The drive cycles spanned a range of velocities, which allowed for dynamic and stationary analyses of both the tire temperature- and the velocity dependence of rolling resistance. When analysing the results of the transient analysis, a strong dependence upon tire temperature for given constant low velocity i.e. v ≤ 60 kmh−1 was clearly visible. The indicated dependency showed that the rolling resistance decreased as the tire temperature increased over time at a given velocity, and vice versa, towards a stationary temperature and thereby rolling resistance. The tire temperature evolution from one constant velocity to another, took place well within 50 min to a somewhat stationary value. However, even though the tire temperature had reached stationarity, rolling resistance did not; there seemed to be a delay between stationary tire temperature, and rolling resistance. The results did not indicate any clear trends for v ≥ 60 kmh−1, where the results at v = 80 kmh−1 were chaotic. This suggests that some additional forces were uncompensated for, or that the compensation for air drag was somehow wrongly treated at higher velocities. Several factors ruled out any attempts at proposing a new rolling resistance model. These included: the chaotic results for v = 80 kmh−1, the delayed rolling resistance response upon tire temperature stabilization, and the lack of literature support for the observed tendency. The results from the coastdown series on the other hand, showed good agreement with a dynamical model suggested in literature. The stationary temperature behaviour for the considered velocity range at assumed constant condition is also supported in literature. Finally, an investigation of the aerodynamic property AHDVCd inspired by ongoing work in ACEA (European Automobile Manufacturers’ Association), was carried out assuming both zero and non-zero air drag at low velocities. The results indicated surprisingly good agreement with wind tunnel measurements, especially when neglecting air drag at low velocities: as suggested by ACEA. / För att övervinna de motstånd som ett fordon utsätts för under drift krävs energi, vilket levereras genom förbränningen av bränsle. Genom att minska de körmotstånd som ett fordon utsätts för under drift, kan man öka dess energieffektivitet. Denna potential är idag högt värderad i fordonsindustrin, både ur ett miljömässigt och ekonomiskt perspektiv. På senare år har stora framsteg gjorts inom området energieffektiva fordon, men fortfarande råder det förvirring kring de energiförluster som förknippas med luftmotstånd Fd och rullmotstånd Frr, där luftmotståndet skapas av den omkringliggande viskösa luften, medan rullmotståndet genereras av hysteresen som uppstår när fordonets viskoelastiska pneumatiska däck utsätts för deformation. De energiförluster som förknippas med luft- och rullmotstånd motsvarar den största delen av de motstånd som ett fordon påverkas av, och beror på en mängd stokastiska och yttre parametrar, varav vissa är starkt korrelerade både inom och mellan nämnda motstånd. För att förbättra förståelsen kring dessa energiförluster, med fokus på förståelsen av rullmotstånd, har ett antal helfordonstest genomförts. Dessa genomfördes på provbanan Malmby Fairground med en R440 lastbil från Scania CV AB, utrustad med en mängd sensorer sammankopplade i ett mätsystem. Det uppbyggda mätsystemet möjliggjorde samtida mätningar av bl.a. drivande moment, motorvarv, fordonshastighet, däcktemperatur, omkringliggande lufts hastighet och dess riktning. Under specifika förhållanden kunde dessa parametrar möjliggöra analys av rullmotstånd genom en explicit subtraktion av luftmotstånd från den uppmätta drivande kraften. Denna metod är möjlig tack vare en förhållandevis bra modell av ekipagets aerodynamiska egenskap AHDVCd(β), som generats från vindtunneltest och CFD simuleringar. Två körcykler som möjliggjorde ovan formulerade separation designades och genomfördes. Dessa använder två skilda mätmetoder, varav den ena möjliggör analys av rullmotståndets övergående förlopp från dynamiskt till stationärt genom att hålla konstant hastighet. Den andra studerade det dynamiska förloppet genom den väletablerade metoden utrullning, dvs. utan något drivande moment. Dessa körcyklar genomfördes, för ett antal hastigheter, vilket möjliggjorde analys av både hastighets- och däcktemperaturberoendet hos rullmotstånd, under dynamiska såväl som stationära förlopp. Analysen av rullmotståndets dynamik i strävan mot stationära förhållanden visade på ett starkt temperaturberoende vid låga hastigheter dvs. v ≤ 60 kmh−1. Beroendet visade på att rullmotståndet avtog med ökande däcktemperatur och vice versa, tills dess att en någorlunda stationär temperatur för given hastighet uppnåtts. Däcktemperaturen stabiliserades till ett nytt stationärt värde inom 50 min från att hastigheten ändrats. Resultaten tyder dock på att även om stationär däcktemperatur uppnåtts finns det en fördröjning i rullmotståndets tidsspann innan rullmotståndet stabiliserat sig. För högre hastigheter, dvs. v ≥ 60 kmh-1, var dock inga klara trender synliga, varken i hastighet eller temperatur och resultaten vid v = 80 kmh-1 var kaotiska. Detta antyder att man missat att kompensera för någon kraft vid höga hastigheter, alternativt att man på något sätt kompenserar fel för luftmotståndet vid högre hastigheter. Flera faktorer hindrade försök att föreslå någon ny rullmotståndsmodell. Dessa faktorer inkluderar det kaotiska resultatet vid v = 80 kmh-1, tidsfördröjningen mellan stationärt rullmotstånd och däcktemperatur samt att resultatet för antagna stationära värden inte finner stöd i litteraturen. Resultatet från utrullningsprovet överstämmer dock bra med tidigare föreslagen dynamisk modell, samt att resultaten av beteendet hos stationär temperatur för olika hastigheter även de överensstämmer med och finner stöd i litteraturen. Slutligen har en studie kring den aerodynamiska egenskapen AHDVCd, inspirerad av pågående arbete inom ACEA (European Automobile Manufacturers’ Association) utförts både med antagandet av ett noll- skilt och med ett försumbart luftmotstånd vid låga hastigheter. Resultatet visar på en överraskande god överensstämmelse med vindtunnelmätningar, framför allt under antagandet av försumbart luftmotstånd vid låga hastigheter i enlighet med förslagen metod från ACEA.

Les Véhicules Etroits et Inclinables (VEI) sont la convergence d’une voiture et d’un motocycle. Un mètre de largeur seulement suffit pour transporter une ou deux personnes en Tandem. Les VEI sont conçus dans le but de résoudre partiellement les problèmes de trafic routier, de minimiser la consommation énergétique et l’émission de polluants. De par leurs dimensions(ratio hauteur/largeur), ces véhicules doivent s’incliner en virage pour rester stable en compensant l’effet de l’accélération latérale. Cette inclinaison doit dans certains cas être automatique : elle peut être réalisée à l’aide d’un couple d’inclinaison généré par un actionneur dédié (système DTC), soit encore en modulant l’angle de braquage des roues (Système STC). Nous avons proposé dans ce mémoire une méthodologie de synthèse d’un régulateur structuré minimisant la norme H2 d’un problème bien posé au bénéfice d’une régulation optimisée de l’accélération latérale, considérant tour à tour les systèmes DTC et STC. Les régulateurs proposés sont paramétrés par la vitesse longitudinale et s’avèrent performants et robustes, et les moyens de réglages proposés permettent d’étudier l’intérêt relatif d’une solution DTC pure ou mixte DTC/STC, permettant de supporter les développements futurs sur le sujet. L’originalité des solutions proposées en regard des études rencontrées dans la littérature porte en particulier sur le fait de choisir de réguler directement l’accélération latérale perçue (plutôt que l’angle d’inclinaison), en anticipant la prise de virage par la prise en compte des angles et vitesse de braquage. L’optimisation de la régulation permet de réduire de manière importante le couple d’inclinaison requis, et l’accélération latérale subie par les passagers est faible. Tous les développements proposés s’appuient naturellement en amont sur un travail de modélisation (recherche du modèle juste nécessaire), et de bibliographie conséquent. Le modèle retenu comprend 5 degrés de libertés. Nous avons démontré qu’il possédait la propriété intéressante d’être plat, et avons utilisé cette propriété pour ouvrir des perspectives relatives à la conception d’un régulateur non-linéaire robuste, susceptible apriori d’accroître les performances dans le cas de « grands mouvements ». Au contraire de ce qui existe dans la littérature,le régulateur multivariable conçu pour le système SDTC permet le contrôle coordonné des actions sur les systèmes STC et DTC. / Narrow Tilting Vehicles (NTV) are the convergence of a car and a motorcycle. One meter wide, these vehicles are designed for one or two people sitting the one in front the other. The idea behind the conception of NTV is the minimization of traffic congestion, energy consumption and pollutant emission. But because of their dimensions, these cars would have to lean into corners in order to compensate for the lateral acceleration and maintain their stability. The tilting should be automatic, and can be achieved by a tilting torque generated by a dedicated tilting actuator (DTC) or by modifying the steering angle (STC) or both (SDTC). In this thesis, we first propose a methodology for the design of an output feedback structured regulator, minimizing the H2 norm of a well-posed problem, built to optimize the lateral acceleration of the NTV, considering DTC and SDTC systems.The designed controllers, with the longitudinal velocity as a parameter, lead to the minimization of the tilting torque and of the lateral acceleration perceived by the driver, and have good performances as well as good robustness properties. Furthermore, the tuning methodology allows the comparison of a pure DTC solution and a mixed SDTC alternative. Compared to the literature, the originalities in this thesis are the direct control of the measured value of the lateral acceleration (instead of the tilting angle), and the anticipation of the tilt, thanks to the use of the steering angle and angular velocity. Furthermore, the SDTC solution allows to drive both the STC and DTC systems in a coordinated manner. The design strategies are based on a preliminary study of vehicle models, and a design model with 5DoF was developed. We demonstrated that the model has the nice property to be flat, and in the last section of the thesis, used this property to initiate the design of a non-linear robust controller, which can a priori lead to better performances in case of “large motions”.

La suspension CRONE Hydractive, développée par l’équipe CRONE dans le cadre des suspensions de véhicules automobiles, présente des performances remarquables. En effet, l’association de l’approche CRONE, garantissant la robustesse du degré de stabilité aux variations de la masse suspendue, et de la stratégie Hydractive, permettant la commutation d’une architecture de suspension orientée confort vibratoire à une autre orientée comportement routier,permet la mise en défaut de la plupart des dilemmes inhérents aux architectures traditionnelles de suspension. La présente étude propose ainsi le développement d’une version alternative de la suspension CRONE par deux approches. Une première approche consiste en la mise en place d’une version passive métallique reposant sur l’utilisation des ressorts à lames en s’inscrivant dans une démarche de modernisation et d’optimisation des technologies historiques. La seconde approche, quant à elle, consiste à proposer le développement d’une version active pneumatique de la suspension CRONE. La modélisation complète de l’architecture « CRONE » orientée confort est alors proposée à travers celle de ses accumulateurs et gicleurs pneumatiques. Cette nouvelle version de suspension, en adoptant une technologie d’actualité de plus en plus répandue et pouvant bénéficier des développements du Véhicule Autonome Connecté, ouvre de nouvelles perspectives d’évolution de la suspension automobile. / The Hydractive CRONE car suspension developed by the CRONE team provides outstanding performances. Indeed, the CRONE method ensures the robustness of the stability degree with respect to variations of the sprung mass, while the Hydractive strategy enables the switchover between a comfort-oriented architecture and a road-behavior-oriented one. The association of the CRONE method with the Hydractive strategy allows to circumvent most of the dilemmas that occur with traditional architecture suspensions. The present study aims to develop an alternative version of the CRONE suspension using two approaches. A first approach consists of the implementation of a passive metallic version based on leaf springs aiming the modernisation and optimisation of historical technologies. The second one, however, involves the use of a more relevant and increasingly widespread technology with the development of an active pneumatic version of the CRONE suspension. The complete modeling of the ``CRONE'' comfort-oriented architecture is then proposed through its pneumatic accumulators and nozzles. This new version, benefiting from the pneumatic active system and from the development of the Autonomous Connected Vehicle, opens up new prospects for the development of car suspensions.

Cette thèse s'inscrit dans le cadre de la conception des systèmes mécatroniques. Les travaux se positionnent dans les premières phases du cycle de conception, là où les principaux efforts méthodologiques sont à mener pour améliorer la qualité et la fonctionnalité des produits, et reposent sur le prototypage virtuel (modélisation et simulation). Une approche méthodologique envisageable est de reformuler le problème de conception sous une forme inverse, pour directement utiliser les spécifications du cahier des charges, usuellement exprimées sur les sorties, pour calculer les inconnues du problème. Dans ce contexte, le laboratoire Ampère développe une méthodologie de conception et dimensionnement, basée sur l'inversion de modèle, utilisant le formalisme bond graph, pour proposer une démarche reposant sur des critères dynamiques et énergétiques, et dont la principale originalité est sa phase d'analyse structurelle, permettant une hiérarchisation d’analyse suivant différents niveaux de la structure physique du modèle (topologie, phénoménologie, paramétrage). L'objectif est de contribuer au développement de cette méthodologie, en l’étendant aux modèles appartenant à la classe des systèmes singuliers, porté par la velléité de décliner la démarche à la conception fonctionnelle du châssis automobile et de ses sous-systèmes, comportant un certain nombre d'abstractions de modélisation et d'idéalisations. Cette déclinaison est proposée, d’une part, au niveau de la structure du modèle et, d’autre part, à un niveau considérant sa phénoménologie et ses lois de comportement. Elle requiert la mise en place préalable d'un référentiel algébrique, essentiellement issu de travaux sur la commande des systèmes, pour constituer une base de validation des extensions graphiques (digraphe et bond graph) proposées. En plus de la généralisation qu'ils constituent à la classe des modèles singuliers, les présents travaux proposent une uniformisation des précédentes approches de la méthodologie, originellement appliquées respectivement aux modèles directs et aux modèles inverses, de sorte qu'il n'est à présent plus nécessaire de les différencier. / The context of this PhD thesis is the modeling and design of mechatronic systems. The study is positioned in the early design stage of the conception cycle (V-Cycle), where the main efforts have to be produced in terms of methodology, to enhance the quality and the functionality of the products, and based on virtual prototyping (modeling and simulation). One of the possible methodology is to reformulate the design problem as an inverse problem, in order to directly use the design specification of the product, usually given in terms of the system outputs, and then solve the design problem. In this context, the Ampere laboratory of INSA Lyon has developed a conception and design methodology, based on inverse approach and using the bond graph formalism, to propose a step-by-step method based on dynamic and energetic criteria, with a structural analysis phase that allows hierarchical analysis steps, depending on the structural physical layout of the model (topological, phenomenological, parameter set). The aim of the present works is to contribute to the development of this methodology, by enhancing it to the class of descriptor systems. This choice is led by the aim to apply the methodology in the context of chassis design and vehicle dynamics, where, among other, multi-body models represented as a differential-algebraic equation (DAE) system could occur. The contributions are proposed at the level of the topology of the model, as well as at the level of the phenomenological / behavioral aspects. A preliminary step is to enhance the existing algebraic framework to support graphical extension (in term of digraph and bond graph). The overall methodological extensions allow, firstly, a generalization of the approach to the class of descriptor systems, and, secondly, to reach a standardization of the procedures, previously dedicated to direct or inverse models, so as no mandatory differences between those models have to be done anymore.

O tema do conforto na automobilística é bastante extenso e possuidor de muitas interpretações. A ideia central deste trabalho é definir e direcionar alguns métricos para que, durante as fases de conceituação e desenvolvimento de um veículo, seja possível ter um direcional de definição de componentes e atributos veiculares de modo a facilitar o direcionamento dos atributos no programa veicular, e assim atingir suas necessidades. Como exemplo empregado, é empregado um veículo de plataforma tipo B em desenvolvimento por uma montadora, o qual teve as molas de suspensão definidas e rigidezes laterais de eixos com base em material técnico interno equivalente aos estudos apresentados neste trabalho. É adotada uma abordagem inicialmente empírica conforme os primeiros estudos de suspensões independentes realizados neste continente, depois o trabalho é complementado com exigências de normas especificas para vibrações (ISO2361, ISO5008, BS6055) de modo a caracterizar energia vibracional e a interpretação pelo ser humano. Porém como hoje em dia as suspensões automotivas são muito mais complexas, existem componentes específicos para as várias condições de solicitação, deste modo a análise é limitada a situações de ride (conforto) primário e handling (dirigibilidade) em situações de sublimite na faixa linear (cerca de 0,5 g). Como conclusão dos estudos, é possível ter em um veículo atributos de estabilidade sem necessariamente prejudicar o conforto, pois sendo definidos corretamente os componentes elásticos da dinâmica vertical para situações estacionárias e de ride primário, é definido seu equilíbrio estacionário e assim não é necessário comprometimento dos atributos de outros componentes para compensar alguma deficiência existente. / The range of assumptions for ride comfort is considered very wide in the automotive world and they can assume lots of possible interpretations. The central idea in this work is define and manage some metrics that, during the concept and development phases of a vehicular program, be possible to follow a better direction for the attributes development and so reach the program targets. As the example in this work, a B platform typical vehicle is used and it is under development in a carmaker, its suspension springs and axle roll stiffness were setup with technical information similar to the ones presented in this work. The initial approach is empiric as occurred with the first independent suspension system studies in this continent and in the sequence, the work is complemented with standards for vibrational issues (ISO2361, ISO5008, BS6055), after this, finally how the vibrational energy is defined and perceived by human beings. The automotive suspensions of current days are very complex and there are lots of specific components to do a specific work, so the analysis are limited to primary ride and sub limit handling (up to 0,5 g). As conclusion, its possible setup a car that is comfortable and stable in the same time, since the elastic components for the vertical dynamics and steady state conditions are correctly set, so its correct balance is reached and no other components attributes are compromised to compensate any deficiency.

Several standardized courses for Formula SAE (FSAE) testing are introduced and described with sufficient detail to be reproduced by any Formula SAE team. Basic analysis methods for the courses are given as well as explanations of how those analyses could be used. On-car data from the Global Formula Racing (GFR) SAE cars is used to verify the analysis methods, give estimates to unknown variables, and show the relevance of the standard testing courses. Using the courses and methods described in this paper should allow standardized comparison of FSAE car performance, as well as provide a method to verify simulations and evaluate changes in vehicle performance from tuning. Instrumentation of all suspension member forces with strain gauge load cells is shown to be an extremely powerful tool for measuring vehicle performance and quantifying vehicle dynamic characteristics. The design and implementation of strain gauge load cells is described in detail to provide a template for reproducing similar results in other vehicles. Data from the GFR 2011 FSAE car is used throughout the paper to: show the design process for making effective suspension member load cells, show the calibration processes necessary to ensure quality data is collected, illustrate the calculation of suspension corner forces, and show the effectiveness of measuring vehicle dynamic characteristics with this technique. Using the methods described in this paper should provide data that allows a more complete and thorough understanding of on-car vehicle dynamics. This data may be used to validate vehicle models. / Graduation date: 2012