Control strategies of series active variable geometry suspension for cars

This thesis develops control strategies of a new type of active suspension for high performance cars, through vehicle modelling, controller design and application, and simulation validation. The basic disciplines related to automotive suspensions are first reviewed and are followed by a brief explanation of the new Series Active Variable Geometry Suspension (SAVGS) concept which has been proposed prior to the work in this thesis. As part of the control synthesis, recent studies in suspension control approaches are intensively reviewed to identify the most suitable control approach for the single-link variant of the SAVGS. The modelling process of the high-fidelity multi-body quarter- and full- vehicle models, and the modelling of the linearised models used throughout this project are given in detail. The design of the controllers uses the linearised models, while the performance of the closed loop system is investigated by implementing the controllers to the nonlinear models. The main body of this thesis elaborates on the process of synthesising H∞ control schemes for quarter-car to full-car control. Starting by using the quarter-car single-link variant of the SAVGS, an H∞ -controlled scheme is successfully constructed, which provides optimal road disturbance and external force rejection to improve comfort and road holding in the context of high frequency dynamics. This control technique is then extended to the more complex full-car SAVGS and its control by considering the pitching and rolling motions in the context of high frequency dynamics as additional objectives. To improve the level of robustness to single-link rotations and remove the geometry nonlinearity away from the equilibrium position, an updated approach of the full-car SAVGS H∞ -controlled scheme is then developed based on a new linear equivalent hand-derived full-car model. Finally, an overall SAVGS control framework is developed, which operates by blending together the updated H∞ controller and an attitude controller, to tackle the comfort and road holding in the high frequency vehicle dynamics and chassis attitude motions in the low frequency vehicle dynamics simultaneously. In all cases, cascade inner position controllers developed prior to the work in this thesis are employed at each corner of the vehicle and combined with the control systems developed in this thesis, to ensure that none of the physical or design limitations of the actuator are violated under any circumstances.Open Acces

Vibration isolation under isolator-structure interaction

This thesis analyses a general case of the vibration isolation (VI) problem, considering both a rigid and non-rigid supporting structures. The aim is to study changes on the behaviour of both systems isolators and supporting structure when the interaction phenomenon between them is considered. The influence of the VI task on the base response is evaluated. In addition, the effect of the base dynamics on the the VI and alignment problem is studied. The novel contribution to the knowledge of this thesis is formulation of a novel VI approach, which facilitates a holistic analysis of the problem considering all the systems involved on it. This approach is valid for any number of isolators and for any type of base structure. Moreover, different control objectives can be easily defined; evaluation of the interaction phenomenon on both the platform and base response for different VI techniques; demonstration of the importance of the isolator damping ratio on the influence that the VI task has on the base response; evaluation of the effects of the supporting structure dynamics on the VI and alignment problem when multiple isolators are involved; analysis of the Multiple-Input-Multiple-Ouput (MIMO) control strategy by comparison with the Single-Input-Single-Output (SISO) control strategy. This comparative has been made for the VI and alignment problem of multiple isolators on a non-rigid supporting structure and includes analysis of the effectiveness of the Coral Reefs Optimization algorithms to find nearly-optimal control gains in VI and alignment problems. Through the investigation made for this thesis, a number of significant results have been reached, which show the importance of the supporting structure dynamics on the VI and alignment task. Moreover, the interaction phenomenon, and its consequence on the base response, has been investigated experimentally. The results derived from this thesis conclude that, for most scenarios, the dynamics of the base affects the VI task. Also, the active VI (AVI) technique shows a greater influence on the base response than passive VI (PVI) technique, for most cases. It has been observed that the use of AVI technique can additionally be oriented to control vibrations of the supporting structure, while the VI task is developed. Significant differences have been found when multiple isolators are involved in the same task for the alignment and VI problem, depending on whether or not the dynamics of the base are considered. The best set of control gains for the rigid-support case (which lead to maximum damping ratio) differ from those obtained when the supporting structure is considered as a flexible system, for different cases analysed in this thesis. The MIMO control strategy has shown great improvement with respect to the use of the SISO control strategy. Also, the Coral Reefs Optimization algorithms have been demonstrated to be a suitable tool to find nearly-optimal solutions for this type of problems

Optimised configuration of sensing elements for control and fault tolerance applied to an electro-magnetic suspension system

New technological advances and the requirements to increasingly abide by new safety laws in engineering design projects highly affects industrial products in areas such as automotive, aerospace and railway industries. The necessity arises to design reduced-cost hi-tech products with minimal complexity, optimal performance, effective parameter robustness properties, and high reliability with fault tolerance. In this context the control system design plays an important role and the impact is crucial relative to the level of cost efficiency of a product. Measurement of required information for the operation of the design control system in any product is a vital issue, and in such cases a number of sensors can be available to select from in order to achieve the desired system properties. However, for a complex engineering system a manual procedure to select the best sensor set subject to the desired system properties can be very complicated, time consuming or even impossible to achieve. This is more evident in the case of large number of sensors and the requirement to comply with optimum performance. The thesis describes a comprehensive study of sensor selection for control and fault tolerance with the particular application of an ElectroMagnetic Levitation system (being an unstable, nonlinear, safety-critical system with non-trivial control performance requirements). The particular aim of the presented work is to identify effective sensor selection frameworks subject to given system properties for controlling (with a level of fault tolerance) the MagLev suspension system. A particular objective of the work is to identify the minimum possible sensors that can be used to cover multiple sensor faults, while maintaining optimum performance with the remaining sensors. The tools employed combine modern control strategies and multiobjective constraint optimisation (for tuning purposes) methods. An important part of the work is the design and construction of a 25kg MagLev suspension to be used for experimental verification of the proposed sensor selection frameworks

A New Control Strategy for Coordinated Control of Ground Vehicle Vertical Dynamics via Control Allocation

The scope of this thesis concerns the basic research and development of a coordinated control system for the control of vehicle roll and pitch dynamics using suspension forces as actuators. In this thesis, the following question is explored: How can suspension control (particularly semi-active control) be generalized to control all vertical vehicle dynamics in a coordinated way, and which would ideally be integrable with modern ESC systems? The chosen approach to this problem will be the application of the control allocation methodology for overactuated systems, which makes use of online mathematical optimization in order to realize the desired control law. Background information on vehicle dynamics and modeling, suspension control, control allocation and optimization is presented along with a brief literature review. The coordinated suspension control system (CSC) is designed and simulated. High-level controllers and control allocators are designed and their stability properties are explored. Then, the focus is shifted towards implementation and experimentation of the coordinated control system on a real vehicle. The semi-active actuators are statistically modeled along with the deployed sensors. Both the hardware and software designs are explored. Finally, experiments are designed and results are discussed. Recommendations for future inquiry are given in the conclusion of this work.4 month

Integration of Active Systems for a Global Chassis Control Design

Vehicle chassis control active systems (braking, suspension, steering and driveline), from the first ABS/ESC control unit to the current advanced driver assistance systems (ADAS), are progressively revolutionizing the way of thinking and designing the vehicle, improving its interaction with the surrounding world (V2V and V2X) and have led to excellent results in terms of safety and performances (dynamic behavior and drivability). They are usually referred as intelligent vehicles due to a software/hardware architecture able to assist the driver for achieving specific safety margin and/or optimal vehicle dynamic behavior. Moreover, industrial and academic communities agree that these technologies will progress till the diffusion of the so called autonomous cars which are able to drive robustly in a wide range of traffic scenarios. Different autonomous vehicles are already available in Europe, Japan and United States and several solutions have been proposed for smart cities and/or small public area like university campus. In this context, the present research activity aims at improving safety, comfort and performances through the integration of global active chassis control: the purposes are to study, design and implement control strategies to support the driver for achieving one or more final target among safety, comfort and performance. Specifically, the vehicle subsystems that are involved in the present research for active systems development are the steering system, the propulsion system, the transmission and the braking system. The thesis is divided into three sections related to different applications of active systems that, starting from a robust theoretical design procedure, are strongly supported by objective experimental results obtained fromHardware In the Loop (HIL) test rigs and/or proving ground testing sessions. The first chapter is dedicated to one of the most discussed topic about autonomous driving due to its impact from the social point of view and in terms of human error mitigation when the driver is not prompt enough. In particular, it is here analyzed the automated steering control which is already implemented for automatic parking and that could represent also a key element for conventional passenger car in emergency situation where a braking intervention is not enough for avoiding an imminent collision. The activity is focused on different steering controllers design and their implementation for an autonomous vehicle; an obstacle collision avoidance adaptation is introduced for future implementations. Three different controllers, Proportional Derivative (PD), PD+Feedforward (FF) e PD+Integral Sliding Mode (ISM), are designed for tracking a reference trajectory that can be modified in real-time for obstacle avoidance purposes. Furthermore, PD+FF and PD+ISM logic are able to improve the tracking performances of automated steering during cornering maneuvers, relevant fromthe collision avoidance point of view. Path tracking control and its obstacle avoidance enhancement is also shown during experimental tests executed in a proving ground through its implementation for an autonomous vehicle demonstrator. Even if the activity is presented for an autonomous vehicle, the active control can be developed also for a conventional vehicle equipped with an Electronic Power Steering (EPS) or Steer-by-wire architectures. The second chapter describes a Torque Vectoring (TV) control strategy, applied to a Fully Electric Vehicle (FEV) with four independent electric motor (one for each wheel), that aims to optimize the lateral vehicle behavior by a proper electric motor torque regulation. A yaw rate controller is presented and designed in order to achieve a desired steady-state lateral behaviour of the car (handling task). Furthermore, a sideslip angle controller is also integrated to preserve vehicle stability during emergency situations (safety task). LQR, LQR+FF and ISM strategies are formulated and explained for yaw rate and concurrent yaw rate/sideslip angle control techniques also comparing their advantages and weakness points. The TV strategy is implemented and calibrated on a FEV demonstrator by executing experimental maneuvers (step steer, skid pad, lane change and sequence of step steers) thus proving the efficacy of the proposed controller and the safety contribution guaranteed by the sideslip control. The TV could be also applied for internal combustion engine driven vehicles by installing specific torque vectoring differentials, able to distribute the torque generated by the engine to each wheel independently. The TV strategy evaluated in the second chapter can be influenced by the presence of a transmission between themotor (or the engine) and wheels (where the torque control is supposed to be designed): in addition to the mechanical delay introduced by transmission components, the presence of gears backlashes can provoke undesired noises and vibrations in presence of torque sign inversion. The last chapter is thus related to a new method for noises and vibration attenuation for a Dual Clutch Transmission (DCT). This is achieved in a new way by integrating the powertrain control with the braking system control, which are historically and conventionally analyzed and designed separately. It is showed that a torsional preload effect can be obtained on transmission components by increasing the wheel torque and concurrently applying a braking wheel torque. For this reason, a pressure following controller is presented and validated through a Hardware In the Loop (HIL) test rig in order to track a reference value of braking torque thus ensuring the desired preload effect and noises reduction. Experimental results demonstrates the efficacy of the controller, also opening new scenario for global chassis control design. Finally, some general conclusions are drawn and possible future activities and recommendations are proposed for further investigations or improvements with respect to the results shown in the present work

Statistical Learning and Stochastic Process for Robust Predictive Control of Vehicle Suspension Systems

Predictive controllers play an important role in today's industry because of their capability of verifying optimum control signals for nonlinear systems in a real-time fashion. Due to their mathematical properties, such controllers are best suited for control problems with constraints. Also, these interesting controllers can be equipped with different types of optimization and learning modules. The main goal of this thesis is to explore the potential of predictive controllers for a challenging automotive problem, known as active vehicle suspension control. In this context, it is intended to explore both modeling and optimization modules using different statistical methodologies ranging from statistical learning to random process control. Among the variants of predictive controllers, learning-based model predictive controller (LBMPC) is becoming more and more interesting to the researchers of control society due to its structural flexibility and optimal performance. The current investigation will contribute to the improvement of LBMPC by adopting different statistical learning strategies and forecasting methods to improve the efficiency and robustness of learning performed in LBMPC. Also, advanced probabilistic tools such as reinforcement learning, absorbing state stochastic process, graphical modelling, and bootstrapping are used to quantify different sources of uncertainty which can affect the performance of the LBMPC when it is used for vehicle suspension control. Moreover, a comparative study is conducted using gradient-based as well as deterministic and stochastic direct search optimization algorithms for calculating the optimal control commands. By combining the well-established control and statistical theories, a novel variant of LBMPC is developed which not only affords stability and robustness, but also surpasses a wide range of conventional controllers for the vehicle suspension control problem. The findings of the current investigation can be interesting to the researchers of automotive industry (in particular those interested in automotive control), as several open issues regarding the potential of statistical tools for improving the performance of controllers for vehicle suspension problem are addressed

Online condition monitoring of lithium-ion and lead acid batteries for renewable energy applications

Electrochemical Impedance Spectroscopy (EIS) has been largely employed for the study of reaction kinetics and condition monitoring of batteries during different operational conditions, such as: Temperature, State of Charge (SoC) and State of Health (SoH) etc. The EIS plot translates to the impedance profile of a battery and is fitted to an Equivalent Electric Circuit (EEC) that model the physicochemical processes occurring in the batteries. To precisely monitor the condition of the batteries, Kramers-Kronig relation: linearity, stability and causality as well as the appropriate perturbation amplitude applied during EIS should be adhered to. Regardless of the accuracy of EIS, its lengthy acquisition time makes it impracticable for online measurement. Different broadband signals have been proposed in literature to shorten EIS measurement time, with different researchers favouring one technique over the other. Nonetheless, broadband signals applied to characterize a battery must be reasonably accurate, with little effect on the systems instrumentation. The major objective of this study is to explore the differences in the internal chemistries of the lithium-ion and lead acid batteries and to reduce the time associated with their condition monitoring using EIS. In this regard, this study firstly queries the methodology for EIS experiments, by investigating the optimum perturbation amplitude for EIS measurement on both the lead acid and lithium-ion batteries. Secondly, this study utilizes electrochemical equations to predict the dynamics and operational conditions associated with batteries. It also investigates the effect of different operational conditions on the lead acid and lithium-ion batteries after EEC parameters have been extracted from EIS measurements. Furthermore, different broadband excitation techniques for rapid diagnostics are explored. An online condition monitoring system is implemented through the utilization of a DC-DC converter that is used to interface the battery with the load. The online system is applied alongside the different broadband signals. The deviation in the broadband impedance spectroscopy result is compared against the Frequency Response Analyzer (FRA) to determine the most suitable technique for battery state estimation. Based on the comparisons, the adoption of a novel technique – Chirp Broadband Signal Excitation (CBSE) is proposed for online condition monitoring of batteries, as it has the advantage of being faster and precise at the most important frequency decade of the impedance spectrum of batteries

Advances and Trends in Mathematical Modelling, Control and Identification of Vibrating Systems

This book introduces novel results on mathematical modelling, parameter identification, and automatic control for a wide range of applications of mechanical, electric, and mechatronic systems, where undesirable oscillations or vibrations are manifested. The six chapters of the book written by experts from international scientific community cover a wide range of interesting research topics related to: algebraic identification of rotordynamic parameters in rotor-bearing system using finite element models; model predictive control for active automotive suspension systems by means of hydraulic actuators; model-free data-driven-based control for a Voltage Source Converter-based Static Synchronous Compensator to improve the dynamic power grid performance under transient scenarios; an exact elasto-dynamics theory for bending vibrations for a class of flexible structures; motion profile tracking control and vibrating disturbance suppression for quadrotor aerial vehicles using artificial neural networks and particle swarm optimization; and multiple adaptive controllers based on B-Spline artificial neural networks for regulation and attenuation of low frequency oscillations for large-scale power systems. The book is addressed for both academic and industrial researchers and practitioners, as well as for postgraduate and undergraduate engineering students and other experts in a wide variety of disciplines seeking to know more about the advances and trends in mathematical modelling, control and identification of engineering systems in which undesirable oscillations or vibrations could be presented during their operation

Improving driver comfort in commercial vehicles : modeling and control of a low-power active cabin suspension system

Comfort enhancement of commercial vehicles has been an engineering topic ever since the first trucks emerged around 1900. Since then, significant improvements have been made by implementing cabin (secondary) and seat suspensions. Moreover, the invention of the air spring and its application to the various vehicle's suspension systems also greatly enhanced driver comfort. However, despite these improvements many truck drivers have health related Problems, which are expected to be caused by their exposure to the environmental vibrations over longer periods of time. The most recent suspension improvements in commercial vehicles date back more than a decade and the possibilities for further improvements using passive devices (springs and dampers) seem nearly exhausted. Consequently, in line with developments in passenger cars, truck manufacturers are now investigating semi-active and active suspension systems. Herein, active suspensions are expected to give the best performance, but also come at the highest cost. Especially the high power consumption of market-ready devices is problematic in a branch where all costs need to be minimized. In this dissertation the field of secondary suspension design and controllable suspensions for heavy vehicles is addressed. More specifically, the possibilities for a low power active cabin suspension design are investigated. The open literature on this topic is very limited in comparison to that of passenger cars. However, as heavy vehicle systems are dynamically more challenging, with many vibration modes below 20 Hz, there is great research potential. The dynamic complexity becomes clear when considering the developed 44 degrees of freedom (DOF) tractor semi-trailer simulation model. This model is a vital tool for suspension analysis and evaluation of various control strategies. Moreover, as it is modular it can also be easily adapted for other related research. The main vehicle components all have their own modules. So, for example, when evaluating a new cabin suspension design, only the cabin module needs to be replaced. The model has been validated using extensive tests on a real tractor semi-trailer test-rig. The control strategy is a key aspect of any active suspension system. However, the 44 DOF tractor semi-trailer model is too complex for controller design. Therefore, reduced order models are required which describe the main dynamic properties. A quarter truck heave-, half truck roll-, and half truck pitch-heave model are developed and validated using a frequency-domain validation technique and the test-rig measurements. The technique is based on a recently developed frequency domain validation method for robust control and adapted for non-synchronous inputs, with noise on the input and output measurements. The models are shown to give a fair representation of the complex truck dynamics. Furthermore, the proposed validation method may be a valuable tool to obtain high quality vehicle models. As a first step, in search of a low power active cabin suspension system, various suspension concepts are evaluated under idealized conditions. From this evaluation, it follows that the variable geometry active suspension has great potential. However, the only known physical realization - the Delft Active Suspension - suffers from packaging issues, nonlinear stiffness characteristics, fail-safe issues and high production cost. Recently, a redesign - the electromechanical Low-Power Active Suspension (eLPAS) - was presented, which is expected to overcome most of these issues. This design is modeled, analyzed and a controller is designed, which can be used to manipulate the suspension force. Feasibility of the design is demonstrated using tests on a hardware prototype. Finally, the validated reduced order models are used to design suitable roll and pitch-heave control strategies. These are evaluated using a combination of the 44 DOF tractor semi-trailer and eLPAS models. Four eLPAS devices are placed at the lower corners of the cabin and modal input-output decoupling is applied for the controller implementation. It is shown, that driver comfort and cabin attitude behavior (roll, pitch and heave when braking, accelerating or steering) can be greatly improved without consuming excessive amounts of energy. So, overall these results enforce the notion that the variable geometry active suspension can be effectively used as low power active cabin suspension. However, there are still some open questions that need to be addressed before this design can be implemented in the next generation commercial vehicles. Durability and failsafe behavior of the eLPAS system, as well as controller robustness to variations in the vehicle parameters and environmental conditions, are some of the topics that require further study

Benelux meeting on systems and control, 23rd, March 17-19, 2004, Helvoirt, The Netherlands

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