Increased knowledge transfer by using modern high-speed camera

A broad theoretical knowledge in Optics and Photonics is essential for media engineers. A combination of theory in the lectures augmented by practical work during the laboratory experiments forms the foundation of our gradual approach in communicating clearly and intensively all of the required topics. All laboratory experiments are guided but carried out by the students themselves and produced with a modern high-speed camera. This offers possibilities to analyze and iterate very fast phenomena. The slow motion footage makes it easily to analyze, to measure and to calculate certain sequences. This leads to a very intensive discussion regarding the provided topics and the used camera technology, resulting in a high standard knowledge transfer. Physics get now visible and more accessible for students. This paper presents how the students execute and analyze experiments using modern technology. The results are prepared as media-friendly computer animation and video recordings

An improved multiaxial stress-strain correction model for elastic FE postprocessing

In this paper, the model of Köttgen, Barkey and Socie, which corrects the elastic stress and strain tensor histories at notches of a metallic specimen under non-proportional loading, is improved. It can be used in connection with any multiaxial s -e -law of incremental plasticity. For the correction model, we introduce a constraint for the strain components that goes back to the work of Hoffmann and Seeger. Parameter identification for the improved model is performed by Automatic Differentiation and an established least squares algorithm. The results agree accurately both with transient FE computations and notch strain measurements

Undesired drift of multibody models excited by measured accelerations or forces

In the ground vehicle industry it is often an important task to simulate full vehicle models based on the wheel forces and moments, which have been measured during driving over certain roads with a prototype vehicle. The models are described by a system of differential algebraic equations (DAE) or ordinary differential equations (ODE). The goal of the simulation is to derive section forces at certain components for a durability assessment. In contrast to handling simulations, which are performed including more or less complex tyre models, a driver model, and a digital road profile, the models we use here usually do not contain the tyres or a driver model. Instead, the measured wheel forces are used for excitation of the unconstrained model. This can be difficult due to noise in the input data, which leads to an undesired drift of the vehicle model in the simulation

Model reduction of nonlinear problems in structural mechanics

This contribution presents a model reduction method for nonlinear problems in structural mechanics. Emanating from a Finite Element model of the structure, a subspace and a lookup table are generated which do not require a linearisation of the equations. The method is applied to a model created with commercial FEM software. In this case, the terms describing geometrical and material nonlinearities are not explicitly known

MSB Simulation of a hexapod based suspension test rig

Testing a new suspension based on real load data is performed on elaborate multi channel test rigs. Usually wheel forces and moments measured during driving maneuvers are reproduced on the rig. Because of the complicated interaction between rig and suspension each new rig configuration has to prove its efficiency with respect to the requirements and the configuration might be subject to optimization. This paper deals with modeling a new rig concept based on two hexapods. The real physical rig has been designed and meanwhile built by MOOG-FCS for VOLKSWAGEN. The aim of the simulation project reported here was twofold: First the simulation of the rig together with real VOLKSWAGEN suspension models at a time where the design was not yet finalized was used to verify and optimize the desired properties of the rig. Second the simulation environment was set up in a way that it can be used to prepare real tests on the rig. The model contains the geometric configuration as well as the hydraulics and the controller. It is implemented as an ADAMS/Car template and can be combined with different suspension models to get a complete assembly representing the entire test rig. Using this model, all steps required for a real test run such as controller adaptation, drive file iteration and simulation can be performed. Geometric or hydraulic parameters can be modified easily to improve the setup and adapt the system to the suspension and the load data

Optimal control methods for the calculation of invariant excitation signals for multibody systems

Input signals are needed for the numerical simulation of vehicle multibody systems. With these input data, the equations of motion can be integrated numerically and some output quantities can be calculated from the simulation results. In this work we consider the corresponding inverse problem: We assume that some reference output signals are available, typically gained by measurement and focus on the task to derive the input signals that produce the desired reference output in a suitable sense. If the input data is invariant, i.e., independent of the specific system, it can be transferred and used to excite other system variants. This problem can be formulated as optimal control problem. We discuss solution approaches from optimal control theory, their applicability to this special problem class and give some simulation results

Usage of Simulation for Design and Optimization of Testing

Die Simulation von Prüfständen und insbesondere von Baugruppen und Gesamtfahrzeugen auf Prüfständen durch Kopplung von Mehrkörpersimulation mit Modellen für Regelung und Aktuatorik leistet einen wesentlichen Beitrag zur Entwicklungszeitverkürzung. In diesem Beitrag wird ein Kooperationsprojekt vorgestellt, in dem ein Co- Simulationsmodell für die beweglichen Massen sowie die Regelung und Hydraulik eines Gesamtfahrzeugprüfstands erstellt wurde. Es wird sowohl auf die Validierung des Fahrzeugmodells durch Straßenmessungen als auch auf die Identifikation und Validierung des Prüfstandsmodells einschließlich Servohydraulik und Regelung eingegangen.Simulation of test rigs and especially of vehicle parts or complete vehicles on test rigs by combining multi-body simulation with models for control and hydraulics permits a major reduction of product development time expense. This paper presents such a co-simulation model for a full vehicle test rig. The validation of the vehicle model by means of test track measurements as well as identification and validation of the test rig model (including hydraulics and control) is discussed

Calculating invariant loads for system simulation in vehicle engineering

For the numerical simulation of a mechanical multibody system (MBS), dynamical loads are needed as input data, such as a road profile. With given input quantities, the equations of motion of the system can be integrated. Output quantities for further investigations are calculated from the integration results. In this paper, we consider the corresponding inverse problem: We assume, that a dynamical system and some reference output signals are given. The general task is to derive an input signal, such that the system simulation produces the desired reference output. We present the state-of-the-art method in industrial applications, the iterative learning control method (ILC) and give an application example from automotive industry. Then, we discuss three alternative methods based on optimal control theory for differential algebraic equations (DAEs) and give an overview of their general scheme

Customer loads correlation in truck engineering

Safety and reliability requirements on the one side and short development cycles, low costs and lightweight design on the other side are two competing aspects of truck engineering. For safety critical components essentially no failures can be tolerated within the target mileage of a truck. For other components the goals are to stay below certain predefined failure rates. Reducing weight or cost of structures often also reduces strength and reliability. The requirements on the strength, however, strongly depend on the loads in actual customer usage. Without sufficient knowledge of these loads one needs large safety factors, limiting possible weight or cost reduction potentials. There are a lot of different quantities influencing the loads acting on the vehicle in actual usage. These ‘influencing quantities’ are, for example, the road quality, the driver, traffic conditions, the mission (long haulage, distribution or construction site), and the geographic region. Thus there is a need for statistical methods to model the load distribution with all its variability, which in turn can be used for the derivation of testing specifications

Comparison of the solutions of the elastic and elastoplastic boundary value problems

In this article, we consider the quasistatic boundary value problems of linear elasticity and nonlinear elastoplasticity, with linear Hooke’s law in the elastic regime for both problems and with the linear kinematic hardening law for the plastic regime in the latter problem. We derive expressions and estimates for the difference of the solutions of both models, i.e. for the stresses, the strains and the displacements. To this end, we use the stop and play operators of nonlinear functional analysis. Further, we give an explicit example of a homotopy between the solutions of both problems