Testing and evaluating of dampers, top mounts and its assemblies, can be challenging when it comes to HiL-applications and characterization in the small signal range with real-time capability. Especially the real-time environment has to cope with signal input, signal recording, vehicle model simulation and the control of actuators at the same time to meet the specification of hard real-time capability. Another challenge is the low velocity identification of small damper forces which are important for adequate friction modelling. In this paper a successfully implemented concept of a chassis HiL test bench will be presented. This chassis HiL test bench is designed especially for ride comfort tests in the small signal range. Although there are some limitations due to actuator dynamics, it is possible to carry out characterization and HiL tests with small displacement and velocity amplitudes. A fast actuator control is possible by implementing a fiber optic based communication system which guarantees 125 μs latency. Furthermore, test scenarios based on advanced characterization and HiL tests are presented. These tests scenarios were developed for tests and ride comfort investigations in the small signal range. Using the example of a rear axle twin-tube damper assembled with a top mount, these test scenarios show very good results. With this chassis HiL test bench and the tests scenarios more accurately test results for the product development process of passive, semi-active and active dampers, top mounts and its assemblies are possible.
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- Damper HiL-tests and damper characterizations with focus on real-time application
Peter E. Pfeffer
AVL List GmbH/© AVL List GmbH, dSpace, BorgWarner, Smalley, Valeo Logo/© Valeo, FEV, Ansys