An example of achieving the reproduction of actual vehicle driving torque in powertrain evaluation through mathematical operation control.
At the testing site for drive-related components, when conducting simulations, we assign computational elements such as air resistance, rolling resistance, gradient resistance, and acceleration/deceleration resistance, along with site-specific testing specifications and coefficients, to calculation formulas to derive load torque. However, the existing methods were insufficient to accurately reproduce the load torque generated during actual vehicle operation in response to changes in vehicle models and testing content, necessitating the flexible addition, modification, and deletion of elements, coefficients, and calculation formulas. Integrated computation of physical parameters according to acceleration and deceleration states At Seagull Co., Ltd., we adopted a method that allows for the flexible addition, modification, and deletion of calculation formulas and necessary physical parameters for accurately reproducing load torque for each driving state, such as vehicle models and acceleration/deceleration. Specifically, parameters such as rotational speed (rpm), incline angle (°), gravitational acceleration (m/s²), vehicle weight (kg), tire radius (m), reduction ratio, inertia (kg·m²), and coefficients, along with calculation formulas corresponding to the states during acceleration and deceleration, are set for each vehicle model. The load torque is output to the testing machine through real-time computational processing in milliseconds by the CPU and FPGA of the embedded unit.
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basic information
The company faced the challenge that the torque load during acceleration and deceleration in the bench test of the mission gear test specimens was smaller compared to the torque load during actual vehicle operation. The existing calculation formulas based on the running resistance model were unable to adequately reproduce the load torque during acceleration and deceleration. This was due to the inertia values, reduction ratios, sampling intervals, coefficients, and formulas not being appropriately reflected in the load control for the specific test conditions and environment. As a result, as shown in the graph above, the simulated torque in the bench test was overall lower compared to the torque during actual vehicle operation, with a particularly noticeable discrepancy during acceleration and deceleration.
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Applications/Examples of results
In the testing environment, it is important for customers to be able to adjust various formulas and parameters, as the determination of acceleration and deceleration and the switching of conditions are required depending on the situation. In this case, we incorporated a function that allows for the addition, modification, and deletion of various parameters and formulas into the existing software, thereby renovating it into a system that can mathematically reconstruct the torque load during operation. As a result, we were able to realize a testing environment that combines scalability and flexibility, allowing customers to build optimal control logic according to differences in testing conditions and vehicle models. [Implementation Effects] Improvement of Reproducibility, Cost Reduction, and Shortened Lead Time This proposal has made it possible to reproduce load torque that is close to actual vehicle operation. In other words, it has enabled the reproduction of transmission malfunctions and data measurement environments without conducting "real vehicle tests." Additionally, by being able to stably reproduce conditions close to those of an actual vehicle, it has become possible to conduct repeated tests under the same conditions, significantly contributing to improved verification accuracy and ensuring reproducibility of evaluations. To reproduce the appropriate load torque during operation, it is necessary to construct control that encompasses the formulas for acceleration and deceleration, the inertia of the test machine and specimen, the reduction ratio, and response characteristics.
Detailed information
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Parameters such as rotation speed (rpm), inclination angle (°), gravitational acceleration (m/s²), vehicle weight (kg), tire radius (m), reduction ratio, inertia (kg·m²), and coefficients are set for each vehicle model according to the conditions during acceleration and deceleration. The CPU and FPGA of the embedded unit perform real-time calculations in milliseconds to output load torque to the test machine. By allowing flexible configuration of parameters and calculation formulas to correspond to the vehicle model and the inertial load torque during acceleration and deceleration, it has become possible to reproduce the load torque of actual vehicle operation, providing an environment where tests approximating real vehicle operation can be constructed on the field side.
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Our company is engaged in measurement and control applications, test simulation proposals, replacement and functional enhancement of test equipment and measurement, and the provision of original hardware. With the mission of "making the world simpler and better" through software and electronics technology, we create value through technological development and will continue to contribute sustainably to various industrial fields. Please feel free to contact us when you need our services.
