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主动悬置电控技术介绍

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主动悬置通过辅助助动器施加外载,该外载与PT传递过来的激励振幅相同,相位相反,从而使传递到车身的激励最小.

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SGM PATAC Tech day Date : 2015/06/26 Table of contents 1pr–esHeunttcahtiinonson group presentation – Arnaud Lede's 2 – GM programs supplied & developed by Hutchinson • 2.1 In US ‒ 2.1.1 End of life projects ‒ 2.1.2 Current projects ‒ 2.1.3 Advanced projects • 2.2 In Asia – Leijie Gao’s Presentation • 2.3 In Europe – Leijie Gao’s Presentation 3 – Hutchinson’s active systems overview • 3.1 – Active Systems Development at Hutchinson • 3.2 – Hutchinson Mass Production Experience • 3.3 – Active System Studies Experiences • 3.4 – On Going Activities • 3.5 – On going developments 2 2 – GM programs supplied & developed by Hutchinson 3 2.1.1 – GM end of life programs in US 4 GMT 17X/14x–Chevy Equinox/GMC Terrain RHS LHS FRR RRR All parts developed in US Produced in US and in China Clevis brackets 5 GMT 311 – Chevy Captiva - Mexico RHS LHS FRR RRR Clevis brackets 6 All parts developed in US Produced in US GMX 521/511 – Zeta 2 Chevy Camaro These parts developed in US Produced in US RHS & LHS AT trans & MT trans Cross member V6 LHS RHS V8 V6 AT trans V8 MT trans 7 These parts developed in US Produced in China Lambda 2 platform All parts developed in US Produced in US Buick Enclave & Chevrolet Traverse & GMC Acadia 8\ GMI700 Replacement light truck for S-10 • Best selling in Brazil • 2.4L SOHC & DOHC • 4.1L HFV6 • 2.5L & 2.8L Diesel All parts developed in Argentina with US support Produce in Brazil SOHC & DOHC 9\ HFV6 2.1.2 – GM recent programs in US 10 K2xx Program overview North American Program only Full Size Truck Program supporting Pick-ups and SUVs SOP April 2013 Manufacturing Location – Cadillac, MI – Engine Mounts – replaces T900 – Trans Mounts – T900 was produced in China Volume evolution: – Sourcing – 745,000 Vehicles – Jan 2012 – 850,000 Vehicles – Sept 2012 – 940,000 Vehicles 11 K2xx design RHS engine mount 4 1 LHS engine mount 3 Design keys: 1- Steel (stamping , welding) 2- Aluminum (HPDC) – internals 3- Aluminum heat shield (folding) 4- Silicon seals & dust boot (injection) 5- MRE (SE-HTC+ compound) Transmission mount 4WD 12 2WD GM D2Jxi North America Chevy Volt Gen2 – GM Lead in USA – Hutchinson Design Lead in France / Production in USA • Paul Leason – Program Manager • Michael Champrenault – Design Engineer • Dedicated tooling in USA for the following 2 brackets – LHS Off Engine Bracket – RHS Off Engine Bracket SOP : – PPAP to GM in July 2015 13 GM D2Jxi North America North America Production Annual Volume: – Projected Volume for North America 35,000 vehicle a year RHS Off Engine Bracket Others mounts will come from Europe which are common with the D2xx platform LHS Off Engine Bracket Big Bush 14 C1xx Program overview SOP: October 12th, 2015 Buick Enclave Annual Volume: 440,000 vehicles – 400,000 vehicles for US market – 40,000 vehicles for China market Production Location: – Grand Rapids & Cadillac, MI • Hydraulic mounts + Front mount (plastic brackets) • Rear mounts + Pass through brackets – Suzhou (China) • All mounts and brackets except the plastic front mounts which will be provided by Grand Rapids & Chevrolet Traverse & GMC Acadia Chevrolet Equinox & GMC Terrain V6 engines only Current Paulstra business Cadillac SRX GM Production: – Spring Hill, MI USA – Lansing, MI USA – Shanghai in China 15 New business C1xx design complexity 1 AWD clevis bracket in plastic Rear Torque Reaction mount 3 FWD clevis brackets in plastic LHS NON decoupled hydraulic Mount 2 OFF engine brackets 16 2 T brackets 13 NTA powertrains combinations: - 4 cyl. Gasoline engines – 6 PT - 6 cyl. Gasoline engines – 6 PT - 4 cyl. Diesel engine – 1 PT 4 plastic bracket designs Front Torque Reaction mount 3 transmission brackets RHS & LHS mounts similar to: - Chrysler / FIAT PF program - D2xx program Front and Rear bush: - Meet the new GM requirement for travels & limitations. - Similar design D2xx rear bush C1xx Key words New products will be developed – All the rear clevis bracket will be made from Plastic • Nylon 66 GF50% is used AWD brackets FWD brackets 17 \ GM 2016 Alpha Program - Key Points SOP: June, 2016 • Annual Volume: 50,000 vehicles • Production Location: Grand Rapids, MI • GM Production: Lansing, MI United States 18 Multi State Mount – Validation Complete Non-Energized Floating decoupler to provide low dynamic stiffness for idle and IOD at 0.3mm p-p First Set of parts Tested on vehicle • Meet all SOR specs • Good Performance on vehicle 19 Energized Locks the decoupler to increase Phase and Dynamic Stiffness Multi State Mount – Modular Design Overview Common MRE Sub-Assembly Integrated Actuator Common MRE Sub-Assembly Alternate Design 20 Common MRE is validated for either Technology Common MRE 2.1.3 GM advanced projects 21 Advanced projects done with GM Electrical Active engine mounts – GMNA • DFSS projects has been performed to define the most robust design Vacuum Multi-state mount – GMNA • Developed to achieve 4 different states. Dual channels mount – GM Holden • Passive solution to switch between 2 modes (Idle and Shake) based on engine excitation. Decoupled hydraulic bushing – GMNA • Application developed for torque road and for Roll restrictor to improved Start/Stop. ‒ Currently tested on C1xx for potential production on ??? (high end vehicle) Electrical switchable mount – GMNA Active Mass Damper system – GMNA • Balanced shaft removal – Chevy Volt 1 used as a demo car • AFM application – Alpha, Lambda and SRX vehicles have been used as demo car. Electrical Multi-state mount – GMNA • Currently in development for the A1xx which is to improve Start/Stop and SRS. 22 Hutchinson property – Confidential document Advanced projects on going with GM Second generation Electrical Multi-state mount – GMNA • Requirements are: Purpose: Design a 3-State switchable mount that has two different peak damping tunings (7.5 and 12.5hz) when the Decoupler is Locked The mount will be tuned to 12hz when the decoupler is Free Floating Mount activation must be electronic with only one linear or rotational actuator. The actuator can have multi-state positions. Condition # 1 2 3 Decoupler State Free Lock Lock Peak Phase Freq (Hz) Peak Phase Tuning IOD Amp (mm) p-p 12 1.0mm p-p 0.3 mm p-p 7.5 2.0mm p-p Locked Decoupler 12.5 0.1 mmp-p Locked Decoupler MIN Peak Phase 55 degree 55 degree n/a MIN 0.1 p-p K* n/a n/a 1250 (at 17Hz) MAX 0.1 p-p K* (0-50Hz) 310 N/mm n/a n/a 23 Hutchinson property – Confidential document 3 – Hutchinson’s active systems overview 24 3.1 – Active Systems Development at Hutchinson 25 Active Systems History at HUTCHINSON Development regarding Active Control of Vibration for more than 20 years • First patent in 1991 / More than 20 patents • Development studies with many car makers Whole Antivibration Control System in one casing : Electronic Control Unit + Sensor + Actuator Active Control Systems in production Integrated Active System for over 10 years Active System • Active Engine Suspension with pneumatic actuation • Active Damper System with electro-magnetic actuation Active roll restrictors Switchable mount 2017 2010 Antivibration Control System: - Electronic Control Unit - Sensor - Actuator 26 Hutchinson property – Confidential document 2003 2005 Mechatronics skills and tools Hutchinson develop, industrialize, produce and deliver stand alone Active Systems: Actuators: pneumatic, electromagnetic Electronic control units (power and control) Algorithms for open and closed loop control Acceleration sensors By being equipped with development tools for the complete system: FEA of magnetic circuits calculation / Multi domain simulation Tuning and calibration tools Rapid prototyping of control electronics Software development tools Supported by established partners in automotive electronics for: EMC validation (certified laboratory required) Specific software layers development (certified supplier required) Electronics manufacturing 27 Hutchinson property – Confidential document Active Systems Development Team Active Systems Manager JL Gastineau NA INTEGRATION Technical Team Leader M. Kamps (Product Development Engineer) Project Team Leader A. Theron (Program Manager) Vehicle testing / NVH measurements S. Palko (NVH Engineer) ACTUATORS Design / Modelization / Measurements E. Seminatore (Electro-Mechan. Engineer) Actuators Development B.Piquet (Manager) C.Cosset (Devlpt Technician) D. Prudhomme (Mechanics Designer) ELECTRONICS HW Specification / Electric Architecture / Mechanics / EMC / Subcontractors monitoring B. Eveillard (Electronics Engineer) ELECTRONICS SW Application SW Development / SW Validation Low Layers suppliers monitoring E. Vandervorst (SW Engineer) Subcontractors MHUST (Mechatronics HUT. Support Team) 15 people Hutchinson Corporate Research Center Hutchinson Aerospace & Industry Algorithms specification / Rapid Proto / Demonstrators / NVH measurements A. Delaby (Acoustics Engineer) Vehicle testing / NVH measurements H. Chanal & J. Jaffres (NVH Technicians) 28 Hutchinson property – Confidential document Active Systems applications Mass production / Developments studies / Demonstration vehicles: • NVH comfort improvement at idle (mainly with automatic transmission), • Engine downsizing : Reduction of engine displacement and evolution from 6-cyl. to 4-cyl. or even from 4 cyl. to 3-cyl. even on premium vehicles, • Removal of balance shafts on 3 and 4 cyl. Engines, • Cylinder deactivation (V8 to V4, V6 to V4 or L3, L4 to L2), • Sound Design applications. With adapted active control solutions: • Active Dampers systems, • Active Clevis, • Active Mounts systems, • Active torque rods 29 Hutchinson property – Confidential document 3.2 – Hutchinson Mass Production Experience 30 Hutchinson property – Confidential document Hutchinson mass production experience: Active Roll Restrictors (1/2) Mass Production since 2004: • NVH comfort improvement at idle on PSA/Citroën vehicles with V6 Diesel engine (auto transmission). • Target: Same idle comfort as vehicle with gas engine. • Hutchinson supply : + 31 Hutchinson property – Confidential document Hutchinson mass production experience: Active Roll Restrictors (2/2) Principle of operation: • Engine ECU Controls directly the 2 solenoid valves using PWM signals at 3rd engine order frequency. • Hutchinson specified the Open Loop control software. Actuator Pressure pulses at third order of engine rpm Active force Resulting vibrations 32 Hutchinson property – Confidential document Force transmitted by rubber Hutchinson mass production experience: Active Damper System (1/3) Vehicles: Citroën C5 – PSA Vehicles equipped with 2.2 Diesel engine Purpose: – Makes possible to decrease idle RPM (from 820 RPM to Peugeot 508 700RPM) for fuel saving while preserving premium comfort. • Paulstra supply : Actuator + electronic control unit + sensor In production since October 2010 – (The only Active Damper system in production in the world) ACTIVE DAMPER (variable reluctance actuator) ECU (Control & amplifier) 33 Hutchinson property – Confidential document Sensor (accelerometer) Variable reluctance actuator (2/3) Variable reluctance electro-magnetic Actuator – Force produced at idle: 100N @ 23Hz – 2 kg moving mass over 2.5 kg (80% of the global mass is useful) Dynamic Force 140 120 100 80 60 40 20 0 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 Frequency (Hz) 34 Hutchinson property – Confidential document Force (N) Closed Loop Active Vibration Control (3/3) Single Input Single Output (SISO) Active Control System. – The active damper generates a vibration in order to cancel the acceleration measured at the control point. – The controller calculates in real time the signal for the actuator (amplitude & phase), depending on the measured vibration and provides the appropriate output current. ECU From engine From actuator SENSOR 35 Hutchinson property – Confidential document Resulting vibration ACTURATO 3.3 – Active System Studies Experiences 36 Hutchinson property – Confidential document Cylinder deactivation – AFM for GM Potential Application: Vehicles equipped with V8, V6 or I4 engines and cylinder deactivation. Purpose: Make possible to drive with only some cylinders in action for fuel saving while preserving comfort. Target: Increase the operating range of the Eco mode. V8 to V4 37 Hutchinson property – Confidential document V6 to V4 or V3 I4 to I2 AFM - I4 → I2 demonstrator Application: Vehicle with pendulum suspension equipped with 4 cyl gas engine with cylinder deactivation I4 → I2. Purpose: Increase the operating range of the I2 mode by improving vibration at steering wheel X,Y,Z and seat track Z. Active Closed Loop Control (SISO) of 1st E.O. during eco mode. I4 to I2 Engine Nm 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 CylinCdyleinrdedr edeaaccttiivvaatiotnioanreaa rea Allowed by Hutchinson Active System Without Active System 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 450R0PM 38 Hutchinson property – Confidential document Active Damper Characteristics Actuator designed to cancel 1st engine order (1500 to 4000 RPM) Typical frequency bandwidth : 25Hz to 70Hz Force (N) 120 100 80 60 40 20 0 0 Dynamic Force (5A) 50 100 150 Frequency (Hz) 39 Hutchinson property – Confidential document AFM demonstrator Results on vehicle: ramp up 1250 – 3200rpm, 125 Nm torque Target: Improve vibration at steering wheel X,Y,Z and seat track Z. Results steering wheel X steering wheel Y steering wheel Z Driver seat track Z Active Damper installed inside the cradle 40 Hutchinson property – Confidential document Baseline Active On AFM - V6 → V4 demonstrator Application: Vehicle with North-South suspension equipped with V6 gas engine & cylinder deactivation V6 → V4. Purpose: Increase the operating range of the 4cyl. mode by improving tactile feeling at steering wheel and seat track. Active Closed Loop Control (MIMO) of 1st E.O. during 4cyl. mode. GM North America Actuators 41 Hutchinson property – Confidential document AFM - V6 → V4 demonstrator LF Active Damper characteristic Actuator designed to cancel 1st engine order (1000 to 2400 RPM) Typical frequency bandwidth : 17Hz to 40Hz Force (N) Dynamic force (8A) 110 100 90 80 70 60 50 40 30 20 10 0 10 15 20 25 30 35 40 Frequency (Hz) GM North America Variable reluctance actuator 42 Hutchinson property – Confidential document AFM - V6 → V4 demonstrator results GM North America Improvement of acceleration @ SW and seats by 3dB to 10dB in V4 mode 43 Hutchinson property – Confidential document Idle vibration Application: 3 cyl. gas engine without balance shaft and automatic transmission Purpose: Decrease vibration level at steering wheel and seats. Current level is much higher than the targets (vehicle considered not salable) especially for the 1.5 Engine Order. Active Control solution: Installation of an active system similar to the one in production (same actuator but new sensor and ECU 100% Hutchinson design) Active Damper under the craddle - LHS 44 Hutchinson property – Confidential document Acceleration sensor Idle vibration – Results on 3 Cyl. AT Results with active control on the 1N & 1.5N Engine Order F F 2 .0 0 e -3 1 .8 0 e -3 1 .7 0 e -3 1 .6 0 e -3 1 .5 0 e -3 1 .4 0 e -3 1 .3 0 e -3 1 .2 0 e -3 1 .1 0 e -3 1 .0 0 e -3 0 .9 0 e -3 0 .8 0 e -3 0 .7 0 e -3 0 .6 0 e -3 0 .5 0 e -3 0 .4 0 e -3 0 .3 0 e -3 0 .2 0 e -3 0.0 0 0 D r iv e r s e a t X : O F F D R IV E A C O N D r iv e r s e a t X : O N D R IV E A C O N 1N 1.5 N Curv e 1 6.0 0 2 4.00 Hz 0.3 2e -3 0 .37 e-3 m/s 0.2 2e -3 0 .28 e-3 m/s 10 20 30 40 50 55 Hz F F 2.0 0e -3 1.8 0e -3 1.7 0e -3 1.6 0e -3 1.5 0e -3 1.4 0e -3 1.3 0e -3 1.2 0e -3 1.1 0e -3 1.0 0e -3 0.9 0e -3 0.8 0e -3 0.7 0e -3 0.6 0e -3 0.5 0e -3 0.4 0e -3 0.3 0e -3 0.2 0e -3 0 .00 0 D r iv e r s e a t Y : O F F D R IV E A C O N D r iv e r s e a t Y : O N D R IV E A C O N 1N 1 .5 N Cu rv e 1 6.00 2 4 .0 0 Hz 1 .6 8 e -3 1 .4 1 e -3 m/s 0 .7 9 e -3 0 .1 0 e -3 m/s 10 20 30 40 50 55 Hz F F 2 .00 e-3 1 .80 e-3 1 .70 e-3 1 .60 e-3 1 .50 e-3 1 .40 e-3 1 .30 e-3 1 .20 e-3 1 .10 e-3 1 .00 e-3 0 .90 e-3 0 .80 e-3 0 .70 e-3 0 .60 e-3 0 .50 e-3 0 .40 e-3 0 .30 e-3 0 .20 e-3 0 .0 0 0 D r iv e r s e a t Z : O F F D R IV E A C O N D r iv e r s e a t Z : O N D R IV E A C O N 1N 1 .5 N Cu rv e 1 6 .0 0 2 4.00 Hz 1 .1 6 e -3 0 .7 7 e -3 m /s 0 .6 8 e -3 0 .2 1 e -3 m /s 10 20 30 40 50 55 Hz Driver seat track improved Idle with gearbox in D position m/s Amplitude m/s Amplitude m/s Amplitude 45 Hutchinson property – Confidential document Active control of torque vibration Aim at: Vehicles with pendulum suspensions equipped with light engines with high torque. Ex: Small turbocharged engines with 2, 3 or 4 cylinders. Purpose: Makes possible to install small engines in premium vehicles Vibration source: Gas forces (oscillating forces) Increase of the magnitude of dynamic excitation Light engine with low inertia Static loads on torque rods (even at idle with automatic transmissions) Static torque under engine load 46 Hutchinson property – Confidential document Clevis incorporating an inertial actuator Principle: The inertial actuator is integrated inside the clevis. The clevis links the torque rod to the subframe, making « Active » any standard torque rod. To be integrated inside the subframe 47 Hutchinson property – Confidential document Active Clevis Characteristics Typical frequency bandwidth : 25 Hz – 130 Hz 48 Hutchinson property – Confidential document Balance shafts removal GM North America Applications: Reduce emissions of 4 cyl. engines thanks to balance shafts removal: less friction, less weight… Hutchinson Solution: 1 Electrodynamics Active damper Performance: 35N from 80 to 400 Hz Location: side rail Main vibration to cancel: Vertical direction 2nd E.O. (4 cyl. Engine) Off On 49 Hutchinson property – Confidential document Results on 4 cyl. gas engine car: SPL at driver seat (right ear) 2nd Order 4th Order Sound Design Applications: Adding sound to modify engine sound perception Making sound consistent with the sporty image of vehicles: Coupé with downsized engine, Diesel or electric motor Hutchinson Solution: 1 Electrodynamic Active damper Performance: 35N from 80 to >1000 Hz Location: Bulkhead (@3.5A RMS) Results in a car with V6 Diesel engine: Sound generated: 8 independent level harmonics in the same time Natural sound taking into account numerous vehicle parameters Advanced control strategy - Software based tuning 50 Hutchinson property – Confidential document 3.4 – On going activities 51 Cost-effective new design of actuators Active inertial actuators new designs: Reduction of magnetic material usage Reduction of mass Active mounts new design : Improvement of high frequency force Box type Active Mount 52 Hutchinson property – Confidential document Cost-effective new design of our ECU In house development of a new ECU Evolution of the ECU currently in production, optimized for cost Taking into account evolution of our customers standards New MCU (more power), for high real time constraints and compliant 500kb/s CAN communication PCB surface decreased by 30% Prototypes already validated and delivered to our client 53 Hutchinson property – Confidential document Cost-effective new design of our acceleration sensor In house development of a new acceleration sensor, having thus our own automotive sensor Optimized for cost High sensitivity for better minimization (15V/g) Possibility to install it directly inside an actuator Prototypes validated and delivered to our client 54 Hutchinson property – Confidential document 3.5 – On going developments 55 On going developments In Europe: • Active Mass Damper for 3 cyl. Engine • Active engine mount for AFM In US: • Active Engine Mount or Active Mass Damper for balance shaft removal. OR ‒ Future GM D3xx platform • Active Mass Dampers for AFM application ‒ V8 V4 IP6K9K Compliant 56 Hutchinson property – Confidential document ECU & Software tuned for each application Active Engine Mounts for AFM Application: Vehicle equipped with V8 petrol engine with cylinder deactivation V8 → V4 • Same size as the current hydraulic mount • Low consumption (16W at the maximum) Maximum amplitude of the vibration for which the transfer path is cancelled 57 Hutchinson property – Confidential document Electric Active mount for longitudinal suspension Comparison with competition: Audi S8 Active mount Same application: V8 petrol engine with cylinder deactivation V8 → V4 • Same performance from 30Hz to 200Hz • Less height (- 34 %) • Lower consumption (- 30% in average) • Smaller magnet (- 10% NdFeB 42SH) Hutchinson prototype DTR-VMS for Audi S8 58 Hutchinson property – Confidential document Demo vehicle: Mercedes ML 250 Bluetec Prototypes designed to fit vehicle packaging Minimisation Accelerometer RHS Active Mount LHS Active Mount AHM prototypes in Mercedes ML environment 59 Hutchinson property – Confidential document 5th gear WOT: Driver seat track -10dB -10 -10 -20 -20 seat:driver:+X seat:driver:+X m/s2 dB m/s2 dB -30 -40 1100 1400 1600 1800 2000 2200 2400 -7dB rpm Tacho1 (T1) seat:driver:+X seat:driver:+X 2800 -10 -20 -30 -40 1100 1400 1600 1800 2000 2200 2400 rpm Tacho1 (T1) -10 -20 2800 m/s2 dB m/s2 dB -30 -40 1100 1400 1600 1800 2000 2200 2400 2nd Order rpm -4dB Tacho1 (T1) seat:driver:+Y seat:driver:+Y 2800 -10 -20 -30 -40 1100 seat:driver:+Y seat:driver:+Y 1400 1600 1800 2000 2200 2400 2800 rpm 4th Order Tacho1 (T1) -10 -20 m/s2 dB m/s2 dB -30 -40 1100 1400 1600 1800 2000 2200 2400 rpm Tacho1 (T1) seat:driver:+Z seat:driver:+Z 2800 60 Hutchinson property – Confidential document -30 -40 1100 1400 1600 1800 2000 2200 2400 rpm Tacho1 (T1) seat:driver:+Z seat:driver:+Z 2800 5th gear WOT : SPL 95 90 -5dB 80 dB Pa 70 60 1100 2nd Order 癬 mic:driver:S off_run-up_4 Avg 癬 mic:driver:S on_run-up_4 Avg 1400 1600 1800 2000 2200 2400 rpm Tacho1 (T1) 2800 95 90 -7dB 80 dB Pa 70 60 1100 癬 mic:pass:S off_run-up_4 Avg 癬 mic:pass:S on_run-up_4 Avg 1400 1600 1800 2000 2200 2400 rpm Tacho1 (T1) 2800 61 Hutchinson property – Confidential document Pa Pa dB dB 95 90 癬 mic:driver:S off_run-up_4 Avg 癬 mic:driver:S on_run-up_4 Avg 80 70 60 1100 1400 1600 1800 2000 2200 2400 2800 rpm Tacho1 (T1) 4th Order 95 90 癬 mic:pass:S off_run-up_4 Avg 癬 mic:pass:S on_run-up_4 Avg 80 70 60 1100 1400 1600 1800 2000 2200 2400 rpm Tacho1 (T1) 2800 Questions?

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