Honda Applies Breakthrough in Durability Engineering

In the previous issue of LMS News, we introduced the concept of the virtual test rig and its use in load prediction. The idea was groundbreaking: the forces acting at any point on any component of a new vehicle type An excellent correlation between model HONDA Accord: can be synthesized using virtual system simulations com-bined with and measurements was achieved, again measurements The practice is suspension taken on corresponding vehicle.LMS TecWare for of course more challenging. Being loads making use of successful and fatigue relevant comparison and prediction productive with such a virtual durability design process not only requires having automatic reporting. Forknow-how the test track FEM and Hondas goal was to be able technologies: applicationbetween model and innovativesoftware tools are HONDAmultibody model to An excellentof the half car modelagain Accord: simulation correlation (rear perform durability optimization and measurements a special algorithm needed in order to get these numerical models correlated with reality. suspension only), was achieved, suspension prototype entirely at the virtualloads stage An excellent correlation between model making use of LMS TecWare for HONDA Accord: was implemented to derive body and to use physical prototyping only and measurements was achieved, again fatigue relevantacceleration and comparison and predictionThis would allow a motion from For the testmodel correlation suspension between for final sign-off.LMS had all the HONDA Accord: able to An excellentand test track (unconstrained making use of LMS TecWare for automatic reporting. loads apply For many years, simulation) measurements and track gyroscopic Hondas goal and more flexible design was achieved, again faster, cheaper, was to be necessary and measurementshalf car modelto be fatigue multibody model with applied and the technology and software tools simulation) experiments test rig model prediction needed for test-based spindle loads Formulti-link rear this to the of of virtual TecWare(rear suspensiontoloads TecWare simulation MBSsimulated foralgorithm LMS DADSrelevant comparison track perform durability the traditional optimization making use LMS process compared test rig. LMS automatic reporting. of the test suspensionof an iteration process. A to create a virtual considered only), a special different and Hondas entirely atin which, prototype stage fatigue goal was to be able comparison and process the virtual for example, simulation prediction load sequencesonly by meansrelevant advantagetestroadto suspension of the half car model (rear could pre-process and road was conditions, including rough body derive this very implemented to optimization important perform durability and to use physical prototyping automatic reporting. For the of track
suspension design validation can only synthesize customer-correlated load Hondas goal was to be able to for final sign-off. This would finished start when the body-in-white is allow a scenarios, as well as optimization perform durabilitypost-process faster,loading and more flexible design MBS cheaper, responses. LMS the and generated conditions onDADS entirely at the virtual prototype stage process compared to the traditional was proven have prototyping only suspension tocannot high changed and to use physical the be frequency process in accuracy required for the inte-gration which, for example, anymore. for final sign-off. This would allow a suspension design validation can only multi-body modeling of virtual test rigs. faster, cheaper, and more flexible design start when theunique and very efficient It also had a body-in-white is finished The LMS task was to derive MBS process compared to the traditional and loading conditionsintegrated direct dynamics calculation on the modeling guidelines that would enable process in which, for example, suspension betweenLast, but not least, awith LMS FALANCS. the calculation trade-off cannot be changed suspension design validation can only anymore. Waveform of the predicted LMS and Replication (TWR) speed Timethe body-in-white is finished start when accuracy software could perform the test drive durability loads. Both virtualrig and generation conditionsvirtual the on test file loading was to derive MBS The LMS task to drive the test track (constrained simulation)be changed suspension was neededand to work in cannot was rigs. All that modeling guidelines that would enable (unconstrained simulation) anymore. acollaboration with experienced durability trade-off needed be calculation experiments betweentothe con-sidered engineers to make the the predicted speedsimulated for ofvirtual test rig and and LMS accuracy different road The task was to possible and practical. derive MBS durability loads. Both testroad rig conditions, including would enable modeling guidelines that rough (constrained simulation) and test track simulationexample was atstrike. LMS aOne such and a curb HONDA, where trade-off between the calculation (unconstrained suspension models simulation) developed different tools the predicted speed technologies, of and services LMS and accuracy to be con-sidered experiments needed in DADS with different levels rig durability itloads. Both test of have made possible to deliver road and simulated for different the complexity (quarter and half axle,track integrated virtual test rig as test with (constrained simulation) andpart of their conditions, torsion bar) and optimized including rough road and withoutdevelopment process for day-to-day (unconstrained simulation) simulation and a curb strike. LMS suspension needed to and damping durability optimization. experiments stiffness be con-sidered developed differentto get optimal suspension models characteristics for different road and simulated in DADS with different measured levels of correspondence with rough road HONDA Accord: suspension conditions, including complexity (quarter and half axle, with responseprediction purpose LMS simulation andFor curb strike. data loads data. a this and optimized and withouton both bar)test rig and the acquisition torsion suspension models developed different the suspension stiffness and damping testDADS with different levels of Hondas (including be able to transin track goal was towheel forceperform characteristics to get optimal ducers) were performed. durability optimization entirely at the complexity (quarter and half axle, with correspondence with measured virtual prototype stage and optimized and without torsion bar)and to use response data. For this purpose data physical prototyping only for final signsuspension stiffness and damping acquisition on both the test rig and the off. This would allow get cheaper, characteristics to a faster,optimal test track (including wheel force transand more flexible with measured correspondence design process ducers) were performed. process in compared to the traditional response data. For this purpose data which, for on both suspension design acquisitionexample, the test rig and the validation can only wheel force transtest track (includingstart when the bodyin-white is finished and loading conditions ducers) were performed. on the suspension cannot be changed anymore. The LMS task was to derive MBS modeling guidelines that would enable a trade-off between the calculation speed and accuracy of the predicted durability loads. Both test rig (constrained simulation and a curb strike. LMS and motion fromthat front and rear technique of the acceleration (rear is entirely at the virtual car model stage simulation different suspension models in half prototype developed gyroscopic measurements and apply suspensiononly), a special algorithm can be optimized for and to use physical prototyping only suspension different levels of complexity DADS the MBS virtual test rig this to withindependently of eachmodel durabilitysign-off. This would allow a other for implemented to derive body was finaland half axle, with and without (quarter by means of an iteration process. A while stillfromand morethe car design considering flexible body faster, cheaper, optimized suspension motionbar) and acceleration and torsion very important advantage of this motion compared tocharacteristics to process the gyroscopicrequired for and apply measurements accurate stiffness and that front traditional technique isdamping rear unconstrainedwhich, for andmodel process in loads prediction. measexample, this optimalMBS virtual test with rig get to the can be optimized for suspension correspondence suspension design validation can only by means of an iteration process. A ured response data. For of purpose durability independentlythiseach other start important advantage finished data when the body-in-white isof this very acquisition on both the test rig and while still considering the car body and loading conditions on the the above is history has and that technique case that front shown rear The test track (including wheel force motion required for accurate suspension cannotoptimized be transducers) were be Loads Prediction suspension can performed.changed the LMS approach to prediction. for unconstrained loads anymore. independently of each other durability using a virtual test rig closely matches An excellent correlation while still considering between model with reality. We would the car thank like to body and measurements was achieved, again The LMS task was to accurate motion required for derive MBS Honda for their cooperation in making use of loads prediction.enable modeling case The aboveguidelines that wouldfatigue unconstrained LMS TecWare forand for develop-ing thehistory has shown that technology relevant approach toand calculation a LMS comparison Loads Prediction between the thetrade-off to publish automatic permission the results. reporting. accuracy closelypredicted speed virtual using a andFor the testof thesimulation of rig track matches Together with test (rear suspension only), complete Digital Test the reality.model car loads. Both test rig durability We withhalf(includingwould like to thank Tracks algorithm washas shown Tire LMS implemented to The above case history Advancedtrack a special for simulation) and test that (constrained Honda suitedtheir cooperation in modelsbody motionto Loads Prediction for accurate durability the LMS approach from acceleration derive (unconstrained simulation) develop-ing the technology and for and gyroscopictest rig closely matches and a virtual measurements and apply usingride comfort simulations) these experiments needed to the results. permission to publishbe con-sidered toolstoare available todayrigto Loads this the MBS virtual test with reality. We would likeasmodel by and simulated for differentthank Together with complete Digital road Test Predictionan iterationcooperation for capabilities and services in means Hondaoffor their process. A very conditions, including rough Tire Tracks (including LMS Advanced road full vehicles.the technologytechnique important advantage of this and for develop-ing and a curb strike. LMS simulation models suited for accurate durability is that front and publish the results. rear suspension can be permissiondifferent suspension models developed to and ride comfort simulations) these optimized for durability independently Together with complete Digital Test in DADS with different levels of tools are availablestill considering the of each other while today as Loads Tracks (including LMS Advanced Tire complexity (quarter and for axle, with Prediction capabilities and services for car body motion requiredhalf accurate models suited for accurate durability and without full vehicles. torsion bar) and optimized unconstrained loads prediction. and ride comfort simulations) these suspension stiffness and damping tools are availableto get as Loads today optimal characteristics Conclusion Prediction capabilities and services for correspondence with measured full vehicles. response case For this purpose data The abovedata. history has shown that acquisition on both Loads rig and the the LMS approach tothe test Prediction test track (including wheel force transusing a virtual test rig closely matches ducers) were performed. with reality. We would like to thank Honda for their cooperation in developing the technology - and for permission to publish the results. Together with Half-axle LMS DADS multi-body model of complete Digital Test Track (including rear suspension Tire models suited for LMS advanced accurate durability and ride comfort simulations) these tools are available today as Loads Prediction capabilities Half-axle LMS for fullmulti-body model of and services DADS vehicles.

Conclusion Conclusion Conclusion

suspension only), a special algorithm was implemented to derive body LMS DADS multibody model with applied motion from acceleration and test-based spindle loads of multi-link rear gyroscopic suspension measurements and apply this to the MBS virtual test rig model LMS DADS multibody model with applied testby spindle of an iteration process. A LMS means multibody model rear suspension basedDADS loads of multi-link with applied very important advantage of this test-based spindle loads of multi-link rear suspension is that front and rear technique suspension can be optimized for durability independently of each other while still considering the car body motion required for accurate unconstrained loads prediction.
Virtual Test Rig: LMS DADS multi-body model of multi-link rear suspension simulating physical testing on suspension test rig

LMS DA test-bas suspensi

Conclusion

The above case history has shown that

Virtual Test approach to Loads Prediction the LMS Rig: LMS DADS multi-body model of multi-link rear Rig: LMS DADS multi-body Virtual Test suspension simulating physical using a virtual test rig closely matches testing of multi-link rear suspension modelon suspension test rig

with reality. We testing like to thank simulating physical would on suspension Honda for their cooperation in test rig

develop-ing the technology and for Virtual Test Rig: LMS DADS multi-body permission to publish suspension model of multi-link rear the results. simulating physical testing on suspension Together with complete Digital Test test rig (including LMS Advanced Tire Tracks models suited for accurate durability and ride comfort simulations) these tools are available today as Loads Prediction capabilities and services for full vehicles. Unconstrained vehicle simulation: LMS DADS multibody model of multi-link rear suspension LMS Unconstrained vehicle simulation: simulating driving on durability test track DADS multi-body model of multi-link rear suspension simulating driving on durability test track

Virtual model simulati test rig

Unconstrained vehicle simulation: LMS DADS multi-body model of multi-link rear suspension simulating driving on durability test track Unconstrained vehicle simulation: LMS DADS multi-body model of multi-link rear suspension simulating driving on durability test track
Half-axle LMS DADS multi-body model of rear Interleuvenlaan 68 suspension 3001 Leuven - Belgium

Unconst DADS m suspensi test trac

rear suspension

Half-axle LMS DADS multi-body model of rear suspension

Half-axle LMS 384 multi-body model of Phone: +32 16DADS200 rear +32 16 384 Fax: suspension 350 e-mail: [email protected] http://www.lmsintl.com

LMS 07.02 International - 07.02

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