Dynamic Simulation in Motorsports with MSC.

ADAMS

Dipl.-Ing. Marcello Di Fina Development TR Engineering GmbH

Dipl.-Ing. Eckardt Dhrer, TR Engineering GmbH

EMEA 2004
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TRE - Engineering Partner for Automotive and Motorsport Industry 1/2

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CAD-Design Simulation Testing

Prototyping Fabricating Composites

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TRE - Engineering Partner for Automotive and Motorsport Industry 2/2

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is a subsidiary of

racing in DTM Euro F3 BMW ADAC Formula Junior

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Simulation Integrated Suspension Development

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Kinematic Sim.

Full Vehicle Sim.

CAD-Design

Tracktest

Hardware

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Dynamics Simulation Project Structure

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step 0: determination of vehicle parameters step 1: kinematic analysis step 2: parameterising and validation step 3: full vehicle analysis

EMEA 2004
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Step 0: Determination of Vehicle Parameters

in house measurements kinematic points measurement drivetrain + differential rig torsion test rig damper dyno, etc. external wind tunnel tests 7-post suspension rig

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Step 1: Kinematic Analysis 1/2

virtual test rigs
parallel wheel travel opposite wheel travel single wheel travel steering static loads

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benefit
race engineers handbook calculation of suspension forces for component strength analysis (FEA, etc.)

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Step 1: Kinematic Analysis 2/2

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Step 2: Parameterising and Validation 1/3

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Mandatory track test with specifically equipped race car simulation of track test manouvers
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coast down: braking: acceleration: crc: circuit sim:

aero forces and ride heights tyre longitudinal behaviour engine and aero forces tyre lateral behaviour, roll angle/stiffness final validation of further physical quantities

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Step 2: Parameterising and Validation 2/3

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Step 2: Parameterising and Validation 3/3

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Tools: MSC.ADAMS.CAR-Motorsport 1/3

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MSC.ADAMS.CAR-Motorsport is an MSC.ADAMS.CAR plug in, with which it is possible to take advantage of all of the analysis capabilities available in ADAMS/Car, besides many other features respecting the specific demands of motorsport industry, like: Setup Adjustments like ride heights, caster, camber, toe Aerodynamics:
basic in plane in function of ride_heights (scalable, offsettable) advanced 3D aero forces gives a direct access to vehicle assembly setup parameters features the capability of saving different set-up copnditions in setup sheet

Setup Utility:

Testrigs Tire_testrig, Suspension_testrig, Four_Post_testrig, ... Suspension Analysis Full_Vehicle Analysis:

quasi-static simulations Aerolap solver dynamic events open loop & closed loop (with SmartDriver) EMEA 2004
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Tools: MSC.ADAMS.CAR-Motorsport 2/3

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Tools: MSC.ADAMS.CAR-Motorsport 3/3

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Caster adj. lower control arm mod Toe adj. trackrod mod Ride Height adj. pushrod mod

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Tools: MSC.SmartDriver

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MSC.SmartDriver is a driver control module allowing to build standard manouvers like const radius cornering time based open loop control of the model inputs closed loop control in different configurations, e.g.
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steering control by following a target path, throttle/brake by following a time or path based speed profile steering control by following a target path, throttle/brake by following a time or path based longitudinal acceleration profile clutch/gear control can be either closed or time based open loop

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Boundary Conditions for Circuit Simulation

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plane roads no course selection, driver target path created by hand simulating lap extracts (one or two corners / chicane) control input: closed loop target path / acceleration method not yet compliances in suspension not yet friction in uniballs

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Considering the Race Driver Performance 1/4

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The best possible implementation of the real race driver behaviour is crucial simulating a qualifying lap at the limit of performance means
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model inaccuracies can cause simulation failure model control inacurracies can cause simulation failure control input files coming from data acquisition need treatment

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Considering the Race Driver Performance 2/4

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Control input sensitivity of the simulation of a track section driven by a Formula 3 driver target path created by hand together with race driver two long. target acceleration profiles created from data acquisition
Target Acceleration Profile for MSC.SmartDriver Simulation
1.00 0.50 0.00
long. acceleration [g]

Area of interest: differing acceleration control input between the 2 simulations

700

0 -0.50 -1.00 -1.50 -2.00 -2.50 -3.00

100

200

300

400

500

600

measured with g-sensor caculated from front wheel speed trigger 20 Dots mod. ACC map - for simulation 20 Dots basis - for simulation
path [m]

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Considering the Race Driver Performance 3/4

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300 300
Target Acceleration Profile for MSC.SmartDriver Simulation
1.00 0.50 0.00
long. acceleration [g]

400 400

Area of interest: differing acceleration control input between the 2 simulations

700

0 -0.50 -1.00 -1.50 -2.00 -2.50 -3.00

100

200

300

400

500

600

measured with g-sensor caculated from front wheel speed trigger 20 Dots mod. ACC map - for simulation 20 Dots basis - for simulation
path [m]

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Considering the Race Driver Performance 4/4

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The slightly different target acceleration profiles cause major differences in

steer angle and subsequently in the path error higher long. forces with approx. the same lateral force demand cannot be generated by the tire being already at the performance limit (friction circle)

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Step 3: Full Vehicle Analysis simulation targets setup support development support

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Methods constant radius cornering (crc) step steer, etc. lap extract simulation curb driving simulation road grip variation
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Full Vehicle Analysis Curb Driving Simulation 1/3 Task:

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find a spring/damper setup for a new three damper front suspension reference is a mono shock front suspension with appropriate setup main difference between the concepts is roll damping mono

3 damper
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Full Vehicle Analysis Curb Driving Simulation 2/3

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reference run with mono suspension 3 damper design state, same heave and roll stiffness than mono analysing results -> path error, tire force plot, etc. run with 3 damper, less roll stiffness front run with 3 damper, less roll stiffness front and rear (balance)
Fright front tire force [N]

region of curb 1 mono 3 damper design

path [m]

EMEA 2004

Full Vehicle Analysis Curb Driving Simulation 3/3

mono 3 damper design 3d front roll softer 3d fr+re roll softer

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path error [m]

path [m]
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Full Vehicle Analysis Constant Radius Cornering (crc) 1/2

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Constant radius cornering (r=70m, a=0.05g) simulation with different car setups. The Understeering Index is the gradient of the steering angle needed to maintain the corner radius while lateral acceleration grows.

EMEA 2004
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Full Vehicle Analysis crc 2/2

Understeering Index
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Contact
Dipl.-Ing. Eckardt Dhrer Technical Director Phone: +49 6321 / 914 131 Fax: +49 6321 / 914 205 email: e.doehrer@trengineering .de

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TR Engineering GmbH Nachtweide 35 67433 Neustadt / Wstr. Germany

Dipl.-Ing. Marcello Di Fina Development Phone: +49 6321 / 914 113 Fax: +49 6321 / 914 205 email: m.difina@trengineering .de

www.trengineering.de

EMEA 2004
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