USE OF VEHICLE DYNAMICS SIMULATION IN

A FORMULA STUDENT TEAM

CONTENT.
INTRODUCTION FORMULA
1. STUDENT
INTRODUCTION
2. KA-RACEING

3. SIMULATION MODELS
4. CONCEPT DECISIONS
5. SUSPENSION TUNING
CONTROL SYSTEM
6. VERIFICATION
INTRODUCTION FORMULA STUDENT
INTRODUCTION FORMULA STUDENT

Design competition with an

race car theme
11 events in 10 countries
and on 5 continents per
year
Formula Student teams in
over 50 different countries
Over 70 teams in Germany
INTRODUCTION FORMULA STUDENT

8 disciplines in an event
5 dynamic disciplines
3 static disciplines
Goal is to score 1000 points
INTRODUCTION KA-RACEING
INTRODUCTION KA-RACEING

Formula Student Team of the Karlsruhe Institute of Technology (KIT)

Founded in 2006, first car in 2007
Since 2010 every year one electric and one combustion car

One team, two cars!

7
INTRODUCTION KA-RACEING

In 2014:
55 Students
2 cars
5 events
INTRODUCTION KA-RACEING

KIT14c

199 kg
Self-developed combustion engine
Drag Reduction System
10 tires on CFRP rims
Hybrid Chassis
INTRODUCTION KA-RACEING

KIT14e

211 kg
Self-developed electric engines
Drag Reduction System
Monocoque
10 tires on CFRP rims
Active Yaw Control and Traction Control
SIMULATION MODELS
SIMULATION MODELS

Tire Model

2007 2013: Magic Formula

Pro:
very good for steady-state analysis
low computing time
available Fitting Software
Contra:
over 160 parameters
often problems with oscillations
hard to properly fit transient
coefficients
no road uneveness
no thermal model
SIMULATION MODELS

Tire Model Fz Slip Vel.

1. Order
Wheel Load
Dynamics
Since 2014: KA-RaceTire Model
Model

Scale Factor Slip Camber

TMEasy Camber Model

Fx Fy Fx Fy

Output
13
SIMULATION MODELS

Electric Powertrain
Simulink Model of Electric Powertrain containing:
Engine model with efficiency map
Battery model with efficiency factors
Recuperation considered
Control Systems embedded
SIMULATION MODELS

Aerodynamics
Aerodynamic coefficients as function of ride height, roll and
pitch angle
Model for DRS actuation
CONCEPT DECISIONS
CONCEPT DECISIONS

Lap-Time Simulation

Lap-Time Simulation suitable for basic concept decisions

Driver handling the car close to its physical limits
Comparison of lap-times sensitivy of lap-time on different
parameters
CONCEPT DECISIONS

Powertrain Concept
Concept 1 Concept 2 Concept 3
2WD, very 4WD, high 4WD, high
Concepts different in: light car inertia, weight,
medium medium
Mass weight inertia, high
Intertia torque

Number of driven wheels Acceleration 100 % 81 % 78 %

Center of Gravity
Engine Power Skid-Pad 100 % 104 % 106 %

Autocross 100 % 88 % 87 %

Endurance 100 % 88 % 87 %
CONCEPT DECISIONS

Aerodynamics Concept

Aerodynamics in general

Without Aero With Aero

Cz - 0,2 % 100 %
Cx 31,3 % 100 %
Lap-Time Skid-Pad 103 % 100 %
Lap-Time Autocross 114,2 % 100 %
CONCEPT DECISIONS

Aerodynamics Concept
DRS Concept
SUSPENSION TUNING
SUSPENSION TUNING

Sensitivity Studies with Open-Loop-Maneuvers

Steady-State Cornering
Steer-Step
Sinus-Sweep
Accelerating
SUSPENSION TUNING

Parameter Studies to:

Learn about influences of parameters on vehicle dynamics
Know which parameter to change
Save Test Time!
CONTROL SYSTEMS VERIFICATION
CONTROL SYSTEMS VERIFICATION

Control Systems on electric since KIT12e

KIT12e: Traction Control
KIT13e & KIT14e: Traction Control and Active Yaw Control
CONTROL SYSTEMS VERIFICATION

Verification of Control Systems in CarMaker:

Do the Control Systems work?
How is the interaction?
Is there any strange behaviour in certain maneuvers?
Do the Control Systems work in all disciplines?

Validation and Parameter Tuning on track!

Thank you!