A Comprehensive Simulation-Based Framework for Design of Army ...

A Comprehensive Simulation-Based Framework for Design of Army Ground Vehicles G.M. Hulbert, Z.-D. Ma, Y. Hahn, G. Ryu 2007 SAE World Conference April 16, 2007

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16 APR 2007

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A Comprehensive Simulation-Based Framework for Design of Army Ground Vehicles

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Hulbert,GM; Ma,Z-D; Hahn,Y; Ryu,G

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US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI 48397-5000 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

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Presented at the 2007 SAE World Congress, Detroit, MI 16 April 2007, The original document contains color images. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: a. REPORT

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Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

Presentation Overview

AA comprehensive Tire-Terrain for Interaction comprehensive framework framework for Distributed Simulation supporting analysis supporting analysis and and design design of of & Design Platform (D-Sim) Army’s Army’s current current and and next next generations generations of of tactical tactical vehicles vehicles Blast Durability and Ride

Crash

Rollover 2

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Presentation Overview

•• Working Working capability capability for for distributed distributed simulation simulation across across multiple multiple domains domains Tire-Terrain Interaction

•• New New modeling modeling capability capability for for rapid rapid configuration configuration of of HMMWV HMMWV variants variants

Distributed Simulation & Design Platform (D-Sim)

•• New New modeling modeling techniques techniques for for accurate, efficient simulation and accurate, efficient simulation and Blast design Durability and Ride design Crash

Rollover 3

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Research Objectives ¾ Develop an integrated simulation and design capability to support: ƒ Modularized product development of current and future vehicle families

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The HMMWV Family

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Research Objectives ¾ Develop an integrated simulation and design capability to support: ƒ Modularized product development of current and future vehicle families ƒ Innovative vehicle concepts in support of Army transformation

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Future Tactical Truck System

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Research Objectives ¾ Develop an integrated simulation and design capability to support: ƒ Modularized product development of current and future vehicle families ƒ Innovative vehicle concepts in support of Army transformation ƒ Efficient integration of distributed models, simulation codes, and new design methodologies for commercial and military applications

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Vision of Distributed Simulation and Design

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Requirement: Multi-Domain Simulation

Vehicle Model Human Model Air

Exhaust gas

C

T

Exhaust gas

T

INTERCOOLER

I M

Air

C

MBD Engine Model

INTERCOOLER

E M

E M

I M

FUEL SYSTEM

V12 ENGINE . W

Combustion Model

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Requirement: Subsystem Design Embedded in Hierarchy of Systems

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Requirement: Rapid Configuration to Assess Innovative Vehicle Concepts

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Overview

Tire-Terrain Interaction Distributed simulation & design platform (D-Sim)

Blast

Distributed Simulation & Design Platform (D-Sim)

Crash

Durability and Ride

Rollover 13

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Major Components of D-Sim Model ModelDatabase Database

Distributed DistributedArchitecture Architecture

ΓiR

Interpolation

Simulation SimulationCode CodeWrapper Wrapper

i ΓVR

i +1 ΓVA

TT Gluing

ΓiA+1

Interpolation

Non-matching Non-matching Interfaces Interfaces 14

Web-based Web-basedInterface Interface

Gluing GluingAlgorithm Algorithm Automotive Research Center

Collection of HMMWV Subsystem Models

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Integrated Systems Approach

Chassis System

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Rapid Configuration of Different Vehicles Common Parts

HOOD ASSEMBLY

HMMWV BASE UPPER BODY

M1097A2 UPPER BODY

B-PILLAR CROSS MEBER

RR DOOR

M1025 UPPER BODY

ROOF ASSEMBLY

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DOOR ASSEMBLY

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Rapid Substitution of Different Fidelity Models Rigid Body

Rigid Body Static Model

Dynamic Model

Dynamic Model 18

Flexible Body Automotive Research Center

Web-Based Interface Main Web Page for D-Simulation

UPPER BODY PARTS SUSPENSION & AXLE PARTS FRAME PARTS

¾Search multi-layered model database ¾Define interfaces for model integration ¾Generate new distributed simulation and design models

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Gluing Algorithm and Non-Matching Interfaces ¾Enables multi-platform, multi-layered plug and play capability

TI

¾Standardizes model interfacing

TII

¾Protects proprietary data / models

Matching

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Non-Matching

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Overview

Tire-Terrain Interaction D-Sim

Blast

Crash

Durability

Rollover 21

Durability Automotive Research Center

Durability Road Simulation Durability Road Computed Body Mount Forces

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Gluing Algorithm for Durability 1.20E+04 X input

Y input

Z input

1.00E+04

Force (N)

8.00E+03 6.00E+03 4.00E+03 2.00E+03 0.00E+00 -2.00E+03 0.0

5.0

10.0

15.0

20.0

25.0

30.0

Time (sec)

Assembly of Main Body and Hood

Apply external force at 6 body mounts

Forces computed using ADAMS

CPU-1 HOOD ASSEMBLY

TI CPU-1

CPU-2

TII

CPU-2

D-Sim Results (coupled simulation)

MAIN BODY ASSEMBLY 23

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Overview

Tire-Terrain Interaction D-Sim

Blast

Safety Crash

Durability and Ride

Rollover 24

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Safety Applications

Rollover

Crash

Blast

Extreme Terrain 25

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HMMWV Rollover

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J-Turn Rollover Simulation (Flat Ground) Driving Conditions - Modified test protocol - Initially driven in a straight line - Initial speed: 10 mph and up - Test runs for 5 seconds

Steering Wheel Angle ± 330 deg 1000 deg/sec

0.33 sec

5.0 sec

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J-Turn (Rigid Body Model) ¾¾Predict Predictcritical criticalspeed speedrange range ¾¾Study Studyrollover rolloverbehavior behavior ¾¾Assess Assesseffect effectof ofup-armor up-armor system system ¾¾Design Designfor forrollover rolloverprevention prevention

Nominal speed

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Nominal speed +Center 10 mph Automotive Research

J-Turn Analysis Results

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Roof Strength Analysis ¾ Drop Test

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Simulating the Response of Structures and Occupants to Blast Loads

Response of vehicle floor and occupant under blast 32

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J-Turn Rollover under a Blast

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Overview

D-Sim Tire-Terrain Interaction

Blast

Crash

Tire-Terrain Interaction

Rollover 34

Durability Automotive Research Center

Extreme Terrain

Sand

Snow

Ice 35

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Tire-Terrain Interaction ¾ Tire passes forces / moments to vehicle ¾ Vehicle passes hub position / orientation to tire

Position / Orientation

Forces/Moments 36

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Vehicle Performance for Off-Road Events

No sand

Michigan Sandy Loam Loam

On-road

Off-road Maneuver 37

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Summary ¾ Comprehensive, integrated platform for analysis and design to support current and next generation vehicles ¾ Enabling technologies: ƒ General, functional simulation framework ƒ Algorithms for coupling different models and simulation codes ƒ Algorithms for coupling non-matching interfaces

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Future Developments ¾ Continue development of model database ¾ Incorporate human models ƒ Driver perception ƒ Assess safety systems

¾ Expand integration with commercial software ¾ Verify, validate and update model database using instrumented vehicles ¾ Simulation-based certification 39

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Future Developments

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