SIMULATION FOR AIRBAG SENSOR CALIBRATION

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... AIRBAG ECU ? An airbag sensor has to be calibrated based on acceleration signals. ... A new airbag sensor will be introduced in FH trucks and in the mean time, some parts will be modified: ... influence of barrier position (height, angle…).
SIMULATION FOR AIRBAG SENSOR CALIBRATION Jérôme LAGRUT 2nd European HyperWorks Technology Conference

Volvo 3P AB VOLVO GROUP – Business Area Volvo Trucks

Buses

Renault Trucks

Mack Trucks

Volvo Penta

Volvo Aero

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

Nissan Diesel

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Construction Equipment

Financial Services

Volvo 3P AB VOLVO GROUP – Corporate Values

QUALITY SAFETY ENVIRONMENT

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P AB VOLVO GROUP – Corporate Values

QUALITY “Safety is – and must always be – the fundamental principle SAFETY of our design work-” Assar Gabrielsson and Gustaf Larson, founders of Volvo

ENVIRONMENT

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Sept. 30 - Oct. 1

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Volvo 3P AIRBAG TEST

FM 30 km/h 0° TRAILER BACK

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Sept. 30 - Oct. 1

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Volvo 3P AIRBAG CONTROL ECU Electronic Control Unit

NON FIRE

CRASH SITUATION

ECU FIRE

accelerations

algorithm

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P HOW TO CALIBRATE AN AIRBAG ECU ?

TODAY = TESTS NON FIRE

accelerations

ECU

accelerations

FIRE algorithm

FUTURE = SIMULATION

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Sept. 30 - Oct. 1

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Volvo 3P HOW TO CALIBRATE AN AIRBAG ECU ? An airbag sensor has to be calibrated based on acceleration signals. HIGH SPEED

HIGH SPEED

TEST 1

TEST 1

HIGH SPEED TEST 2

HIGH SPEED

Acceleration signals

TEST 2

HIGH SPEED TEST 3

DEVELOPMENT TESTS

LOW SPEED

Sensor

VERIFICATION

CALIBRATION

TESTS

TEST 1

LOW SPEED TEST 2

LOW SPEED TEST 3

R O S ER N SE PLI P U S

Jerome LAGRUT Sept. 30 - Oct. 1

TEST 3

LOW SPEED TEST 1

Volvo 3P EHTC 2008

HIGH SPEED

algorithm

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LOW SPEED TEST 2

LOW SPEED TEST 3

Volvo 3P RESEARCH AND DEVELOPMENT PROJECT A two years research and development project has been done to define the simulation methodology:

• MESH GUIDELINES: recommendations for the mesh quality, mesh size (mesh class) and element formulation • TEST SENSOR ACCELERATION: frequency analysis to find the frequency spectrum that needs to be caught • FILTERING: cut off frequency and sampling rate have been set up to filter numerical noise and catch physical accelerations • SENSOR MODELING: recommendations to represent the sensors

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P PROJECT APPLICATION: FH trucks A new airbag sensor will be introduced in FH trucks and in the mean time, some parts will be modified:

2007-2008: 1st application of airbag sensor calibration with simulation help in the VOLVO Group

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P PROJECT APPLICATION: FH trucks Airbag sensor calibration matrix

HIGH SPEED

HIGH SPEED

TEST 1

TEST 1

HIGH SPEED TEST 2

HIGH SPEED

Acceleration signals

SIMULATION TEST 2

HIGH SPEED TEST 3

DEVELOPMENT TESTS

LOW SPEED

Sensor

VERIFICATION

CALIBRATION

TESTS

TEST 2

LOW SPEED TEST 3

R O S ER N SE PLI P U S

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

TEST 3

LOW SPEED

SIMULATION TEST 1

TEST 1

LOW SPEED

HIGH SPEED

algorithm

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LOW SPEED TEST 2

LOW SPEED

SIMULATION TEST 3

Volvo 3P PROJECT APPLICATION: FH trucks

Finite Element model 1.5 million elements RADIOSS 5.1 solver

Complete BIW + DIW + Dummies + Dashboard + Seats + Steering column + … Complete chassis + Engine + FUPS + Power train

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P PROJECT APPLICATION: FH trucks

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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A IR B A VE G S LO EN C IT SO R Y

Simulation / Physical test

A IR B A A C G C EL SE ER N SO A TI R O N

B A R R

IE R

FO

R C E

Test versus simulation correlation:

Volvo 3P PROJECT APPLICATION: FH trucks Test versus simulation correlation: validation of the model with the airbag sensor supplier

PHYSICAL TEST (from the development test phase)

Same Time To Fire  Model is validated

accelerations

SENSOR ALGORITHM Different Time To Fire

accelerations

 Model is not validated SIMULATION

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P PROJECT APPLICATION: FH trucks Sensitivity analysis: done if the model is validated to improve the robustness of the algorithm

• influence of new or modified parts • influence of cab variants

Influence on the airbag Time To Fire  Algorithm adjustments

• influence of chassis variants • influence of truck mass • influence of test speed • influence of barrier position (height, angle…)

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P PROJECT APPLICATION: FH trucks Airbag sensor calibration matrix

HIGH SPEED

HIGH SPEED

TEST 1

TEST 1

HIGH SPEED TEST 2

HIGH SPEED TEST 3

DEVELOPMENT TESTS

LOW SPEED TEST 1

LOW SPEED TEST 2

LOW SPEED TEST 3

: G N I V SASensor € k 0 0 ~2 CALIBRATION

R O S ER N SE PLI P U S

Jerome LAGRUT Sept. 30 - Oct. 1

SIMULATION TEST 2 HIGH SPEED

algorithm

Volvo 3P EHTC 2008

HIGH SPEED

Acceleration signals

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VERIFICATION TESTS

TEST 3

LOW SPEED

SIMULATION TEST 1 LOW SPEED TEST 2

LOW SPEED

SIMULATION TEST 3

Volvo 3P CONCLUSIONS: DIFFICULTIES ENCOUNTERED

 Level of details needed in the models (pipes, tanks, brackets…)  Material characteristics for crash application  Rupture, tearing (welds, glue, bolts, sheet metal…)  Model size: 64 bits workstations and software needed  Model size : CPU time  Test robustness

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P CONCLUSIONS: CAE BENEFITS  Many variants can be simulated (cab size, engine...)  Details can be seen in simulation and not in test (transparent vehicle)  The worst case scenario can be found by computation and influence the verification test configuration  New test conditions can be tested (speed, angle...)  Simulations will bring higher robustness to the algorithm  Simulations can show how new introduced parts (eg Front lid in steel instead of plastic) will effect the sensor signal and the algorithm

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P THANK YOU FOR YOUR ATTENTION

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P BACKUP SLIDE: sampling rate If we need 10 sampling points per period and if we want to catch accelerations up to 1500 Hz we need a sampling frequency :

Tsamp

1 1 = = = 0.06ms 10ν 15/ ms

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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Volvo 3P BACKUP SLIDE: mesh size • We need 10 elements (10.lc) per wavelength (c.T = c/ν) for the highest frequency and the slowest (plastic) stress wave :

50mm/ms c = = 3.333mm lc ≤ 10ν 15/ ms • For thicknesses of 2.mm or less this is close to the mesh convergence requirement

Volvo 3P Jerome LAGRUT EHTC 2008

Sept. 30 - Oct. 1

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