The model-based development of a dynamic test bench for testing damper assemblies with a focus on amplitudes with small excitations

Abstract

Damper assemblies are often tested on test benches with relatively large displacement amplitudes at high velocities. Stochastic excitations, as road irregularities can usually be described, have a high proportion of amplitudes with small excitations; the so-called small signals. Testing with small signals poses special challenges for test benches. A methodology is presented that uses a quarter vehicle model and synthetically generated road irregularities to estimate the displacement, velocity, and acceleration amplitudes occurring at a damper assembly model. In order to describe a more realistic vehicle behavior, the synthetically generated road irregularities undergo a reduction of the amplitudes in corresponding frequency ranges by means of linear filters. The evaluation of the amplitudes occurring at the damper assembly is used to make a selection of the actuator for the test bench. A nonlinear dynamic model of the test bench, a so-called “Digital Twin,” is then created, which focuses on both, the model of the permanent magnet synchronous machine and the mechanical model of the linear actuator. Furthermore, a controller optimization procedure is used to virtually optimize the test bench’s controller parameters. Using the optimized parameters after the build process of the test bench, damper assembly tests with small signals of high quality are possible. With the help of virtual development methods such as synthetically created filtered road irregularities and with a Digital Twin of the test bench, a fast test bench development is possible. Realistic results can be achieved.