减振器实物在环系统开发及其应用技术研究
摘要
为满足车辆操纵稳定性、安全性和乘坐舒适性提升的需求，悬架减振部件的结构和功能越趋复杂化、多样化。为了进一步加快新型减振器，特别是阻尼可调减振器的研发步伐，客观上需要新的技术手段来分析研究新型减振器的实际阻尼特性，并在此基础上快速实现阻尼特性与整车性能的匹配以及半主动悬架系统控制策略的制定。
围绕上述需求，本文构建了减振器实物在环系统(Damper-in-the-Loop, DIL)，并对该系统的关键技术进行了深入的理论分析和试验研究。另外，针对普通双筒减振器，位移敏感减振器和阻尼可调减振器，文中还对所构建的减振器实物在环系统开展了应用技术研究。概括起来，本文完成了如下几个方面的研究工作：
首先，应用xPC-Target对DIL试验系统的实时运行平台进行了构建，在该平台上开发了车辆实时动力学模型并完成了DIL试验系统数值子系统与实物子系统的实时通信。在对液压伺服试验台伺服作动器、伺服阀、伺服控制器等各个组成单元以及测试样件的动力学特性进行分析研究的基础上，完成了减振器伺服试验台及测试样件耦合动力学模型的构建。将车辆以70km/h的速度行驶于B级随机路面时的悬架动行程作为试验台的激励信号，在试验关注的频率范围内对减振器伺服试验台及测试样件耦合动力学系统(下文简称为耦合动力学系统)进行了参数识别和模型验证，并在此基础上分析了各个物理特性参数对耦合动力学系统频率响应特性及稳定性的影响。
其次，文中建立了考虑阻尼力、弹簧力以及阻尼-弹簧单元力时滞的1/4车辆实物在环系统时滞动力学模型。考虑到耦合动力学系统在研究的频率范围内表现为显著的相位滞后特性，并且在低频段，耦合动力学系统可简化为纯时滞环节，文中使用Páde近似方法对上述时滞动力学系统进行了求解。随后，还就时滞对减振器实物在环系统、弹簧实物在环系统以及弹簧-减振器单元实物在环系统的动力学特性、稳定性的影响进行了分析并对上述时滞动力学系统的临界稳定滞后时间进行了解算。最后，应用能量耗散理论就滞后时间对上述实物在环系统稳定性的影响机理进行了理论分析。
然后，由于耦合动力学系统对DIL试验系统的位移跟踪性能及稳定性具有非常重要的影响，且考虑到耦合动力学系统在低频段主要表现为固定时滞的动力学特性，文中首先对基于函数外插的非时变跟踪校正控制方法进行了研究，并就该控制方法对耦合动力学系统在低频段的开环及闭环跟踪校正效果进行了仿真分析。基于滞后时间在线识别算法，文中构建了基于函数外插的时变自适应跟踪校正控制器(EATC)，并对该控制器的开环及闭环跟踪校正效果进行了仿真分析。为了进一步改善耦合动力学系统的位移跟踪校正控制效果，对耦合动力学系统在中、高频段的时变时滞及幅值衰减特性进行补偿控制，文中根据耦合动力学系统模型信息设计了基于模型的前馈跟踪校正控制器(MFTC)。为了减小由于模型参数摄动及传感器量测噪声对耦合动力学系统位移跟踪效果的影响，文中应用随机线性最优控制理论，设计了基于模型的前馈-反馈复合跟踪校正控制器(MCTC)，并使用遗传算法对随机线性最优反馈跟踪校正控制器的加权矩阵进行了离线优化，在有/无噪声干扰的工况下对MFTC和MCTC控制器的开环和闭环跟踪校正控制效果进行了仿真分析。最后，在不同激励输入下对EATC、MFTC及MCTC控制器的开环和闭环跟踪校正控制效果进行了试验分析和验证。试验表明：MCTC控制器与EATC、MFTC控制器相比，MCTC控制器具有较好的位移跟踪校正性能和抗干扰能力。
最后，应用MCTC跟踪校正控制器构建了减振器实物在环系统并使用微分-跟踪算法对位移传感器噪声抑制效果和微分解算精度进行了改善。构建了普通双筒减振器实物在环试验系统，对MVP (Multiple Velocity Peak Force Curve, MVP)曲线模型表达的阻尼特性和减振器实际阻尼力特性进行了对比分析并充分验证了DIL试验的有效性。通过减振器阻尼力整体缩放、拉伸阻尼力缩放以及压缩阻尼力缩放DIL试验，分析了减振器阻尼特性对车辆性能的影响。构建了位移敏感减振器实物在环试验系统，对位移敏感减振器的软阻尼特性、硬阻尼特性以及软-硬交替阻尼特性进行了试验研究，并对上述阻尼特性区MVP曲线模型和实际减振器阻尼特性进行了对比分析，通过DIL试验分析了位移敏感减振器工作于不同阻尼特性区时对车辆性能的影响。构建了阻尼可调减振器实物在环系统并使用无扰切换逻辑(Bump-less Transfer Logic)结合MCTC控制器来进一步提高阻尼可调减振器在阻尼力切换时耦合动力学系统的位移跟踪精度。并在此基础上对阻尼可调减振器的动态阻尼特性、阻尼力跟踪特性及车辆半主动控制进行了DIL试验研究。阻尼可调减振器DIL试验除了包含CDC(Continuous DampingControl, CDC)减振器实物外，还包含电磁阀驱动器和半主动控制器硬件，通过DIL试验，本文实现了对电磁阀驱动器性能的优化设计和对阻尼可调减振器参考模型的改进，从而提高了CDC减振器的阻尼力跟踪精度。
本文主要创新点如下：
（1）建立了减振器伺服试验台及测试样件耦合动力学模型，揭示了伺服试验台及测试样件各个物理特性参数对耦合动力学系统频率响应特性及稳定性的影响机理。
（2）建立了DIL系统时滞动力学模型并对该时滞动力学系统的临界稳定滞后时间进行了解算，应用能量耗散理论从本质上阐释了滞后时间对DIL系统稳定性及动力学特性的影响。
（3）设计了基于函数外插的时变时滞自适应跟踪校正控制器和基于模型的前馈-反馈复合跟踪校正控制器，成功实现了对耦合动力学系统在研究频率范围内相位滞后及幅值衰减特性的补偿控制。
（4）成功开发了国内首台车辆减振器实物在环试验系统，并应用该试验系统实现了对车辆普通双筒减振器、位移敏感减振器以及阻尼可调减振器阻尼特性的研究。
Adapting to the demands on improving vehicle handling stability, safety and ridecomfort, the structure and function of vehicle damping components are increasingly complexand diverse. To speed up the development of new damping products, especially for dampingadjustable dampers, it is imperative that engineers need new technical means by which thereal damping characteristics of new type dampers can be analyzed, moreover, the matchingexperiment between damping characteristics and vehicle dynamic performance, the controlstrategy for semi-active suspensions can be carried out conveniently.
According to the demands above, the Damper-in-the-Loop (DIL) system is constructedin this dissertation, theoretical analysis and experimental research of its key technologies arecarried out. To study the damping characteristics of dampers (e.g. double tube damper,displacement sensitive damper and damping adjustable damper) and the influences ofdamping characteristics on vehicle dynamic performance, application technology research ofthe DIL system is also processed in this article. To summarize, the main contributions of thisdissertation are listed as follows:
Firstly, real time platform of the DIL system is constructed based on xPC-Target, thereal time vehicle dynamic model and real time communication between physical subsystemand numerical subsystem of DIL system are developed on this platform. The dynamiccharacteristics of servo actuator, servo valve, servo controller, etc. of the hydraulic servo testrig and testing specimen are analyzed systematically in this dissertation. A coupled dynamicsystem which takes the interrelation of hydraulic test rig and testing specimen intoconsideration is established. Parameter identification and model validation of this coupleddynamic system are processed using suspension deflation of which the vehicle driving onB-level random road at70km/h as actuating signal. The influences of these parameters onfrequency response characteristics and stability of the coupled dynamic system are alsodiscussed.
Secondly, in consideration of significant phase delay characteristics of the coupleddynamic system, moreover, the coupled dynamic system can be simplified as a pure transferdelay in low frequency band. Based on analysis mentioned above, a delay dynamic system of quarter car model is built in which a delay damping force, delay spring force and delaydamper-spring force are embedded respectively. The delay dynamic system mentioned issolved by using Páde approximation. The influences of time delay on dynamics, stability andthe critical delay time of the delay dynamic system are also analyzed and solved. Finally, theinfluence mechanisms of time delay on the delay dynamic systems above are studiedtheoretically by using energy dissipation theory.
Furthermore, because dynamics of the coupled dynamic system has extremelyimportant influences on tracking accuracy and stability of the DIL system, the time-invarianttracking compensator is developed based on extrapolation and the frequency responsecharacteristics in which the coupled system can be simplified as a constant transfer delay.The simulation analysis of this tracking controller is conducted under open loop and closedloop condition in the low frequency band. An extrapolation based adaptive trackingcompensator (EATC) is also developed based on time delay identification online algorithm.The simulation analysis of EATC is also studied under open loop and closed loop conditionto make a compensation of variant time delay. For the purpose of further improving thetracking accuracy of the coupled dynamic system and implement compensation on thevariant time delay and amplitude attenuation in frequency spectrum of interest, model basedfeed-forward tracking compensator (MFTC) is developed by using the information of thecoupled dynamic system, and its tracking accuracy is also validated under open loop andclosed loop condition. In order to reduce the influence of model parameter perturbation andsensor measurement noise on displacement tracking accuracy, model based compoundtracking compensator (MCTC) is developed on the basis of MFTC and stochastic optimalcontrol theory. MCTC in which the weighted matrix of the feedback compensator isoptimized using Genetic Algorithm off-line and MFTC are analyzed under open loop andclosed loop condition with/without noise interference. Finally, compensators developedabove are validated in the experiment by using various command signals, the results ofexperiments demonstrate that MCTC has better capacity of resisting disturbance andtracking ability than EATC and MFTC.
At last, the DIL system is constructed using MCTC controller, the differentiate-trackingalgorithm is also implemented in the DIL system which can improve the signal quality ofLVDT sensor and the accuracy of differential operation of displacement signal.1) Completing the construction of the DIL system of normal double tube damper, acomparative analysis is processed between MVP (Multi-Velocity Peak force, MVP) dampermodel and the real damping characteristics, and the effectiveness of the DIL system has beenverified. The influences of damping characteristics on vehicle dynamic performance areanalyzed by means of the entire damping force scaling DIL experiment, the stretchingdamping force scaling DIL experiment and the compression damping force scaling DILexperiment.2) Completing construction of the DIL system of displacement sensitive damper,a comparative analysis is carried out between MVP damping characteristics of differentdamping areas (soft damping area, hard damping area and soft-hard damping area) and thereal damping characteristics. The influences of different damping area on vehicle dynamicperformance are analyzed by means of DIL experiment.3) Completing construction of theDIL system of damping adjustable damper using MCTC compensation and bump-lesstransfer logic by which the displacement tracking accuracy has been improved when thedamping force of CDC (Continuous Damping Control) damper is varying during the DILexperiment. This DIL system not only include CDC damper but also the drivers of solenoidvalve and semi-active controller. Dynamic damping, damping force tracking and semi-activecontrol of the CDC damper are studied by means of this DIL experiment. The driver powerand performance have been enhanced from DIL experiment, at the same time, the referenceMVP model of CDC damper also has been revised, which has improved the force trackingaccuracy of CDC damper.
Major Innovations of the Dissertation:
(1) The dynamic model coupled with the dynamics of the servo-hydraulic test rig andtest samples is established. The influence mechanism of physical parameters ofservo-hydraulic test rig and experimental specimen on frequency response characteristicsand stability of this coupled dynamic system is revealed.
(2) The DIL delay dynamic model is constructed and the critical delay time is solved.Moreover, the intrinsic influence of time delay on the dynamical characteristics and stabilityof this DIL system are analyzed based on energy dissipation theory.
(3) An extrapolation based adaptive tracking compensator (EATC) and model basedcompound tracking compensator (MCTC) are developed, compensation on the variant time delay and amplitude attenuation of the coupled dynamic system in frequency spectrum ofinterest are implemented successfully base on compensators developed above.
(4) The first DIL experimental system is developed in China, and the dampingcharacteristics of double tube damper, displacement sensitive damper and dampingadjustable damper of vehicle are studied using the DIL system.
围绕上述需求，本文构建了减振器实物在环系统(Damper-in-the-Loop, DIL)，并对该系统的关键技术进行了深入的理论分析和试验研究。另外，针对普通双筒减振器，位移敏感减振器和阻尼可调减振器，文中还对所构建的减振器实物在环系统开展了应用技术研究。概括起来，本文完成了如下几个方面的研究工作：
首先，应用xPC-Target对DIL试验系统的实时运行平台进行了构建，在该平台上开发了车辆实时动力学模型并完成了DIL试验系统数值子系统与实物子系统的实时通信。在对液压伺服试验台伺服作动器、伺服阀、伺服控制器等各个组成单元以及测试样件的动力学特性进行分析研究的基础上，完成了减振器伺服试验台及测试样件耦合动力学模型的构建。将车辆以70km/h的速度行驶于B级随机路面时的悬架动行程作为试验台的激励信号，在试验关注的频率范围内对减振器伺服试验台及测试样件耦合动力学系统(下文简称为耦合动力学系统)进行了参数识别和模型验证，并在此基础上分析了各个物理特性参数对耦合动力学系统频率响应特性及稳定性的影响。
其次，文中建立了考虑阻尼力、弹簧力以及阻尼-弹簧单元力时滞的1/4车辆实物在环系统时滞动力学模型。考虑到耦合动力学系统在研究的频率范围内表现为显著的相位滞后特性，并且在低频段，耦合动力学系统可简化为纯时滞环节，文中使用Páde近似方法对上述时滞动力学系统进行了求解。随后，还就时滞对减振器实物在环系统、弹簧实物在环系统以及弹簧-减振器单元实物在环系统的动力学特性、稳定性的影响进行了分析并对上述时滞动力学系统的临界稳定滞后时间进行了解算。最后，应用能量耗散理论就滞后时间对上述实物在环系统稳定性的影响机理进行了理论分析。
然后，由于耦合动力学系统对DIL试验系统的位移跟踪性能及稳定性具有非常重要的影响，且考虑到耦合动力学系统在低频段主要表现为固定时滞的动力学特性，文中首先对基于函数外插的非时变跟踪校正控制方法进行了研究，并就该控制方法对耦合动力学系统在低频段的开环及闭环跟踪校正效果进行了仿真分析。基于滞后时间在线识别算法，文中构建了基于函数外插的时变自适应跟踪校正控制器(EATC)，并对该控制器的开环及闭环跟踪校正效果进行了仿真分析。为了进一步改善耦合动力学系统的位移跟踪校正控制效果，对耦合动力学系统在中、高频段的时变时滞及幅值衰减特性进行补偿控制，文中根据耦合动力学系统模型信息设计了基于模型的前馈跟踪校正控制器(MFTC)。为了减小由于模型参数摄动及传感器量测噪声对耦合动力学系统位移跟踪效果的影响，文中应用随机线性最优控制理论，设计了基于模型的前馈-反馈复合跟踪校正控制器(MCTC)，并使用遗传算法对随机线性最优反馈跟踪校正控制器的加权矩阵进行了离线优化，在有/无噪声干扰的工况下对MFTC和MCTC控制器的开环和闭环跟踪校正控制效果进行了仿真分析。最后，在不同激励输入下对EATC、MFTC及MCTC控制器的开环和闭环跟踪校正控制效果进行了试验分析和验证。试验表明：MCTC控制器与EATC、MFTC控制器相比，MCTC控制器具有较好的位移跟踪校正性能和抗干扰能力。
最后，应用MCTC跟踪校正控制器构建了减振器实物在环系统并使用微分-跟踪算法对位移传感器噪声抑制效果和微分解算精度进行了改善。构建了普通双筒减振器实物在环试验系统，对MVP (Multiple Velocity Peak Force Curve, MVP)曲线模型表达的阻尼特性和减振器实际阻尼力特性进行了对比分析并充分验证了DIL试验的有效性。通过减振器阻尼力整体缩放、拉伸阻尼力缩放以及压缩阻尼力缩放DIL试验，分析了减振器阻尼特性对车辆性能的影响。构建了位移敏感减振器实物在环试验系统，对位移敏感减振器的软阻尼特性、硬阻尼特性以及软-硬交替阻尼特性进行了试验研究，并对上述阻尼特性区MVP曲线模型和实际减振器阻尼特性进行了对比分析，通过DIL试验分析了位移敏感减振器工作于不同阻尼特性区时对车辆性能的影响。构建了阻尼可调减振器实物在环系统并使用无扰切换逻辑(Bump-less Transfer Logic)结合MCTC控制器来进一步提高阻尼可调减振器在阻尼力切换时耦合动力学系统的位移跟踪精度。并在此基础上对阻尼可调减振器的动态阻尼特性、阻尼力跟踪特性及车辆半主动控制进行了DIL试验研究。阻尼可调减振器DIL试验除了包含CDC(Continuous DampingControl, CDC)减振器实物外，还包含电磁阀驱动器和半主动控制器硬件，通过DIL试验，本文实现了对电磁阀驱动器性能的优化设计和对阻尼可调减振器参考模型的改进，从而提高了CDC减振器的阻尼力跟踪精度。
本文主要创新点如下：
（1）建立了减振器伺服试验台及测试样件耦合动力学模型，揭示了伺服试验台及测试样件各个物理特性参数对耦合动力学系统频率响应特性及稳定性的影响机理。
（2）建立了DIL系统时滞动力学模型并对该时滞动力学系统的临界稳定滞后时间进行了解算，应用能量耗散理论从本质上阐释了滞后时间对DIL系统稳定性及动力学特性的影响。
（3）设计了基于函数外插的时变时滞自适应跟踪校正控制器和基于模型的前馈-反馈复合跟踪校正控制器，成功实现了对耦合动力学系统在研究频率范围内相位滞后及幅值衰减特性的补偿控制。
（4）成功开发了国内首台车辆减振器实物在环试验系统，并应用该试验系统实现了对车辆普通双筒减振器、位移敏感减振器以及阻尼可调减振器阻尼特性的研究。
Adapting to the demands on improving vehicle handling stability, safety and ridecomfort, the structure and function of vehicle damping components are increasingly complexand diverse. To speed up the development of new damping products, especially for dampingadjustable dampers, it is imperative that engineers need new technical means by which thereal damping characteristics of new type dampers can be analyzed, moreover, the matchingexperiment between damping characteristics and vehicle dynamic performance, the controlstrategy for semi-active suspensions can be carried out conveniently.
According to the demands above, the Damper-in-the-Loop (DIL) system is constructedin this dissertation, theoretical analysis and experimental research of its key technologies arecarried out. To study the damping characteristics of dampers (e.g. double tube damper,displacement sensitive damper and damping adjustable damper) and the influences ofdamping characteristics on vehicle dynamic performance, application technology research ofthe DIL system is also processed in this article. To summarize, the main contributions of thisdissertation are listed as follows:
Firstly, real time platform of the DIL system is constructed based on xPC-Target, thereal time vehicle dynamic model and real time communication between physical subsystemand numerical subsystem of DIL system are developed on this platform. The dynamiccharacteristics of servo actuator, servo valve, servo controller, etc. of the hydraulic servo testrig and testing specimen are analyzed systematically in this dissertation. A coupled dynamicsystem which takes the interrelation of hydraulic test rig and testing specimen intoconsideration is established. Parameter identification and model validation of this coupleddynamic system are processed using suspension deflation of which the vehicle driving onB-level random road at70km/h as actuating signal. The influences of these parameters onfrequency response characteristics and stability of the coupled dynamic system are alsodiscussed.
Secondly, in consideration of significant phase delay characteristics of the coupleddynamic system, moreover, the coupled dynamic system can be simplified as a pure transferdelay in low frequency band. Based on analysis mentioned above, a delay dynamic system of quarter car model is built in which a delay damping force, delay spring force and delaydamper-spring force are embedded respectively. The delay dynamic system mentioned issolved by using Páde approximation. The influences of time delay on dynamics, stability andthe critical delay time of the delay dynamic system are also analyzed and solved. Finally, theinfluence mechanisms of time delay on the delay dynamic systems above are studiedtheoretically by using energy dissipation theory.
Furthermore, because dynamics of the coupled dynamic system has extremelyimportant influences on tracking accuracy and stability of the DIL system, the time-invarianttracking compensator is developed based on extrapolation and the frequency responsecharacteristics in which the coupled system can be simplified as a constant transfer delay.The simulation analysis of this tracking controller is conducted under open loop and closedloop condition in the low frequency band. An extrapolation based adaptive trackingcompensator (EATC) is also developed based on time delay identification online algorithm.The simulation analysis of EATC is also studied under open loop and closed loop conditionto make a compensation of variant time delay. For the purpose of further improving thetracking accuracy of the coupled dynamic system and implement compensation on thevariant time delay and amplitude attenuation in frequency spectrum of interest, model basedfeed-forward tracking compensator (MFTC) is developed by using the information of thecoupled dynamic system, and its tracking accuracy is also validated under open loop andclosed loop condition. In order to reduce the influence of model parameter perturbation andsensor measurement noise on displacement tracking accuracy, model based compoundtracking compensator (MCTC) is developed on the basis of MFTC and stochastic optimalcontrol theory. MCTC in which the weighted matrix of the feedback compensator isoptimized using Genetic Algorithm off-line and MFTC are analyzed under open loop andclosed loop condition with/without noise interference. Finally, compensators developedabove are validated in the experiment by using various command signals, the results ofexperiments demonstrate that MCTC has better capacity of resisting disturbance andtracking ability than EATC and MFTC.
At last, the DIL system is constructed using MCTC controller, the differentiate-trackingalgorithm is also implemented in the DIL system which can improve the signal quality ofLVDT sensor and the accuracy of differential operation of displacement signal.1) Completing the construction of the DIL system of normal double tube damper, acomparative analysis is processed between MVP (Multi-Velocity Peak force, MVP) dampermodel and the real damping characteristics, and the effectiveness of the DIL system has beenverified. The influences of damping characteristics on vehicle dynamic performance areanalyzed by means of the entire damping force scaling DIL experiment, the stretchingdamping force scaling DIL experiment and the compression damping force scaling DILexperiment.2) Completing construction of the DIL system of displacement sensitive damper,a comparative analysis is carried out between MVP damping characteristics of differentdamping areas (soft damping area, hard damping area and soft-hard damping area) and thereal damping characteristics. The influences of different damping area on vehicle dynamicperformance are analyzed by means of DIL experiment.3) Completing construction of theDIL system of damping adjustable damper using MCTC compensation and bump-lesstransfer logic by which the displacement tracking accuracy has been improved when thedamping force of CDC (Continuous Damping Control) damper is varying during the DILexperiment. This DIL system not only include CDC damper but also the drivers of solenoidvalve and semi-active controller. Dynamic damping, damping force tracking and semi-activecontrol of the CDC damper are studied by means of this DIL experiment. The driver powerand performance have been enhanced from DIL experiment, at the same time, the referenceMVP model of CDC damper also has been revised, which has improved the force trackingaccuracy of CDC damper.
Major Innovations of the Dissertation:
(1) The dynamic model coupled with the dynamics of the servo-hydraulic test rig andtest samples is established. The influence mechanism of physical parameters ofservo-hydraulic test rig and experimental specimen on frequency response characteristicsand stability of this coupled dynamic system is revealed.
(2) The DIL delay dynamic model is constructed and the critical delay time is solved.Moreover, the intrinsic influence of time delay on the dynamical characteristics and stabilityof this DIL system are analyzed based on energy dissipation theory.
(3) An extrapolation based adaptive tracking compensator (EATC) and model basedcompound tracking compensator (MCTC) are developed, compensation on the variant time delay and amplitude attenuation of the coupled dynamic system in frequency spectrum ofinterest are implemented successfully base on compensators developed above.
(4) The first DIL experimental system is developed in China, and the dampingcharacteristics of double tube damper, displacement sensitive damper and dampingadjustable damper of vehicle are studied using the DIL system.
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