Karl-Peter Jäker

Mechatronic design of a modular railway carriage

The mechatronic design methodology allows to efficiently design highly complex technical systems. The modular railway system presented here is driven by a linear drive, with an active suspension/tilt system being employed to enhance ride comfort. The two modules, along with their mechanics, sensors, actuators and digital signal processing, make up intelligent mechatronic function modules. They are part of an autonomous mechatronic system, the railway vehicle.

CACE tool for multi-input, multi-output systems using a new vector optimization method

A design environment specially tailored to problems in control engineering is presented. It contains, apart from plant models and operating environments, the formulation of the experimental environment. Linear controllers of any desired structure are designed with the aid of the characteristic variables of the experiments, using a vector optimization procedure in an interactive design process. The hierarchical description of the model, based on an interpreter solution, was realized in the ADA programming language. A complex problem in controller design, taken from the field of vehicle suspension, proves the efficiency and performance of the design tool.

Tool Integration by Way of a C omputer- A ided M echatronic L aboratory (CaMeL)

Abstract Due to the ever increasing efficiency of computers (hardware and software), it is now possible to represent a near lifelike model of the engineers working environment in the computer. Apart from the hierarchical structuring of mechatronic systems the software components dealing with the graphical, symbolic, and numerical representations of these models are organized on different levels The image of a mechatronics laboratory serves as an object-oriented representation of hierarchically organized objects, such as projects, experiments, systems, and devices A development framework for the integration of existing software (components developed at our institute as well as selected external programs) is suggested using modern software techniques such as the Ada®-Task concept and the object-oriented approach The demands are listed and the structures of the so called Computer-Aided Mechatronic Laboratory (CAMeL) are represented. By way of an example of a parameter-optimization experiment built up by different devices, the possibility of parallel operations of individual lab devices on suitable hardware isexplained

An active suspension/tilt system for a mechatronic railway carriage

Abstract This contribution presents the mechatronic design of a technically complex suspension/tilt module. This suspension/tilt module is to be implemented in a fully active railway carriage developed by the Neue Bahntechnik Paderborn (NBP, Novel Railway System Paderborn) research team. An active suspension system yields a comfortable suspension of the carriage body and a reduced sensibility to track irregularities. The tilting device allows higher cornering safety while ensuring the same ride comfort. Modelling and controller designs are the focus of this work. A presentation of the real-time realization of this module and an assessment of ride comfort based on measured results round off the paper.

Development of an Active Suspension/Tilt System for a Mechatronic Railway Carriage

Abstract This contribution presents an active suspension/tilt module designed by the MLaP for a mechatronic, modular railway carriage in the context of the project Neue Bahntechnik Paderborn (NBP, Novel Railway System Paderborn). The development of such a modern technical system requires interdisciplinary design processes - that is, mechatronics. The suspension/tilt module is treated here according to the design cycle for mechatronic systems, from modelling to synthesis to real-time realization, with the actuator and sensor systems and digital signal processing being dealt with along the way. An overview of the testbed technology applied to the module will round off the paper.

Design of a Railway Carriage, Driven by a Linear Motor with Active Suspension/Tilt Module

Abstract This paper presents the design of a railway carriage whose drive is realized by a linear motor. An integrated suspension/tilt module makes possible increased ride comfort and cornering speed in comparison to existing systems.

Interactive Optimization of Controller and Plant Parameters in the Case of Multiple Design Objectives

Abstract This paper presents a design method for simultaneous optimization of a large number of controller and plant parameters of high-order linear time-invariant systems. User-friendly supervision and control of several design objectives is achieved through an interactive graphics-supported design process. The application of the design package for optimal matching of construction and controller parameters is demonstrated in great detail taking as an example a vehicle model with actively controlled tandem wheel suspension.

Indirect force control in hardware-in-the-loop simulations for a vehicle axle test rig

For test rigs with multiaxial excitation of the specimen, the realization of a Hardware-in-the-Loop (HiL) simulation is a challenging task. In general, the excitation unit is a serial or parallel kinematic manipulator and the dynamic properties of the specimen vary in different spatial directions. Hence, the contact situation between the manipulator and the specimen requires extensive consideration. System instabilities and damage are possible. In this paper, it is demonstrated how indirect force controlled manipulators are used to provide realistic and safe HiL simulations. In this context, a HiL controller is developed for a highly dynamic vehicle axle test rig with a hydraulically actuated hexapod used as the excitation unit. The models of the HiL subsystems are shown first, and afterwards the design of the HiL controller is presented. A theoretical system analysis is provided, which includes the investigation of stability, bandwidth limitations and disturbance rejection. Simulation results are provided to emphasize the high quality of the HiL simulation.

Control of a hydraulic hexapod for a Hardware-in-the-Loop axle test rig

Abstract The present paper describes the controller design for a hydraulic hexapod which is used as an excitation unit for a Hardware-in-the-Loop axle test rig. This includes a description of the plant model, the subordinate drive controllers, the sliding mode state observer as well as the position control of the free hexapod. Measurements show the high dynamics of the position-controlled hexapod. The concept is extended to a hybrid position/force control to be used during axle test maneuvers. Its functionality is demonstrated by a measurement used for the identification of the axle kinematics.

Kinematics-based force/position control of a hexapod in a HiL axle test rig

This contribution presents the control strategy currently used to operate a hexapod as part of a Hardware-in-the-Loop (HiL) simulation environment for mechatronic vehicle axles. Using this control scheme on the test rig achieves high closed-loop position control bandwidth while keeping unwanted interaction forces and torques considerably low.