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Alexandria Engineering Journal (2017) 56, 359–370

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Alexandria University

Alexandria Engineering Journal


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ORIGINAL ARTICLE

A universal suspension test rig for electrohydraulic


active and passive automotive suspension system
Mahmoud Omar *, M.M. El-kassaby, Walid Abdelghaffar

Mechanical Department, Faculty of Engineering, Alexandria University, Egypt

Received 29 October 2016; revised 24 December 2016; accepted 16 January 2017


Available online 4 February 2017

KEYWORDS Abstract A fully active electro-hydraulic and passive automotive quarter car suspensions with
Active suspension; their experimental test-rigs are designed and implemented. Investigation of the active performance
Passive suspension; compared against the passive is performed experimentally and numerically utilizing SIMULINK’s
Servo; Simscape library. Both systems are modeled as single-degree-of-freedom in order to simplify the val-
Hydraulic; idation process. Economic considerations were considered during the rig’s implementation. The rig
Control; consists of two identical platforms fixed side by side allowing testing two independent suspensions
PID simultaneously. Position sensors for sprung and unsprung masses on both platforms are installed.
The road input is introduced by a cam and a roller follower mechanism driven by 1.12 kW single
phase induction motor with speed reduction assembly. The active hydraulic cylinder was the most
viable choice due to its high power-to-weight ratio. The active control is of the proportional-inte
gral-differential (PID) type. Though this technique is quite simple and not new, yet the emphasis
of this paper is the engineering, design and implementation of the experimental setup and con-
troller. A successful validation process is performed. Ride comfort significantly improved with
active suspension, as shown by the results; 24.8% sprung mass vibration attenuation is achieved.
The details of the developed system with the analytical and experimental results are presented.
Ó 2017 Faculty of Engineering, Alexandria University. Production and hosting by Elsevier B.V. This is an
open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction its components can only store or dissipate energy and can
never create energy which cannot satisfy both the comfort
The three available classifications of the suspension system and handling requirements under varying road conditions.
(Fig. 1) are passive, semi-active and active suspension systems, Most passive suspension systems employ spring with hydraulic
and this classification depends on the ability of the system to or pneumatic shock absorber. The damping force created by
absorb, add or extract energy. The passive suspension shock absorbers is based on converting vibration energy into
(Fig. 1a) is the most commonly used due to its simplicity, heat, then dissipating it to surroundings. This leads to change
robustness and low price. It has limited performance because in oil viscosity which influences the damping characteristics [1].
Traditional automotive suspension designs have been a
* Corresponding author.
compromise between three conflicting criteria which are road
handling, load carrying, and passenger comfort. Good ride
E-mail address: mahmoudomar91@gmail.com (M. Omar).
comfort requires a soft suspension but it will be sensitive to
Peer review under responsibility of Faculty of Engineering, Alexandria
University.
changes in applied loads. Good handling requires a suspension

http://dx.doi.org/10.1016/j.aej.2017.01.024
1110-0168 Ó 2017 Faculty of Engineering, Alexandria University. Production and hosting by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
360 M. Omar et al.

Nomenclature

ER electrorheological NG6 nominal size 6 valve


DOF degree of freedom PDF pseudo derivative feedback
HILS hardware in the loop PID proportional integral derivative
LPT linear position transducer PWM pulse width modulation
MR magnetorheological QC quarter car

setting neither stiff nor soft. The conventional passive suspen- trol of the Magnetorheological (MR) dampers via several tech-
sion involves spring and damper with constant coefficients [2]. niques while utilizing Hardware-in-the-loop-Simulation
Due to these conflicting demands, suspension design should (HILS) methodology. Another type of semi-active suspension
compromise between these two problems as shown in Fig. 2 utilized the Electro-rheological (ER) damper system. Choi
[3]. et al. [9] performed field test to evaluate performance charac-
Nowadays picking a car became such a prolonged and tir- teristics of a semi-active ER suspension system associated with
ing process. Cars were previously chosen according to their skyhook controller. They demonstrated that ride comfort and
size and power but now as people spend a considerably long steering stability of the vehicle were improved. Cao et al. [4]
time in their cars, comfort became one of the major aspects showed that semi-active systems have advantages over active
of choosing one’s vehicle. Hence, all of car manufacturers systems, including low power requirements, simplicity, ease
are competing in providing the utmost level of comfort by of implementation and low-cost.
modifying their suspension systems to cope up with the road Active suspension systems (Fig. 1c) employ a controllable
bumps and potholes. Although the excitations arising from actuator between the sprung and unsprung masses. This actu-
road roughness primarily affect the vehicle ride comfort, it is ator is able to both add and dissipate energy to and from the
the input over which vehicle design engineers and vehicle dri- system. The early studies on active suspensions performed by
vers have the least amount of control. There are three different Hrovat [10] included numerous approaches such as modal
models for potholes which are smooth, non-smooth and statis- analysis, eigenvalue assignment, model order reduction, non-
tical potholes [4]. Thus automotive manufacturers started to linear programming, multi-criteria optimization, and optimal
explore alternatives for the passive suspension to eliminate control. Classic control methods have also been considered,
the above mentioned compromise and that is when the princi-
ple of active and semi-active suspensions started to be increas-
ingly employed in high-end luxury cars as they improve
comfort and stability despite their high price and power con-
sumption [5]. Vehicle
The semi-active (Fig. 1b) was first introduced by Karnopp Handling
and Crosby in the early 1970s, [6] based on the well-known
skyhook control. The damping coefficient is varied by variety Ride
of methods but still the suspension system can only dissipate Comfort
the road forces and can’t add additional force to the system.
With the right control system, the passive suspension’s com-
promise can be reduced resulting in a smart system making Low Damping ------> High Damping
cars comfortable regardless of the road they are driven on.
Choi et al. [7] and Yao et al. [8] discussed the design and con- Figure 2 Damping compromise for passive dampers.

Figure 1 Suspension system classifications.


A universal suspension test rig for electrohydraulic active and passive automotive suspension system 361

such as root locus, Bode diagrams, and Nichols plots. Before improvement in the ride comfort, also, the rattle space usage
applying any of those control techniques well-defined, linear was reduced by 92.5% compared to the passive suspension sys-
model for the system is a necessity. To design the controller, tem. The settling time in all cases was about 2 s.
linearization of the system is a must. The main obstacle for Fayyad [15], Kumar et al. [16] and Elattar et al. [17]
commercialization of such systems is the significant power designed a PID controller for a QC model to improve the ride
requirement. In order to reduce the cost associated with the comfort and road holding ability. Fayyad showed numerically
required power, practical active suspension designs generally that for the step input of 80 mm, the sprung mass displacement
function as a low-bandwidth system that requires 4 kW of has been reduced by 25% while Kumar found that ride com-
peak power for road vehicle applications. fort is improved by 78.03% and suspension travel has been
Chandekar et al. [11] investigated the servo controlled reduced by 71.05% with active system compared to passive
hydraulic suspension. The hydraulic pressure is supplied by a one both experimentally and numerically. Elattar et al. com-
radial piston pump. Body movement and vehicle level are pared between PID and PDF controllers and showed that
monitored in real time by the controller which operates the although both showed improved performance, PDF has more
hydraulic servos, mounted beside each wheel. potential.
Bello et al. [12] and Venkateswarulu et al. [13] designed a
PID control for a 4 DOF, nonlinear, half vehicle active suspen-
sion system model. A comparison was made between nonlinear 2. Experimental setup
passive and the developed active system which showed a better
active performance. The constructed model ignored nonlinear- A detailed layout of the test rig is shown in Fig. 3 with all com-
ities in the hydraulic actuator as their effect was minimal and ponents specified. During the design stage, a reasonable factor
was created numerically using Matlab/Simulink. Both intro- of safety was employed while designing the tables and the cam-
duced a sinusoidal road input disturbance and the developed shaft to ensure durability of the test rig and its ability to with-
system by Bello performed a 52.29% and 57.47% reduction stand large hydraulic and inertial forces safely.
in front and rear suspension deflection respectively. It was con- The test rig shown in Fig. 3 consists of, two testing plat-
cluded that regardless of the power consumption of the active forms fixed side by side. Each of them consists of 0.5 m steel
system, it has better performance. Bello et al. [14] constructed a square table 0.6 m high (1 & 10), two journal bearings (14)
state space model for 2 DOF quarter car using full state- to hold the camshaft, a bottom base plate (6), 4 steel guide bars
feedback controller numerically via Simulink. For step input (8), a spring and damper shock absorber assembly with its fix-
of 0.1 m, the sprung mass acceleration and displacement of ation points (21), a sprung masse divided into two plates (11,12
the active system has been reduced by 80% and 11% respec- & 2,3), an unsprung mass (4 & 5) and upper plate to hold the
tively compared to the passive system which shows an assembly together (7). Both platforms are almost identical and

Figure 3 Detailed schematic with components.


362 M. Omar et al.

assembled together side by side in a way allowing one camshaft cam profile (X) can be calculated from Eq. (1), where X is in
(15) to drive both platforms to ensure that the road input is mm. [19]
identical for both suspension systems under test. The assembly
is lifted on wheels in case that it is needed to be transported X ¼ OQð1  cos hÞ ¼ 50ð1  cos hÞ ð1Þ
and also equipped with round base plates for ground fixation
where OQ is the offset distance between the cam and rotating
to secure the assembly in position while operating.
centers.
As seen from Fig. 3 the left platform is for the passive sus-
The cam had 100 mm peak to peak stroke (calculated at
pension and the right one is equipped with universal fixation
b = 180°) and it generated a waveform modeled as
points to accommodate a spring and damper assembly, an
rðtÞ ¼ 100 sin xt where x ¼ 2pf and f ¼ 0:7Hz. There was no
active hydraulic cylinder or even both of them side by side.
need for a return spring on the follower because the heavy
Both sprung and unsprung mass plates are equipped with a fix-
weight of the system, about 80 kg, above each follower is
ation point for a linear position transducer of type (OPKON
enough to always ensure surface contact between the cam
LPT200) [18] for the closed loop feedback control system.
and the follower.
The camshaft is supported by four journal bearings for uni-
The test rig allows configurations for 1DOF (Fig. 6(a)) and
form weight distribution, and driven by 1.12 kW induction
2DOF (Fig. 6(b)) systems by removing or installing the springs
motor (19) through a 1:7 reduction gear box and 1:5 reduction
representing the tire stiffness.
chain (17) to reduce the rpm of the motor from 1450 rpm to
41.4 rpm as a camshaft rotation speed, and this speed corre-
2.1. Hydraulic power unit
sponds to a vehicle’s linear velocity of 1.56 km/h which is slow
but was chosen to initially test the control system’s response. A
schematic of the test rig is shown in Fig. 4 indicating important A hydraulic power unit is used to drive the active suspension
sections in the design. system. A schematic for it with the active suspension system
Fig. 5 shows the mechanism for road disturbance input, is designed by Automation Studio Program as shown in
which is developed on the basis of vertical movement of the Fig. 7. It consists of a 60-liter hydraulic oil reservoir (1) and
suspension system produced by a cam (3) and follower (4) a pressure compensated axial piston pump of 14 cm3/rev (2)
mechanism driven by an induction motor (7) through a gear- mounted on top of the reservoir and driven by a 2.23 kW
box (2) and chains (5) for speed reduction and torque augmen- single phase induction motor (3) running at 1450 rpm. The
tation. The desired input is sinusoidal which is achieved by maximum supply pressure of the pump is 8 MPa. A medium
using a circular cam 190 mm in diameter and its driving shaft pressure filter (4) is of filtrations 10 lm filters the oil supplied
is offset from its center a distance OQ = 50 mm (Fig. 5). The by the pump. The pump delivery line includes a check valve

Figure 4 Schematic layout of the test rig.


A universal suspension test rig for electrohydraulic active and passive automotive suspension system 363

Figure 5 Cam profile and cam drive.

Rigid Columns Tire Springs

(a) (b)
Figure 6 (a) 1DOF, (b) 2DOF.

(5), an accumulator (6) of volume 0.6 liter and a pressure and stop push buttons on the front panel, two potentiometers
gauge (7). for manual control of the two servo valves and a main switch.
The pressure line feeds through two lines, the first for the
active suspension’s cylinder servo valve and the second for 2.3. Testing parameters
the road input disturbance cylinder servo valve. Both lines
are connected to a specially designed servo valve adapter block Both numerical and experimental results were performed with
according to the DIN standard porting pattern to adapt a size the same parameters which are stated in Table 1.
6 Rexroth single stage servo valve and a size 6 MOOG single All parameters were calculated experimentally to be applied
stage servo valve. to the Simulink models. Springs were calibrated by a hydraulic
cylinder equipped with one position transducer and two pres-
2.2. Electronic control panel sure sensors for the piston and rod pressures, and the force was
calculated from Eq. (2).
The electric and electronic control panel is developed especially F ¼ ðPpiston  APiston Þ  ðProd  ðAPiston  Arod ÞÞ ð2Þ
for the test rig including the following major components: An
Arduino Mega 2560 used for processing and control of the dig- The distance and force were recorded for the used suspension
ital and analogue I/O signals via serial communications, a uni- (Fig. 8) and tire helical springs (Fig. 9) and the average linear
versal multioutput power supply with input 220 VAC and trend line slope represented the stiffness. For the twin-tube type
outputs +12, 12, +5, 5, +3.3 VDC, a Rexroth and a dampers (Fig. 11) the distance from the sensor was differenti-
MOOG NG6 Driver Card with integrated Signal Generator ated to get the velocity and then it was plotted against the force
and On-Board Relay Module, circuit breakers used as protec- (Fig. 10) and the slope represented the damping coefficient [20].
tion for the main supply and the two induction motors, control The pump [21], Rexroth [22] and Moog [23] valves param-
relays and cooling fan. The human interface is through start eters were obtained from their manufacturer’s datasheets.
364 M. Omar et al.

(1) Hydraulic oil Reservoir (40 l) (6) Accumulator


(2) Variable Displacement Pump (21.17 LPM) (7) Pressure Gauge
(3) Electrical Motor (2.27 kW) (8) 4/3 Servo Valve
(4) Medium Pressure Filter (9) Double Acting Cylinder
(5) Check Valve

Figure 7 Hydraulic circuit diagram of the hydraulic power supply unit

2500
2000 y = 14029x - 345.28
Force (N)

Table 1 Testing parameters. 1500


1000
Suspension parameters
Sprung mass 51 kg 500
Unsprung mass 14 kg 0
Suspension spring stiffness 14,000 N/m 0 0.05 0.1 0.15 0.2
Damping coefficient 5000 N s/m Displacement (m)
Tire stiffness 4  30,000 N/m
Figure 8 Suspension spring calibration.
Active cylinder parameters
Piston diameter 38 mm
Piston side effective area Apiston 0.001134114 m2
Rod diameter 16 mm 1500
Rod side effective area Arod 0.000933053 m2 y = 30012x - 321.51
Force (N)

Stroke 240 mm 1000

Pump parameters 500


Displacement 14.8 cm3/rev
Rated speed 1450 rpm 0
Nominal pressure 70 bar 0 0.01 0.02 0.03 0.04 0.05 0.06
Setting pressure 60 bar Displacement (m)
Rexroth size 6 servo valve
Rated flow at 70 bar 12 l/min Figure 9 Tire spring calibration.
Input signal ±10 mA
Supply ±12 VDC
3. Numerical results
Moog size 6 servo valve
Rated flow at 70 bar 24 l/min
Input signal ±40 mA 3.1. DOF passive suspension
Supply ±12 VDC
A Simulink model has been created to simulate a 1 DOF pas-
sive suspension system using the Simscape library within the
A universal suspension test rig for electrohydraulic active and passive automotive suspension system 365

1500 main actuator, installed parallel to the passive suspension


and driven by a servo valve as seen in Fig. 13.
Force (N)

1000
y = 5008.1x + 1036.3 To make the active suspension effective a control system
500 must be incorporated to control the output signal to the servo
0 valve according to the reference input, which in our case a ref-
-0.1 -0.05 0 0.05 0.1 erence sprung mass height from the ground to be tracked
Velocity (m/s) regardless of the disturbed input road signal. One of the robust
control systems which is utilized here is the PID controller.
Figure 10 Damper calibration. Using the auto tuning feature of the Simulink, the system
was linearized and the correct PID gains were obtained to
enhance the system performance. The servo valve’s parameters
Simulink as seen in Fig. 12. The road input here is either a step were optimized so that the model perfectly simulates the actual
input created by a fast ramp in order to limit the derivative ini- valve’s performance according to its datasheet.
tial overshoot or the actual cam profile of a peak amplitude of Both the numerical active and passive sprung mass dis-
100 mm and a frequency of 0.7 Hz and the output is viewed on placements against the road input were recorded (Fig. 14)
the scope and recorded in the Matlab workspace for the vali- for the half sine wave input. For a half sine wave input of
dation process. 100 mm the passive suspension system reached a maximum
of 101 mm. Also when the input dropped to zero the suspen-
3.2. 1DOF active suspension sion went down for only 0.872 mm which is almost zero.
The overall amplitude achieved by the passive suspension is
To improve the performance, the active suspension system had equal to 101.87 mm which neither attenuated nor augmented
to be incorporated to absorb the shock. A Simulink model was the road input, because both the damping coefficient and
created in the Simscape environment to model the active sus- spring stiffness are relatively high compared to the low sprung
pension system incorporating a double acting cylinder, as the mass value of 50 kg.

Figure 11 Section view of the Twin-tube shock absorber [20].

Figure 12 Simscape 1DOF passive modeling.


366 M. Omar et al.

Figure 13 Simscape 1 DOF active suspension model.

120
Road input
100 Sprung mass displacement (Acve)
Sprung mass displacement (Passive)
80
Displacement (mm)

60

40

20

0
0 0.5 1 1.5 2 2.5 3
-20

-40
Time(sec)

Figure 14 Numerical active, passive and road input vs. time.

The Active suspension had a maximum peak value of which means that 40% of the bump’s input and 41% improve-
23.6 mm, which is a 76.4% reduction in amplitude resulting ment from the passive suspension behavior were successfully
in improved ride comfort. However, after the peak value of achieved.
the input road signal has passed the system took a dive of The obvious drawback of the suspension system is the dive
-36.7 mm which is much higher than the dive level of the pas- that the sprung mass endures when the bump ends, which is
sive system. The system has an overall displacement of 60 mm justified because it is related to the hydraulic characteristics
A universal suspension test rig for electrohydraulic active and passive automotive suspension system 367

of the system. When the bump is introduced to the system the vextension ¼ 0:8227 vretraction ð5Þ
suspension response is to retract the piston via the servo valve which means that the cylinder needs more time to extend than
so pressurized oil flows into the rod side of the cylinder. How- to retract and while the time for the rising and falling ramps of
ever, when the peak tip of the bump passes and the sprung the bump is the same then the active system dives but settles
mass starts falling, the system’s response is to extend the cylin- and reaches steady state after 1 s from passing the bump.
der thus supplying the pressurized oil to the piston side of the
cylinder.
4. Experimental results
Taking into consideration that the maximum flow of the
pump Qmax is constant then the relation between extension
and retraction speeds can be obtained from Eqs. (3)-(5). [24] The two used position sensors are of the linear resistor type
OPKON LPT200. Position sensor 1 has been mounted on
Qmax ¼ Qextension ¼ vextension  Apiston ¼ 0:001134114 vextension ð3Þ the sprung mass and the second one on the unsprung mass
plate. The position sensor only outputs the displacement but
Qmax ¼ Qretraction ¼ vretraction  ðApiston  Arod Þ utilizing the Simulink resources, the signal is differentiated
¼ 0:000933053 vretraction ð4Þ once for velocity and twice for acceleration if needed.

Figure 15 Experimental data acquisition for passive suspension system.

Figure 16 Simulink program for experimental active suspension.


368 M. Omar et al.

120
Road input
100 Sprung mass displacement (Acve)
Sprung mass displacement (Passive)
80

Displacement (mm)
60

40

20

0
0 0.5 1 1.5 2 2.5 3
-20

-40

-60
Time (sec)

Figure 17 Experimental active, passive and road input vs. time.

150

100

50
PWM

0
0 0.5 1 1.5 2 2.5 3
-50

-100

-150
Time (sec)

Figure 18 Applied PID output signal to the servo valve from the PWM pin from the Arduino.

120
Sprung mass displacement Exp (Passive)
100 Sprung mass displacement Num (Passive)
Sprung mass displacement Exp (Acve)
80
Sprung mass displacement Num (Acve)
60
Displacement (mm)

40

20

0
0 0.5 1 1.5 2 2.5 3
-20

-40

-60
Time (sec)

Figure 19 Comparison between experimental and numerical results.

4.1. DOF Quarter car passive suspension system pins of the Arduino Mega 2560 through serial communication.
The transferred data are processed by the Simulink interface as
The camshaft motor is started, and the output signals from the the Arduino board serves the function of input and output
sensors are transferred to the Simulink via the analogue input interface and data acquisition card as seen in Fig. 15.
A universal suspension test rig for electrohydraulic active and passive automotive suspension system 369

Table 2 All obtained results.


Theoretical Experimental
Overshoot (mm) Dive (mm) Overall Displacement (mm) Overshoot (mm) Dive (mm) Overall Displacement (mm)
Passive 101 0.872 101.87 95.7 0.12 95.58
Active 23.6 36.7 60 33.6 41.6 75.2

4.2. DOF Quarter car electro-hydraulic active suspension system active is worse than the passive justification has been made
for that issue. A total improvement of 40% was achieved the-
Another Simulink program was created with the aid of the oretically; however experimentally the improvement was only
Arduino integrated library (Fig. 16) to read the position signal 24.8%; this is due to the design variation between the actual
for both sprung and unsprung mass displacements and intro- system and the mathematical modeling. The settling time for
duce a closed loop PID controller to try to keep the sprung the active suspension was 2.4 s in the numerical work but only
mass’s position constant regardless of the road disturbance. 1.4 s in the experimental results.
The control system uses the sprung mass displacement reading
from the position sensor as a feedback signal to track. Accord- 5. Conclusion
ing to the deviation from the reference position set point, the
PID controller outputs a digital signal to the servo valve driver An electro-hydraulic active suspension PID control system is
card through the PWM (Pulse width modulation) pin in the designed and implemented both numerically in Simulink and
Arduino Mega 2560 board. This digital signal from 0 to 255 experimentally on the specially designed suspension test rig.
is equivalent to an analogue output signal from 0 to 5 V that A successful validation process has been performed to define
is converted by the valve’s electronic driver card to ± 40 mA all the system’s parameters and to compare the developed
needed to drive the MOOG servo valve. model against the experimental setup. The obtained results
The output data obtained from the programs for the cam show that the active suspension has a very good potential of
profile and the sprung mass displacement (Fig. 17) were plot- reducing the road input disturbance of up to 24.8% for
ted against time. It is seen that for 100 mm peak half sine road 100 mm half sine bump.
input the passive sprung mass displacement had a maximum
value of 95.7 mm, while the minimum steady state value was Future work
1.2 mm, with an overall amplitude value of 95.58 mm. Those
results indicate that the suspension system slightly attenuated
Faster speeds should be considered to evaluate the system’s
the road input but a steady state error was produced; this
performance to input road disturbance under variable
could be justified as a result of the ignored friction forces
conditions.
between the guide bars and the sprung mass sliding on them
The need for a larger size hydraulic pump to introduce
or due to internal friction of the shock absorber assembly.
higher oil flow rates into the system which would improve
Those results are slightly different than the Simscape model-
the response speed. Also the regenerative hydraulic connection
ing; however, they are very close thus indicating that a good
for the active hydraulic cylinder would be tested as it will
model validation has been performed.
improve the cylinder’s extension speed thus reducing the large
Tuning process for the active PID controller was performed
dive that occurs with the active system.
until the stable parameter combination was reached and
One more thing would be using another form for the distur-
applied. It is seen that with the actual active suspension system
bance road input resembled in a hydraulic cylinder driven by
and for the same 100 mm half sine input, the peak overshoot
another servo valve to achieve a more controllable custom
for the sprung mass is 33.6 mm, while the maximum recorded
amplitude and frequency road input.
value of dive was -41.6 mm, thus resulting in an overall ampli-
tude of 75.2 mm which means that 24.8% of the bump’s input
and 21.3% of the passive suspension behavior were success- References
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