DoE-gestützter vorderachsentwurf auf einem virtuellen Rollenprüfstand unter Berücksichtigung experimentell ermittelter Lenkungsübertragungseigenschaften

This paper presents a method for designing front axles based on design-of-experiment (DoE) studies using a virtual roller test rig. In addition to standard axle characteristics resulting from kinematic and compliance analyses, dynamic properties of both the steering and the front axle are considered in order to ensure desired steering behavior of the vehicle. The dynamics of the steering subsystem is available from experimental testing, whereas the front axle dynamics is calculated by multi-body simulation. Both subsystems are assembled in the frequency domain to predict vehicle performance. Such a hybrid approach combines the trustworthiness of experimental testing with the high efficiency of simulation models. The extent of the model is limited to the front axle including rolling wheels in order to enable large scale Doe-studies within reasonable time. Even the steering gear is not part of the model, as the steering subsystem is assembled from measurement data afterwards. In order to still perform realistic driving maneuvers, a virtual roller test rig for use with multi-body simulation was developed. After completion of the DoE all the results are used for the training of metamodels, which enable the application of statistical methods to identify solution spaces for all the design parameters of the front axle. By using metamodels, high-dimensional analyses of over one hundred design variables are feasible, without having to dispense with the accuracy of a detailed MBS-model.