Introduction to CarSim

Introduction
Hands On Examples
Animation
Navigation and controls
Data Files
Vehicle model (Overview)
Batch and advanced test control Phil Mather
Simulink and VehicleSim (VS) Commands
tech@carsim.com 10/19/09

Mechanical Simulation 1
What is CarSim?
Computer simulation of a vehicle
Vehicle dynamics testing: braking,
acceleration, handling, ride (limited)
Response to driver controls, ground,
air
Runs under Windows
Options for real-time HIL testing

Mechanical Simulation 2
CarSim Product
Marketing Tools

and PLM Launch

Compress design cycles

Vehicle Proving Ground
Optimize physical testing
Optimization Driving
Collaboration Testing Simulators

Component Test with Hardware

in the Loop
Testing

Controls
Test with Software
in the Loop
Development

System Simulate
with CarSim Aftermarket
Definition

Vehicle Requirements,
Vehicle Capabilities, Capacities
Definition
3
CarSim Hands On

4
Hands On Examples

Get started
Use animator
Making new runs
Making new vehicles
and run them
Overlay results
View Plots

Using CarSim 5
CarSim Software Controls

6
VS Browser Overview
The database is organized
with over 175 graphic screens
Each screen accesses a
library of data sets
Navigate like a web browser
Standard buttons are at the top
of every screen
Use pull-down menus to select
data sets from libraries
Using CarSim
Screens show data in context
Help for all controls
Start by copying existing data
sets and making changes
Past runs are part of the
CarSim database
7
Graphical database

Vehicle math model solvers

Surface animator

The Parts of CarSim

Use the database to define vehicles,
conditions, and test results
Use notes to keep records of the test
Engineering plotter
View results with animation
View engineering plots
Export results to other software

Using CarSim 8
 Libraries and Datasets
Libraries are made up of Datasets

Using CarSim 9
 VS Browser
Librarybrowsing(Back,Forward)

The VS Browser
Moving around
Icon Bars Datasetbrowsing
(Previous,Next)
Linked Data Tree
Keyboard
Adding and deleting data sets
Export and Import
Organizes data for math models,
plotter, animator, Simulink

Using CarSim 10
Viewing Animations
Click the Animate button
Change the camera settings
Overlay other runs for
comparison

Using CarSim 11
Viewing Plots
Click the Plot button
Zoom in on plots
Get data points

Using CarSim 12
Documentation
Right-click
Help
View

CarSim Documentation 13
CarSim Data

14
Parameters
Simple Properties
Known to be significant
Shown on screen in context
Dimensions, masses, ratios
Measurable
No need to be a simulation specialist to
understand them

CarSim Vehicle Models 15

Vehicle Sprung Mass & Coordinate System

Vehicle coordinate system

CarSim Vehicle Data 16

Vehicle Sprung Mass & Coordinate System

Vehicle coordinate system

Front wheel center heights
Equal wheel center heights
BIGGER than rear wheel
center heights

Right wheel center

heights BIGGER than left Equal wheel center heights
wheel center heights

CarSim Vehicle Data 17

Vehicle Sprung Mass & Coordinate System

Vehicle coordinate system

Equal wheel center heights Equal wheel center heights

with small tires front, large
tires rear. Ground is defined
by the bottom of the tires

CarSim Vehicle Data 18

Example 1 Click Along
Problem: Change the CG height of an SUVs sprung mass to see the
effects of handling during a double lane change (DLC) maneuver.
1. Start with the existing example: Category - {* * Quick Start Guide Example}; Dataset -
Baseline
2. Create a new dataset by clicking the New Icon
a. Name the new dataset {Class Examples} DLC SUV Baseline
3. Next to the blue link for the Vehicle, click the pull down arrow and select {CS E-Class} E-
Class, SUV
4. Click the Run Math Model button and animate the results
5. Create another new dataset by clicking the new icon
a. Name this dataset {Class Examples} DLC SUV High CG
6. Next to the blue link for the E-Class, SUV, click the pull down arrow and select [Copy and
Link Dataset]

CarSim Vehicle Data 19

Example 1 Click Along
7. Name the new SUV {Class Vehicles} E-Class, SUV High CG
8. Click on the new link for E-Class, SUV High CG
9. Click on the pull down arrow next to the E-Class, SUV Sprung Mass link.
10. Select [Copy and Link Dataset]
11. Call this dataset {Class Sprung Mass} E-Class, SUV Sprung Mass High CG
12. Change the CG Height from 719 mm to 1250 mm.
13. Click the Home Icon
14. Next to the Animate button, check the Set run color box and select a color
15. Click on Run Math Model
16. Animate
17. Close the animation
18. Check the Overlay other Runs box
19. Select the SUV Baseline simulation
20. Animate and Plot

CarSim Vehicle Data 20

Example 2 Student Exercise
Problem: Change the Wheelbase of an SUV to see the effects of handling
during a double lane change (DLC) maneuver.
1. Start with the existing example: {Class Example} DLC SUV Baseline
2. Create a new dataset by clicking the New Icon
a. Name the new dataset {Class Examples} DLC SUV LWB
3. Next to the blue link for the E-Class, SUV, click the pull down arrow and
select [Copy and Link Dataset]
a. Name the new dataset {Class Vehicles} E-Class, SUV LWB
4. Click on the blue link for E-Class, SUV LWB
5. Next to the blue link for the E-Class, SUV Sprung Mass, click the pull
down arrow and select [Copy and Link Dataset]
a. Name the new dataset {Class Vehicles} E-Class, SUV Sprung
Mass LWB

CarSim Vehicle Data 21

Example 2 Student Exercise
6. Click on the link E-Class, SUV Sprung Mass LWB
7. Change the wheelbase to 4000 mm
8. Click the Home icon
9. Click the Run Math Model Button
10. Animate
11. Overlay other runs and Animate again

CarSim Vehicle Data 22

Payloads, Rate Sensors, and Trailers
Payloads can be added anywhere relative to the sprung mass.
Reference points and rate sensors may be added relative to the
sprung mass
CarSim can accommodate up to a 2 solid axle trailer

For payload and trailer examples, see the category {Trailers and
Payloads} in the example CarSim datasets.

CarSim Vehicle Data 23

CarSim Tables

24
Table Options

Choose Constant, Linear coefficient, or table

Choose table interpolation and extrapolation
Choose data input view Use the calculator to
View data in Excel manipulate table values

CarSim Vehicle Models 25

Nonlinear Properties
Represented with tables of
measurable quantities
Obtained from lab
Obtained from other software
(simulated measurements)

CarSim Vehicle Models 26

CarSim Roads

27
 3D Roads
Simple tabular descriptions
Horizontal, vertical, 3D incremental elevation Roads can be open-ended or
Tables are independent looped
Data from CAD, spreadsheet, GPS, etc.
Can choose type of interpolation and Automatically create shapes for
extrapolation surface animator
Textures can be added for realism
Friction maps applied to the surfaces for
use by the math model

CarSim Roads 28
 Road Shapes
Geometry used by math models also used to generate shape files
based on lanes
Additional shapes can be added
Copies of an object can be located along the road
Saved view from
BMP file made by
animator Lane animation
definitions

Geometry used for

math model & Miscellaneous
shape generator animation info

Click to View

CarSim Roads 29
Examples 3 Click Along
1. Go to Libraries -> Roads -> Road: 3D Surface.
2. Select the dataset {Straight} Flat and Long
3. Click the View with Animator button
4. Create a new road {Class Roads} Long with Hills
5. Change Centerline Elevation of the new road with dataset FHWA Alt
3
6. Update Shapes and view with Animator

CarSim Roads 30
Examples 4 Student Exercise
1. Go to the Datasets menu and select {Scenic Roads} Alt 3 from
FHWA.
2. Create a new dataset {Class Roads} Example Road.
3. Change Centerline Elevation to {Racetrack} Road course elevation.
4. Change the Off-center elevation to {Racetrack} Road course
banking
5. Update Shapes and View with Animator

CarSim Roads 31
Road Segment Builder
Look at example {Road Segment Builder} Cloverleaf

CarSim Roads 32
Road X-Y-Z
Look at example Road: X-Y-Z Coordinates of Centerline {Racetrack}
Road Course

CarSim Roads 33
Variable Width Roads
Look at example {Variable Width Roads} Trough Wander Road

CarSim Roads 34
(More) CarSim Animation

35
Animation Shapes
Shape is defined by set of
triangles
Two open-standard file types:
STL and OBJ
STL and OBJ files created by
third-party software
CarSim Animation
STL and OBJ files accessed
using Animator: Shape File
Link screen
Some lighting properties can
be specified on the screens.
36
Saving Animations

Save animations as:

.exe file
May be used by anybody
Full use of animator
.uaf file
Only used by people with CarSim
.avi file
May be used by anybody
Can only view recorded video, no camera
manipulation

CarSim Animation 37
Playing Animations in Powerpoint
Open SurfAnim
1. Make an animation you like, and set the
screen size, view, etc.
2. Select the menu File->Save Video or
File->Save EXE File As
3. Type in your title and save to your
prefered folder
4. Capture an image of the animation
5. Insert image into PowerPoint
6. Right click on image
7. Select Action Settings
A. If Video, select Hyperlink to -> Other
File
i. Select the video
B. If EXE, select Run Program
i. Select EXE file
CarSim Animation 38
CarSim Data Files

39
Several parsfiles

Parsfiles
Used by database
Used by math models
Used by animator
Used by plotter
Simple format
View with text editor
View with Linked Data Tree

CarSim Data Files 40

Sharing Data

41
Exporting Data
Export Expanded Parsfiles
Use File->Export Expanded Parsfile for one file
Use the Library tool to append or include many data sets
Use to transfer data and also make archives
NOTE: Animator shapes NOT exported (must be copied separately)
Export Encrypted Expanded Parsfile
Export Consolidated Parsfile

CarSim Data Files 42

Import Data
Import Expanded Parsfile
Import Consolidated Parsfile

CarSim Data Files 43

New Database Options

CarSim Data Files 44

CarSim Driver Controls

45
Procedures

Event Programming

CarSim Procedures and Controls 46

CarSim Open and Closed Loop Controls
Steering Controls
Open loop (Angle vs. Time)

Driver Path Follower (Lateral

Offset vs. Distance Traveled)
(Closed Loop Driver Model)

Open loop Torque (Torque

Input vs. Time)

CarSim Driver Controls 47

CarSim Open and Closed Loop Controls
Throttle and Brake Controls

Open loop throttle control (Throttle

control vs. Time)
Open loop brake control (Input
pressure vs. Time, or Pedal force input
vs. Time) NOTE: Must use correct
input for vehicle
Target Speed vs. Time or Distance
(Closed loop throttle control with or
without braking control)

Constant target speed (no throttle

control, no powertrain necessary)

CarSim Driver Controls 48

CarSim Open and Closed Loop Controls
Shifting Controls

Closed loop shifting according to

shift schedule
Automatic Transmission w/
Torque Converter
Manual Transmission w/ Clutch

Open loop gear selection

Gear position vs. Time
MTs may use open or closed loop
clutch control

CarSim Driver Controls 49

CarSim Outputs

50
New Plots

Event Programming

CarSim Outputs 51
 ERD output settings ERD file converter

Input and Output Control

I/O setting screen
ERD utility program
Excel and/or MATLAB format output

ERD utility program

CarSim Outputs 52
CarSim Vehicle Models

53
Main Modeling Objectives
Predict vehicle system
response to:
Driver steering control
Driver braking control
Driver throttle and shifting
control
Road friction and 3D
geometry
Air and wind
CarSim Vehicle Models
Tires are very important
Need realistic shear forces and
moments from the tire model:
Fx, Fy, Fz, Mx, My, Mz
Must calculate realistic input
variables for the tire model:
, , , R
Predict transfer of forces to the
sprung mass by the suspension
54
 Tire
Testing

Inertia
Measurement
Built on 30 Years of Research at UMTRI
Modeling,
Algorithms, &
Suspension
Simulation Measurement

Testing and Parameter

Analysis Measurement

CarSim Vehicle Models 55

 Lateral G Yaw ratedeg/s
0.5 20

10

0 0

-10

-0.5 0 10 20 -20 0 10 20
Road Test
CarSim
System-Level Modeling
Ideal model complexity for chassis control
development & proving ground correlation.
Models are computationally stable
Models run faster than real time on PCs
All model parameters can be measured

CarSim Vehicle Models 56

 Axle stroke
Rear
Sprung mass
6 DOF
Wheel strokes

Wheel Spin

Slip angles
Front

Degrees of Freedom

CarSim Vehicle Model 57

Dynamic states are defined by differential equations
. of System
Math Model
X=f
Simulated test Vehicle
conditions Properties
Equation Solver

Raw Output On-line documentation

CarSim Vehicle Model 58

 x(time)
slope = x(t
1)

.1)
x(t)1+ tx(t

x(t1+ t) True
function
x(t1) x(t)

Solving ODEs t1 t1+ t

time

True closed form solutions dont exist

Numerical solution is good enough approximation
Many methods for numerical integration

CarSim Vehicle Model 59

Example 6 - Demo
1. Change time steps to see differences

CarSim Vehicle Models 60

CarSim Vehicle Data

61
Aerodynamics

CarSim Vehicle Data 62

 Selection of suspension type

Suspension Model Concept

Non-linear and asymmetric suspension kinematics are handled
with full 3D motion
Various suspension types use different models
Independent
Rigid axle
Twist beam
Compliance due to the tire forces and moments is handled with
algebraic effects
Spring hysteresis done with extra state variables

CarSim Vehicle Data 63

Springs and Dampers
Each spring is represented by two tables and two beta parameters
The tables can come right from the test lab
Each beta is about 1/3 the deflection needed to cross through the
friction
The model was created by Paul Fancher at UMTRI and has been
extended by Mechanical Simulation
Dampers are described by a Force vs. Velocity curve

CarSim Vehicle Data 64

 Tire Models
CarSim Internal
CarSim Internal +
Camber Extensions
Pacejka 5.2
TNO-Delft MF-Tyre
TNO-Delft Swift Tire
FTire
External Tire Models

Tires
The built-in model uses test data for pure longitudinal and lateral
The built-in model uses similarity for different tire/ground friction
The built-in model uses Pacejka combined slip theory
Alternate models are available (magic formula, extended camber)
External models can be used

CarSim Vehicle Data 65

Steering System

CarSim Vehicle Data 66

Braking Systems Pressure Input

Wheel load Tire slip

Master
Cylinder
Pressure
Proportioning ABS Fluid
Out
Valve Control dynamics

T Wheel pressure

P
Brake torque

CarSim Vehicle Data 67

Braking Systems Pedal Force w/ Booster
and Temperature Effects

CarSim Vehicle Data 68

 Ie Itrans
Throttle input Ttcin Ttcout Ttcout Ntrans

Ntrans

Te e Ttcin e tco Tg
g
e

Engine Torque Trans. Device Transmission

Engine to Transmission
AT or MT selected
Lockup clutch over the torque converter
Fuel consumption calculated

CarSim Vehicle Data 69

 Transmission to Wheels

FxRF (hwc+@zRF)+MybkF FxRR(hwc+@zRR)+MybkR

Transmission

whRF Tg whRR
TgF TgR MyRR
MyRF
Inter-axle
Front Differential Differential Differential Rear

MyLF MyLR
gF gR
whLF whLR
Drive shafts F,R
FxRF (hwc+@zRF)+MybkF FxLR (hwc+@zLR)+MybkR

CarSim Vehicle Data 70

CarSim Final Example

71
Final Example
Problem: Create an example with the E-Class, SUV LWB on the Class Road.
1. Start with the existing example: {Class Examples} DLC SUV Baseline
2. Create a new dataset: {Class Examples} Final
3. Select the E-Class, SUV LWB
4. Click on the pull down arrow next to the Procedure link: DLC @ 120 km/h and [Copy and
Link Dataset]
a. Name this dataset {Class Procedure} Final Procedure
5. Click on the new blue link Final Procedure
6. Change the speed to Constant 80 km/h
7. Set the Braking control to No Braking
8. Set the Shifting control to AT 7th mode
9. Change the steering controller to {Constant Position} 1.65 m to the Right
10. Select the road {Class Roads} Example Road
11. Set the Stop time to 30, Start Station to 200, and Select Stop run at specified time
12. Click Home, and then Run Math Model, and Animate

CarSim Vehicle Data 72

CarSim Advanced Test Control

73
Events

Event Programming

CarSim Advanced Test Control 74

Batch Matrix
Automatically combine different inputs

Example:
3 different road friction
Batch run: Matrix and 3 different
Vehicles -> 9 different
simulations are run
with one click.
3 different road friction

3 different Vehicles

Base setting: for example DLC

CarSim Advanced Test Control 75

Batch Runs
Automatically update existing runs

Re-do many existing

runs after change
2

Batch run: Generic

1 7 Override properties
or conditions
8

10 11
4

12
3
5

CarSim Advanced Test Control 76

CarSim and Simulink

77
Simulink
Simulink (add-on to MATLAB) is the most used simulation
environment
Add custom controllers
Replace model components

ERD utility program

Extend CarSim with Simulink 78
Simulink Support / Interface
CarSim math models are available as Simulink
S-Function blocks
Use Simulink from CarSim
Use CarSim from Simulink

Extend CarSim with Simulink 79

CarSim and VehicleSim
Commands

80
VehicleSim (VS) Commands

Create new import and output variables

Create equations with existing and new
variables
Replace internal variable values
Create your own controls

Extend CarSim with VS Commands 81

CarSim Website

82
Forums

www.CarSim.com 83
CarSim Tech Support

84
Forums

www.CarSim.com 85
Introduction to CarSim
Introduction
Hands On Examples
Animation
Navigation and controls
Data Files
Vehicle model (Overview)
Batch and advanced test control
Simulink and VehicleSim (VS) Commands Phil Mather
tech@carsim.com

Mechanical Simulation 86
Introduction to CarSim

tech@carsim.com
734-668-2930
Phil Mather
tech@carsim.com

Mechanical Simulation 87