Multi-Mass Flywheel Model for Test Bench Simulation
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Solution Overview
Problem
Current test bench arrangements struggle to simulate the behavior of multi-mass flywheels, particularly dual-mass flywheels, which are critical in hybrid drive systems, due to their complex interaction with combustion engines and the need for real prototypes, leading to limitations in development efficiency and increased costs.
Innovation Solution
Implementing a model for a multi-mass flywheel in the control arrangement with at least two masses and a replacement arc spring model, using an integrative time-stepping method with a fixed step size, and evaluating spring force, friction, and contact mechanics to simulate real-time behavior, allowing for the decoupling of engine and drive train without relying on prototypes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real prototypes of multi-mass flywheels are used on the test bench, then the real behavior can be represented, but the availability is limited and development efficiency is reduced
Solution Approach 1:
The patent creates a virtual model (copy) of the multi-mass flywheel that replicates its real behavior characteristics. This virtual model includes masses from the primary and secondary sides, arc spring replacement models, and contact mechanics that mirror the physical flywheel's operation. The virtual model allows unlimited testing without requiring physical prototypes, thus resolving the contradiction between reliable behavior representation and development efficiency.
Solution Approach 2:
The patent replaces the physical mechanical system (real multi-mass flywheel prototype) with a computational model evaluated through algorithms on the control arrangement. The virtual model uses mathematical representations of masses, springs, and friction that substitute the physical components, enabling testing without the constraints of physical prototype availability while maintaining behavioral accuracy.
2Productivity
If the combustion engine is rapidly activated and deactivated in hybrid systems, then start/stop functionalities are improved, but component destruction may occur
Solution Approach 1:
The patent implements preliminary action by using the virtual multi-mass flywheel model to predict and analyze the effects of rapid engine activation and deactivation before actual testing. The model calculates stresses, friction forces, and contact mechanics that occur during start/stop events, allowing developers to identify potentially destructive conditions and adjust control strategies beforehand, thus preventing component damage while enabling rapid start/stop functionality.
3Measurement precision
If complex multi-mass flywheel behavior is simulated, then development accuracy is improved, but computational complexity increases
Solution Approach 1:
The patent segments the complex multi-mass flywheel system into distinct computational components: primary side masses, secondary side masses, arc spring replacement models, and contact mechanics. Each segment is modeled separately with its own algorithms, allowing the control arrangement to process complex behavior through manageable modular calculations rather than a monolithic complex model, thus balancing accuracy with computational complexity.
Data Source
AI summary
A test bench arrangement is connected to at least one electric machine (4) connected to a test specimen (1) for driving and/or loading the test specimen (1) and includes a control arrangement (6) for the electric machine or each electric machine (4). In order to link the powertrain and vehicle simulation with the real vehicle-specific combustion and transient behavior of the engine, at least one model (7) for a multi-mass flywheel is implemented in the control arrangement (6). At least part of the control requirement for the electric machine or each electric machine (4) is determined from this model (7), and this model (7) includes at least the two masses of the primary and secondary sides of the multi-mass flywheel and a substitute model for the bow spring or each bow spring. Furthermore, an algorithm is implemented in the control arrangement (6) that evaluates the model for a multi-mass flywheel using an integrative time-stepping method.