Day 1 - 6 Torsten Nitschke & Andreas Nessel - Ukintpress ...
Day 1 - 6 Torsten Nitschke & Andreas Nessel - Ukintpress ...
Day 1 - 6 Torsten Nitschke & Andreas Nessel - Ukintpress ...
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The closed air suspension system of the Porsche Panamera<br />
Vehicle Dynamics Expo 22. - 24. June 2010 at the new Messe, Stuttgart<br />
Dipl.- Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, responsible project engineer for the Panamera air spring system, Dr. Ing h. c. F. Porsche AG<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 1<br />
Vehicle Dynamics Expo, 22.06.10
Content<br />
• Introduction<br />
• Operation and function<br />
• Components<br />
• The closed air supply system<br />
• Control unit and software development process<br />
• System functionality and controller strategy<br />
• The new air spring design<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 2<br />
Vehicle Dynamics Expo, 22.06.10
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 3<br />
Vehicle Dynamics Expo, 22.06.10
Comfort<br />
Performance Driving pleasure and emotion Efficiency<br />
• the best possible driving performance and superior traction<br />
• great driving pleasure and agility<br />
• maximum driving safety and superb handling<br />
• excellent driving comfort and the familiar day-to-day usability<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 4<br />
Vehicle Dynamics Expo, 22.06.10
fig. 1: variation of suspension set up fig. 2: variation of spring rate<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 5<br />
Vehicle Dynamics Expo, 22.06.10
Operation and function<br />
fig. 3: interieur Panamera<br />
fig. 4: operation panel<br />
• Comfort<br />
=> shock absorber comfort + normal vehicle level + soft spring rate<br />
• Sport => shock absorber sport + normal vehicle level + soft spring rate<br />
• Sport Plus => shock absorber performance + low vehicle level + hard spring<br />
rate<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 6<br />
Vehicle Dynamics Expo, 22.06.10
Operation and function<br />
Lift level : + 20 mm above normal vehicle level<br />
Normal vehicle level<br />
Low level : - 25 mm below normal vehicle level<br />
fig. 5: various vehicle levels<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 7<br />
Vehicle Dynamics Expo, 22.06.10
Components<br />
• front air spring strut with additional air volume and PASM shock absorber,<br />
• separate rear air spring with additional air volume and PASM shock absorber<br />
• air supply system with compressor, pressure sensor and pneumatic valve block<br />
• 5.2 litre air reservoir<br />
• wheel travel sensor on each corner<br />
• two front and one rear acceleration sensor<br />
• temperature sensor<br />
• Electronic Control Unit (ECU)<br />
fig. 6: airspring system components<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 8<br />
Vehicle Dynamics Expo, 22.06.10
The closed air supply system<br />
fig. 8: pneumatic scheme of the open system<br />
fig. 7: pneumatic scheme of the closed system<br />
Advantages of the closed compared to the open air<br />
supply system:<br />
fig.9a: fig.9b: scheme air spring filling deflate<br />
• energy consumption reduced by around 60%<br />
• compressor operating time reduced by 75%<br />
• high adjusting speed v > 4mm/s<br />
• weight savings of around 1kg<br />
• less costs due to smaller components<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 9<br />
Vehicle Dynamics Expo, 22.06.10
Control unit and software development process<br />
Specification<br />
Car requirements<br />
CAN definition<br />
Development<br />
- Air Spring- Damper<br />
Characteristic<br />
- System behaviour<br />
Testing<br />
HIL, Vehicle<br />
Testing<br />
Approval<br />
Porsche<br />
Development<br />
Actuator Control<br />
Low Level SW<br />
Qualification<br />
SIL, Vehicle Testing<br />
Implementation<br />
Code Generating<br />
System Linking<br />
Basic Testing<br />
Supplier<br />
fig. 10: V- development scheme<br />
fig. 11: ECU Hardware<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 10<br />
Vehicle Dynamics Expo, 22.06.10
System functionality and controller strategy<br />
• Spring rate switch point<br />
a-longitudinal a-lateral a-vertical<br />
steering<br />
angle<br />
height<br />
deviation from<br />
zero position<br />
air spring valve<br />
switch point<br />
V1+V2<br />
V1<br />
soft spring rate<br />
hard spring rate<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 11<br />
Vehicle Dynamics Expo, 22.06.10
System functionality and controller strategy<br />
• Air leakage compensation<br />
suction<br />
pressure<br />
suction<br />
pressure<br />
air spring fast filling<br />
reservoir filling<br />
suction<br />
pressure<br />
deflate reservoir<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 12<br />
Vehicle Dynamics Expo, 22.06.10
System functionality and controller strategy<br />
• Diagnostics and fault detection<br />
fig. 12: PIDT-Tester<br />
fig. 13: user interface<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 13<br />
Vehicle Dynamics Expo, 22.06.10
Handing over to Continental AG<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 14<br />
Vehicle Dynamics Expo, 22.06.10
The new air spring design of the Porsche Panamera<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
<strong>Andreas</strong> <strong>Nessel</strong><br />
Stuttgart, 22.06.10<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 15 © Continental AG<br />
Χ
Panamera front axle – Package of air struts<br />
Limited package space<br />
Additional volume and valve must<br />
be integrated into the air spring<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 16 © Continental AG
Integration of addition volume<br />
valve cartridge<br />
Additional volume<br />
Switch to sport plus mode by<br />
separation of the additional volume<br />
Air spring main volume<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 17 © Continental AG
Addition volume valve<br />
Electrical connector<br />
Air connector<br />
Technical data:<br />
• Nominal opening diameter 12mm<br />
• Mass 370g<br />
• Diameter 40mm<br />
• Switch time < 100ms<br />
• Integrated air spring filling<br />
Air outlet to additional volume<br />
Air from air spring<br />
Development of a new valve to<br />
meet the weight and packaging<br />
targets<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 18 © Continental AG
Dynamical behavior of the front axle air spring<br />
Stiffness vs. frequency<br />
Measurement of air spring only (damper excluded)<br />
Amplitude 5mm<br />
2mm<br />
Stiffness<br />
1mm<br />
0<br />
0 10 20 30 40 50 60 70 80<br />
Frequency (Hz)<br />
No increase of stiffness in the frequency<br />
area relevant for ride comfort<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 19 © Continental AG
Panamera rear axle – Package of air springs<br />
Rear axle design requires<br />
stand alone air spring<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 20 © Continental AG
Design of rear axle air spring<br />
Additional volume<br />
Valve<br />
cartridge<br />
Guiding tube<br />
Air spring<br />
main volume<br />
Switch to sport plus mode by<br />
separation of the additional volume<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 21 © Continental AG
Influence of piston contour on air spring characteristics<br />
Wheel-related stiffness (N/mm)<br />
0<br />
Positive contour<br />
Progressive in jounce<br />
-100 -80 -60 -40 -20 0 20 40 60 80 100<br />
Wheel travel (mm)<br />
Cylindrical contour<br />
degressive rebound characteristic Negative contour<br />
Comfortable center<br />
Air suspension characteristic can be<br />
tailored to the specific vehicle requirements<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 22 © Continental AG
Piston contour<br />
Negative piston contour<br />
=> Reduction of stiffness<br />
=> Lower air spring volume required for given stiffness<br />
negative contour<br />
positive contour<br />
5<br />
Required air spring volume vs. Piston gradient<br />
Volume (l)<br />
4<br />
3<br />
Panamera RA<br />
Comfort Mode<br />
2<br />
Sport Mode<br />
1<br />
0<br />
-25 -20 -15 -10 -5 0 5 10 15 20 25<br />
Piston gradient (Degree)<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 23 © Continental AG
Benchmarking of air spring related harshness<br />
50.00<br />
45.00<br />
40.00<br />
35.00<br />
30.00<br />
25.00<br />
20.00<br />
15.00<br />
10.00<br />
5.00<br />
0.00<br />
Harshness coeffizient (%) Front axle<br />
Harshness coeffizient (%) Rear axle<br />
50.00<br />
45.00<br />
40.00<br />
35.00<br />
30.00<br />
25.00<br />
20.00<br />
15.00<br />
10.00<br />
5.00<br />
0.00<br />
Comfort Sport Comfort Sport<br />
Comfort Sport Comfort Sport<br />
Porsche Panamera Benchmark Porsche Panamera Benchmark<br />
HarshnessCoefficient<br />
=<br />
c<br />
0,1<br />
c<br />
" c<br />
25<br />
25<br />
! 100%<br />
Low harshness due to bellow<br />
design<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 24 © Continental AG
Summary<br />
Switchable rate air springs…<br />
…enable the driver to select between sportive and comfortable characteristic.<br />
…influence the steering behaviour in the direction of a more agile handling in the sport<br />
mode.<br />
A compact design enabled by…<br />
…a new developed smaller valve and the integration of the additional volume into the air<br />
spring module.<br />
…reduction of required air spring volume by appropriate piston contour design.<br />
Outstanding air spring comfort achieved by…<br />
… using outer guiding tubes, for the Porsche Panamera the very first time for a<br />
stand alone air spring module on the rear axle.<br />
…using bellows with comfort supporting harshness properties.<br />
Division Chassis & Safety, BU Chassis Components<br />
Segment Electronic Suspension Systems<br />
Vehicle Dynamics 2010, Stuttgart<br />
<strong>Andreas</strong> <strong>Nessel</strong>, Slide 25 © Continental AG
Questions and<br />
Discussion<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 26<br />
Vehicle Dynamics Expo, 22.06.10
Thank you for your attention<br />
The closed air suspension system of the Porsche Panamera<br />
Dipl.-Ing. <strong>Torsten</strong> <strong>Nitschke</strong>, Aktive und Passive Federungssysteme, Dr. Ing h. c. F. Porsche AG<br />
Page 27<br />
Vehicle Dynamics Expo, 22.06.10
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