Low cost integration of Electric Power-Assisted Steering (EPAS) with Enhanced Stability Program (ESP)

Abstract

Vehicle Dynamics Control (VDC) systems (also known as Active Chassis systems) are mechatronic systems developed for improving vehicle comfort, handling and/or stability. Traditionally, most of these systems have been individually developed and manufactured by various suppliers and utilised by automotive manufacturers. These decentralised control systems usually improve one aspect of vehicle performance and in some cases even worsen some other features of the vehicle. Although the benefit of the stand-alone VDC systems has been proven, however, by increasing the number of the active systems in vehicles, the importance of controlling them in a coordinated and integrated manner to reduce the system complexity, eliminate the possible conflicts as well as expand the system operational envelope, has become predominant. The subject of Integrated Vehicle Dynamics Control (IVDC) for improving the overall vehicle performance in the existence of several VDC active systems has recently become the topic of many research and development activities in both academia and industries Several approaches have been proposed for integration of vehicle control systems, which range from the simple and obvious solution of networking the sensors, actuators and processors signals through different protocols like CAN or FlexRay, to some sort of complicated multi-layered, multi-variable control architectures. In fact, development of an integrated control system is a challenging multidisciplinary task and should be able to reduce the complexity, increase the flexibility and improve the overall performance of the vehicle. The aim of this thesis is to develop a low-cost control scheme for integration of Electric Power-Assisted Steering (EPAS) system with Enhanced Stability Program (ESP) system to improve driver comfort as well as vehicle safety. In this dissertation, a systematic approach toward a modular, flexible and reconfigurable control architecture for integrated vehicle dynamics control systems is proposed which can be implemented in real time environment with low computational cost. The proposed control architecture, so named “Integrated Vehicle Control System (IVCS)”, is customised for integration of EPAS and ESP control systems. IVCS architecture consists of three cascade control loops, including high-level vehicle control, low-level (steering torque and brake slip) control and smart actuator (EPAS and EHB) control systems. The controllers are designed based on Youla parameterisation (closed-loop shaping) method. A fast, adaptive and reconfigurable control allocation scheme is proposed to coordinate the control of EPAS and ESP systems. An integrated ESP & ESP HiL/RCP system including the real EPAS and Electro Hydraulic Brake (EHB) smart actuators integrated with a virtual vehicle model (using CarMaker/HiL®) with driver in the loop capability is designed and utilised as a rapid control development platform to verify and validate the developed control systems in real time environment. Integrated Vehicle Dynamic Control is one of the most promising and challenging research and development topics. A general architecture and control logic of the IVDC system based on a modular and reconfigurable control allocation scheme for redundant systems is presented in this research. The proposed fault tolerant configuration is applicable for not only integrated control of EPAS and ESP system but also for integration of other types of the vehicle active systems which could be the subject of future works.