0% found this document useful (0 votes)
32 views18 pages

Overview of Wheel Corner Modules

This document provides an introduction to wheel corner modules (WCMs), a new technology for controlling vehicle motion. WCMs represent a modular design that integrates components for braking, steering, suspension, and electric wheel propulsion into each wheel. They allow for fully electronic control of the vehicle and improved motion control capabilities. The technology is still under development by several automakers and suppliers for future road vehicles. The goal of the thesis is to evaluate the advantages and disadvantages of WCMs and examine their current development status and impact.

Uploaded by

safal sha
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
32 views18 pages

Overview of Wheel Corner Modules

This document provides an introduction to wheel corner modules (WCMs), a new technology for controlling vehicle motion. WCMs represent a modular design that integrates components for braking, steering, suspension, and electric wheel propulsion into each wheel. They allow for fully electronic control of the vehicle and improved motion control capabilities. The technology is still under development by several automakers and suppliers for future road vehicles. The goal of the thesis is to evaluate the advantages and disadvantages of WCMs and examine their current development status and impact.

Uploaded by

safal sha
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd

Chapter 1

INTRODUCTION

Ever since the Ford Model T was introduced in the beginning of the 20th century,
road vehicles have gradually progressed in terms of technology. Safety, comfort and perfor-
mance have gone through vast improvements, yet the basic vehicle layout is similar to what
it was one hundred years ago.
A wheel corner module (WCM), also called an active wheel module, electric corner
module or robot wheel, represents a new way of controlling the motion of a vehicle. It is
based on a modular design around the geometric boundaries of a conventional wheel. The
typical WCM consists of a wheel containing an electrical in-wheel propulsion motor, a
friction brake, a steering system and a suspension system. Generally, the braking, steering
and suspension systems are controlled by means of electrical actuators. The WCM is
designed to easily, by means of bolted connections and a power connector, attach to a
vehicle platform constructed for the speci c purpose. All functions are controlled via an
electrical system, connecting the steering column to the module. The steering column may
comprise a conventional steering wheel and pedals, or any other feasible solution, such as
e.g. a joystick.
WCMs represent a fairly new technology, currently being developed by several car
man- ufacturers and subcontractors for future implementation in road vehicles. According
to Frost & Sullivan WCMs are likely to be on rear wheels by 2015 and on all four wheels
after 2020 . The goal with this thesis is to provide an overview of WCM technology and to
serve as an introduction to the subject. Advantages and disadvantages related to the
technology shall be evaluated. In addition, this thesis shall provide a view of the present
development stage. The rst part of the thesis treats the technology which WCMs are based
on. A thorough literature study of technical reports and conference papers is the foundation
of this part. The main focus is aimed at novel solutions, even though other more
conventional solutions may also be utilized in terms of WCMs.
In the second part, the impact in terms of vehicular, environmental and economical
aspects are discussed. A concept analysis is presented in the third part of the thesis. Since
detailed technical information is generally infrequent in terms of concept solutions, the
descriptions aim towards principal function rather than details. Most of the information

1
presented in this part has been attained from patents and journal papers. One concern
regarding the WCM is increased unsprung mass. In the fourth part, modeling and
simulations are conducted in the dynamic modeling program Dymola, in order to estimate
the impact on ride comfort and handing performance, due to this matter

2
Chapter 2
Wheel Corner Modules

A wheel corner module, see gure 1, is a novel type of electro-mechanical system related to
vehicular motion control. As the name implies it is based on a modular design. Generally the
module is held within the boundaries of a conventional wheel. The WCM contains
subsystems responsible for longitudinal, lateral and vertical motion respectively. These systems
comprise electro-mechanical actuators and linkages and are operated upon input from a control
system. The corner module is designed to easily, by means of bolted connections and an
electrical connector port, mount to a vehicle body. The vehicle body together with two or four
WCMs form a WCM vehicle. All functions of the WCM are electrically controlled based upon
input from an operational device, in connection with one or several control units. It represents a
pure x-by-wire based vehicle maneuvering system. Mounted around the vehicle are several
sensors that continuously supply the control units with information regarding the vehicle position
and state. The sensors might include position sensors, velocity sensors, acceleration sensors, force
and torque sensors, pressure sensors, ow meters, temperature sensors, etc. [2]. The information
supplied by these sensors might be yaw rate, lateral acceleration, angular wheel velocity, steering
angle and chassis velocity [2]. The operational device comprises a conventional steering wheel
and pedals, or any other feasible solution such as e.g. a joystick. WCMs represent a novel
technology related to vehicular propulsion systems, not yet avail- able in any serial-produced
vehicle. However, some of the technical solutions utilized in WCMs are already available in
subsystems of current conventional passenger vehicles. Hence, comparisons to conventional
vehicles and conventional vehicle technology are con- tinuously carried out in the context of this
thesis. The following paragraph de nes these two expressions according to how they are used
within this thesis.

Conventional vehicle technology refers to standardized technical solutions as found in


most passenger cars, manufactured and sold in large quantities during the last decade. The
conventional technology discussed within this thesis is mainly connected to vehicular motion
control and is of mechanical type. It generally involves an internal combustion engine (ICE) and
friction brakes for means of longitudinal motion control, both connected to pedals in the cabin.
Lateral motion is actuated by operation of a steering wheel connected to the front wheels
through a rack and pinion construction. Vertical motion is passively controlled by means of a
conventional suspension comprising springs and dampers. Conventional vehicles are referred to as

3
vehicles which are constructed around conventional technology as the one described. A
conventional vehicle may alternatively include one or several unconventional technical solutions,
such as throttle-by-wire (TBW) or brake-by-wire (BBW), however the main part of the structure
shall be of conventional type.
A WCM vehicle, as referred to throughout this thesis, is a vehicle containing two or four
WCMs. WCM vehicles involve an increased number of actuators compared to conventional
automotive constructions, enabling improved vehicular motion control, see section 3.1.1. The
corner modules may have di erent setups according to the previous description, hence the number
of actuators may vary. Generally however, the number of actuators contained in a WCM vehicle
exceeds the degrees of freedom, thereby forming an overactuated system

Fig 2.1: A wheel corner module, the Michelin Active Wheel

2.1 X-by-wire

Traditionally, vehicular motion control have been executed through operation of a steering wheel
and pedals mechanically connected to the wheels and ICE. X-by-wire is a fairly novel
technology which involves pure electronic control of longitudinal, lateral or vertical vehicular
motion. It has been successfully utilized in the aviation industry for decades, in that sense called
y-by-wire [5]. There are a variety of terms for the technology in context of road vehicles, such as
x-by-wire, drive-by-wire or simply by-wire.

The basic principle of an x-by-wire (XBW) system is replacement of all mechanical/hydraulic


linkages with electric ones [5]. In turn, the connection between driver and subsystem is no
longer direct. Instead, the mechanical input supplied by the driver through the opera- tional

4
device, is interpreted and processed by computer electronics prior to realization of the
demanded action. In accordance with gure 2, the input device contains a mechanical operational
component, including e.g. a mechanical pedal, sensors for registration of the pedal movement,
microelectronics and a haptic feedback device. The latter applies a force to the pedal to recreate
the feeling of a conventional operational device, by use of a spring and damper device or an
electrical actuator. Depending on what subsystem is being op-
erated, it might allow the driver to physically sense the activity occurring in connection to the
controlled sub-system, i.e. transfer haptic information. If the operational device is a steering
wheel, an electrical actuator mounted in connection to the steering wheel may transfer a torque to
the steering wheel. This torque corresponds to the torque transferred from the front wheels onto
the steering wheel via the steering rack and pinion, during operation of a conventional steering
system. Connected to the operational device via a bus system is the actual control system
containing a microcomputer, power electronics, electrical actuators, mechanical components and
sensors [6]. The mechanical components include eg. steering linkages or friction brakes. The
microcomputer is responsible for ac- tuator control, function control, supervision and management
such as fault handling and optimization [6]. Owing to the non-direct connection structure
including computer power, bene cial new handling and safety solutions are enabled.

Fig 2.2 Block diagram of an XBW system.

2.2 Fault tolerant x-by-wire systems

A fault tolerant system behavior implies a system which can continue to operate properly even in
the event of one or several malfunctions. Concerning vehicular x-by-wire sys- tems, fault-tolerant
behavior is of utmost importance, as failure might lead to hazardous complications including
personal injury.

There are three main XBW subsystems which apply to conventional vehicles, throttle- by-wire,

5
brake-by-wire and steer-by-wire (SBW). TBW is not part of WCM technology, however the
applications made possible due to the use of TBW, are similar to the ones enabled by the by-
wire controlled in-wheel motors of WCMs. Therefore it will be further discussed in this thesis,
see section 2.2.1. The TBW system is available in passenger vehicles as of today, and in its
present form a pure XBW solution. The other two systems are currently utilized in a few
conventional vehicles, however coupled with mechanical back-up systems. This is done in order
to achieve a more reliable system. Steering and braking are safety-critical functions, i.e. a failure
in such might involve personal injury. Electronic components have a di erent fault behavior
compared to mechanical compo- nents, therefore fault-tolerant systems have to be incorporated in
order to meet the high safety demands [6]. Until this is achieved and proven safe, mechanical
back-up systems admit use of the XBW systems and their advantages, by o ering reliable,
fault-tolerant back-up technology in case of malfunction. Electrical failure is often caused by
shortcuts, loose connections, parameter changes, contact problems or electromagnetic compatibil-
ity problems [6]. However, the potential reliability of well-designed, well-manufactured electronic
systems is extremely high [7]. Typically the proportions that are defective in any purchased
quantity are in the order of less than ten per million in case of complex components, and
even lower for simple components [7].
A design containing a mechanical backup system involves additional mass and manufac- turing
costs as well as an increased structural complexity, therefore fault-tolerant electrical back-up
systems are preferable when possible [6, 8]. A way of improving the safety pro le of an electrical
system is to implement redundant electrical components. The redundancy can either be static or
dynamic. Static redundancy means that multiple redundant mod- ules govern the same function by
operating in parallel. If one module fails, the system might be degraded but still function, since all
modules except one still maintain proper functioning. Concerning dynamic redundancy, two or
several modules are available, how- ever merely one of them is in operation. The other modules
are in standby mode, ready to be utilized in case of malfunction regarding the module
currently in operation.

2.2.1 Communication network architecture


Each vehicle containing one or several XBW solutions requires a communication
network. The objective of this network is to handle the data transfer and communication among
components within a subsystem, as well as between di erent subsystems. The compo- nents might
be e.g. maneuvering devices, sensors and actuators. The communication network is responsible
for transmission of control signals managing all functions of the XBW subsystems. Such a

6
function might be to set a speci c steering angle of a wheel contained in a steer-by-wire system,
or to decelerate a vehicle by properly distributing brake forces among the wheels via a brake-by-
wire system. A failure concerning the com- munication network might lead to maneuvering
malfunction, thus fault-tolerant behavior of the network is of utmost importance.

An important issue is to nd a network protocol which provides fast data transfer as well as su
cient levels of safety and reliability. Lots of industrial and academic work have been directed
to solve this matter, and resulted in several reliable communication technologies, such as Time-
Triggered Protocol (TTP), Time-Triggered Controller Area Network (TTCAN) and FlexRay
[9]. The latter was designed speci cally for automotive applications [10]. TTP, TTCAN and
FlexRay are all mainly time-triggered architectures. Common for these protocols is that signi cant
events, such as tasks and messages, occur not randomly in time, such as with the traditional event-
triggered Controller Area Net- work (CAN), but according to a pre-determined time-schedule.
CAN is currently used in automotive systems.

2.3 Longitudinal motion

The longitudinal motion of a WCM vehicle is controlled through operation of in-wheel


motors and friction brakes. The in-wheel motors are able to accelerate as well as decelerate the
vehicle, whilst the friction brakes are utilized when additional brake force is required.

2.3.1 Propulsion
In-wheel motor properties All of the considered WCM concepts, discussed in section
4, utilize electrical in-wheel motors for means of propulsion. One major advantage and key
property related to in-wheel motors is the compact design. In-wheel motors are constructed to
t into the unexploited volume inside the rim of a conventional wheel, see gure 5, in terms of
conventional vehicles generally housing no more than a wheelhub and brake components. By
replacing the traditional ICE with in-wheel motors coupled with batteries, more structural freedom
is enabled concerning the layout of the vehicle body and interiors. Hence, important aspects
concerning passive safety, manufacturing costs and interior design versatility can be improved.

A conventional ICE based driveline requires a gearbox mainly for two reasons. Firstly, it
transforms the high angular velocity and low torque on the outgoing shaft of the ICE to a low
angular velocity and high torque on the propelling wheels. Secondly, the gearbox provides the
ability to compensate for the narrow power spectrum generally related to combustion engines, by
shifting gear ratio depending on desired vehicular velocity, see gure 3a. Electrical motors

7
possess quite di erent output characteristics compared to ICEs. An electrical motor power curve
can be divided into two sections, the constant force region and the constant power region,
referring to tractive force and motor power respectively. The speci c rotational velocity in between
these sections is called the base speed, often expressed in revolutions per minute. Below the
base speed the tractive force is at its maximum rated level, Fmax. At higher rotational velocity,
the motor produces a constant power output, Pm, illustrated in gure 3b [12]. Since tractive
force is available from standstill, no clutch is needed to initiate movement. Owing to the constant
power delivery related to electrical drives, shifting the gear ratio is unnecessary. Depending on
motor speci cations a xed gear might be necessary between motor and wheel. However, in-
wheel motors are often constructed to produce a high torque at low angular velocity, thereby
enabling direct drive operation. Considering the characteristics described, the presence of a multi-
speed gearbox is generally unnecessary in combination with in-wheel motor drives.

Electrical machines suitable for in-wheel operation Regarding in-wheel motor


applications, certain ful llments associated to geometry and torque output are required by the
electrical machines. Since the general idea of in-wheel motor drives includes that the rim shall be
capable to hold the major part of the machine body inside the boundaries of its volume, certain
geometrical properties need to be met. The diameter of the machine may preferably be large in
comparison to the depth, and the overall size and weight shall be kept down, in order for the
motor to t inside the rim and keep the unsprung mass to a minimum. For direct drive to be
feasible, the motor shall also be able to produce a continuous high torque at low angular
velocity.

In addition to these in-wheel motor speci c aspects, the following demands presented by Zeraoulia
et al. [17], are general for electrical machines intended for vehicular tractive applications:

1. High instant power and power density,

2. high torque at low speed for starting and climbing, high power at high speed for cruising,

3. wide speed range, including constant-torque and constant-power regions,

4. fast torque response,

5. high e ciency over the wide speed and torque ranges,

8
6. high efficiency for regenerative braking,

7. high reliability and robustness for various vehicle operating conditions,

8. reasonable costs.

Permanent magnet (PM) brushless motors, also called synchronous motors, are partic- ularly
suitable for in-wheel motor direct drive applications. Characteristic for such a machine is that
the rotor is equipped with permanent magnets instead of windings, see gure 5. There are
various types of PM brushless motors. Generally, they are classi ed according to the mounting
position of the permanent magnets, surface-mounted or buried. The surface-mounted type
contains the magnets on the surface of the rotor, whilst the buried magnet motor keeps the
magnets embedded in the rotor core, see gure 4. The former requires less magnet material
compared to the latter, given an equal size of the machines. It also bene ts from a cheap and
simple construction. However, the buried magnet type may achieve higher air-gap ux density,
which in turn admits higher torque per rotor volume. Additionally, the risk of demagnetization
is smaller. Buried magnet PM motors represent the more rugged solution.

(a) Surface-mounted magnet rotor. (b) Buried magnet rotor.

Figure 2.3 Magnet mounting positions


PM brushless motors have a limited eld weakening capability, owing to the presence of a PM
eld. Thus, the constant power region is generally fairly short. In order to extend the constant
power region, and consequently the speed range, of a PM brushless motor, the conduction angle of
the power converter can be controlled while above the base speed. This way the speed range may
be extended three to four times above the base-speed [17].
PM brushless motors bene t from high power density, high e ciency and e cient heat
dissipation [17]. Low unsprung vehicular mass is desirable in aspect of comfort and handling,
as discussed in subsection 3.1.4. Since in-wheel motor structures generally involve the motor as
part of the unsprung mass, it is important that the mass of the machine is kept down. The high

9
power density of PM brushless motors make them particularly suitable for such applications. In
addition, the design of PM machines can easily be adapted to the boundary conditions related to
the speci c geometry and volume of a wheel rim, see gure 5.

Figure 2.4 In-wheel PM brushless motor

Rahman et. al investigates the axial ux permanent magnet (AFPM) motor, which is a
particular PM brushless motor, as part of a direct drive in-wheel setup. The axialux
permanent magnet motor have favorable characteristics for in-wheel motor drive applications
in terms of e ciency and speci c torque. The torque density can be improved by as much as two
times compared to an induction motor, which is another motor type utilized in vehicular
propulsion systems. The highest amount of torque output is achieved by designing the machine
with a large diameter and high number of poles. Thus, the geometry of AFPM machines
makes them suitable for in-wheel placement [12].

2.3.2 Brakes

In conventional vehicles, friction brakes such as hydraulic, pneumatic or non-hydraulic


mechanical disc or drum brakes are the primarily utilized solutions for means of decelera- tion. In
terms of WCMs, the conventional drums and discs are still being used, although in a di erent
manner. Signi cant amounts of energy are dissipated in form of heat when conventional friction
brakes are applied. Regenerative braking through in-wheel motors makes it possible to re-use

10
parts of this energy. The in-wheel motors and friction brakes can be applied separately or together
depending on required brake force and momentary vehicular velocity. During deceleration from
low velocity the friction brakes are primarily used, since the in-wheel motors require a higher
angular velocity to be able to supply enough brake torque. During light deceleration from high
velocity the in-wheel motors are preferably used exclusively. When excessive brake force is
required, friction brakes and regenerative brakes are applied together.

EHB is based on a conventional hydraulic brake system, implemented with BBW control.
It is realized by combining a hydraulic circuit with an electrical circuit. The latter com- prises
a control unit, wiring and sensors, in accordance with gure 6, as well as electrically controlled
valves. The hydraulic circuit comprises a hydraulic pump connected to a brake caliper, of which
the pump is merely controlled by means of by-wire technology. Alternatively it may, in excess of
the system previously described, contain a complete con- ventional brake system representing a
direct hydraulic connection between brake pedal and brake caliper, for means of backup. In case
of electrical circuit malfunction, the elec- tricity is cut, thereby opening a valve engaging the
conventional hydraulic system. This fault-tolerant function makes it suitable for use during the
transition from conven- tional brake systems to BBW, as the safety of a conventional brake
system remains. Since 2001, Mercedes Benz AG implemented an EHB system into some of their
passenger car models, called the Sensotronic Brake System. It shall however be mentioned that a
problem concerning the system resulted in a recall of more than 680 000 vehicles in 2004. This
was a signi cant set-back for the customers' con dence in both Mercedes and BBW systems in
general.

Figure 2.5 Block diagram of a basic electro-hydraulic brake system.

11
EMB is a pure BBW solution including an operational device coupled with a control unit in
connection with an electro-mechanical brake actuator. Through the operational device, the driver
communicates the vehicular deceleration rate that is desired, after which the control unit
calculates the appropriate brake actuator force to be applied to each wheel. EMB involves faster
response compared to EHB, owing to its fast motor dynamics. A WCM can contain either one of
these two described brake setups, however EMB might be the technology primarily used as the
technology evolves, owing to easier adaption to the vehicle structure and the absence of uids.

12
CHAPTER 3
THE E ECTS OF WHEEL CORNER MODULE
TECHNOLOGY

There are major construction di erences between WCM vehicles and conventional vehi-
cles. This results in quite di erent properties regarding vehicle handling, comfort and safety as
well as environmental and economical impact. The following sections discuss these areas, in
order to enlighten the possibilities and drawbacks involved with WCM technology.
3.1 Vehicular aspects
The following sections describe the characteristics and possible issues related to handling,
comfort and safety of a typical WCM vehicle. The impact of an increased unsprung mass a ects
all of these areas. It is therefore discussed separately in section 3.1.4.

3.1.1 Handling
Handling is de ned as a vehicle's response to driver input [42]. Good handling
performance generally implies that the vehicle responds accurately to driver input. It shall behave
in a safe and controlled manner, even during aggressive driving. The sports car is a typically well
handling vehicle.

There are several factors to take into account when estimating the handling performance
of a vehicle. The driver's subjective experience of how well the vehicle reacts according to
operational inputs can be di cult to measure and may di er between drivers. As of today, there
is no standard of how to objectively measure handling performance.

P.E Uys et al. investigate di erent methods generally utilized in terms of handling performance
estimation, in order to nd the most suitable objective measure. Investigated methods include
among others dynamic wheel load as a measure of driving safety, pitch motion and roll angle as
measures of steering stability and RMS tire contact force as an indication of wheel hop and
road holding capability. Lateral acceleration is generally considered as a good measure of
handling performance.

One of the key features of WCM technology is the opportunity to control all four wheels
in- dividually, enabled by the absence of mechanical connections between the wheels. Propul-
sion, braking, steering and suspension properties can all be set individually. This ability can
drastically enhance the handling capability, since it involves additional degrees of freedom.
Owing to the XBW structure, the handling properties can be set according to driver
characteristics and road conditions.

13
Individually controlled corner modules make it possible for the driver to change the han- dling
characteristics of the vehicle between understeering, neutralsteering and oversteer- ing.
Regardless of the necessity of such a function, it highlights the versatility enabled by utilization
of WCM technology. Individually controlled active suspension admits a higher level of comfort
as well as im- proved handling capability, through instant adaption to prevailing road conditions.
With individual rideheight adjustment comes the possibility of active roll- and pitch-angle man-
agement systems, as seen in e.g. Volvo Autonomous Corner Module (ACM). It also en- ables
the ground clearance of the vehicle to be altered according to driving style and road properties. An
aggressive driving style might bene t from decreased ground clearance, while driving on a rough
bumpy road might bene t from increased ground clearance. In one of the WCM concepts
further to be presented, Volvo's ACM, the camber angles of all four wheels can be
individually controlled. This feature improves the handling versatility even more, by
enabling increased lateral acceleration during cornering. A WCM vehicle can be either two-
or four-wheel driven. The latter alternative enables more advanced handling properties, but also
increases the complexity of the management architecture.

14
Chapter 4
CONCEPT ANALYSIS

Several di erent WCM concepts are currently being developed by a number of car man-
ufacturers, tire manufacturers and other research institutions. This section summarizes a
selection of these concepts by providing information gathered from various patents and articles.
Concerning most of the concepts, the major part of the available technical in- formation is of
general character rather than speci c. Hence, the following descriptions are typically general,
with the exception of certain technical solutions which are described more in detail.

4.1 Michelin Active Wheel

Michelin have been developing the Active Wheel, see gure 14, since 1996. In 2004 it
was rst showcased in the concept vehicle HY-Light, containing a hydrogen fuel cell as
primary power source. The Active Wheel was later implemented into Heuliez Will, a concept
vehicle based on Opel Agila, which was closer to production than the HY-Light. In this form
the vehicle contained two water-cooled in-wheel motors, used for front wheel drive with a total
rated power of 30 kW. Each wheel module weighed 43 kg.

Fig 4.1 Michelin Active Wheel [4].

The in-wheel motor (97) contained in the Active Wheel, see gures 15 and 16, is unsprung [1].
Generally, in-wheel motors are constructed for direct drive applications. However, regarding the
Active Wheel, torque is transferred from the traction motor to the hub (15) via a pinion (95) and
gearwheel (18) [52]. Since the torque is transferred to the wheel via axed gear, the motor can be
constructed for maximum torque output at a higher angular velocity compared to a direct drive
motor. Thus, a more compact design is enabled. For retardation means the in-wheel motors can
15
be used, regenerating power back to the batteries. When excess brake power is required, a
brake caliper (90) coupled with a conventional brake disc (17) is available. The former is
stated to be of hydraulic or electro-mechanical type. For suspension purposes Michelin's
WCM houses a coil spring (80) to hold the static load of the car. In addition, a suspension
actuator (87) is installed to actively handle actuations. The construction comprises a wheel-
barrier connected bar (camber lever) which contains a rack (45), engaging a pinion (85) which is
connected to an electro- mechanical machine (87). Thus, the linear motion of the wheel is
converted to a rotational motion, which is then transferred onto the electro-mechanical machine.
The latter is composed by a rotor (86) and a stator (88), of which the stator is integral with the
guide member

16
Chapter 5
CONCLUSIONS

WCM vehicles enable signi cantly improved handling performance, safety and ride com- fort
compared to conventional vehicles, owing to the x-by-wire technology and an addi- tional number
of actuators related to motion control. Longitudinal, vertical and lateral motions can be
individually set for each comprised corner module.

Several WCM concepts are currently being developed by automotive manufacturers and
subcontractors. In order for serial production to be attainable, additional major invest- ments in
terms of research, testing and manufacturing equipment are required.

Implementation of in-wheel motors is likely to cause an increased unsprung mass in terms of the
WCM vehicle, compared to a conventional equivalent. The simulation results are
summarized in table 9. They indicate that an increased unsprung mass involves deteriorated
handling performance, regardless of the vehicle velocity or road disturbance pro le. In addition, a
majority of the simulations indicates deteriorated ride comfort. At disturbance frequencies above
the eigenfrequency of the unsprung mass, a signi cant ride comfort improvement is however
indicated.

17
Chapter 6
REFERENCES

[1] S. Filippi and A. Valsan, Strategic analysis of European market for Electric Corner
Modules. Frost and Sullivan, September 2008.
[2] A. B. Cherno , J. F. Szczerba, and J. Montousse, Driver control input device for
drive-by-wire vehicle, Patent US006 997 281B2, 2006, GM.
[3] M. Jonasson, Exploiting individual wheel actuators to enhance vehicle dynamics and
safety in electric vehicles, Ph.D. dissertation, Royal Institute of Technology, 2009,
ISBN 978-91-7415-387-3.
[4] P. Evans, Michelin active wheel system to hit roads in 2010, Gizmag, 2008,
2010.10.15. [Online]. Available: [Link]
production-electric-car-by-2010/10489/.
[5] E. Bretz, By-wire cars turn the corner, in IEEE Spectrum 2001, vol. 38, no. 4, pp.
68 73, ISSN 0018-9235.

18

Common questions

Powered by AI

Fault tolerance in x-by-wire systems is of paramount importance for ensuring the safety and reliability of Wheel Corner Module (WCM) vehicles. In x-by-wire systems, all mechanical linkages are replaced by electronic controls, making them highly dependent on sensor data and control units to execute driver commands and maintain vehicle stability . A fault-tolerant design ensures that the system can continue to operate safely even in the event of component failures or data transmission errors, which could otherwise lead to critical safety hazards, such as loss of vehicle control . For WCM vehicles, maintaining operational integrity through built-in redundancies and real-time diagnostics and recovery protocols is essential, given that the increased number of actuators and electronic components heightens the complexity and potential failure points . Thus, fault tolerance is crucial not only for the safety of passengers but also to gain trust in these advanced technologies as viable replacements for conventional systems in commercial vehicles.

Implementing Wheel Corner Modules (WCMs) in vehicles could significantly disrupt traditional automotive design and manufacturing paradigms by introducing modular and flexible vehicle architecture. With WCMs, the propulsion, steering, and braking systems are integrated into the wheel assemblies, allowing for more significant freedom in vehicle design, potentially leading to innovations in vehicle form factor and interior space utilization . The modularity of WCMs means that car manufacturers might see reduced production costs and increased adaptability in assembly lines, as platforms could be standardized across different vehicle models . Moreover, WCMs rely on x-by-wire systems that eliminate the need for mechanical linkages, further simplifying manufacturing processes and reducing vehicle production complexity . However, the transition to WCMs necessitates substantial capital investment in new production technologies, workforce retraining, and new supply chain partnerships to support the increased reliance on electronics and sensor technologies . Overall, while presenting challenges, the shift towards WCMs positions the automotive industry for potential advancements in design innovation and manufacturing efficiency.

In-Wheel Motors drastically change vehicle drivetrain design and functionality by eliminating the need for traditional components like gearboxes and clutches. Unlike internal combustion engines (ICE), which require a multi-speed gearbox to manage power distribution and torque , in-wheel motors can deliver high torque directly at low speeds without the need for a clutch due to their ability to provide constant power output across a broad range of speeds . This allows for a simplified drivetrain, reducing mechanical complexity and enabling greater design flexibility. Additionally, placing the motors within the wheel eliminates the need for drive shafts and differentials, reducing the vehicle's weight and increasing interior space . This structural freedom enhances manufacturing possibilities and could contribute to improvements in vehicle efficiency and passenger safety .

A Wheel Corner Module (WCM) is an electro-mechanical system designed around the geometric boundaries of a conventional wheel and includes several key components: an electrical in-wheel propulsion motor, a friction brake, a steering system, and a suspension system. These components work together to manage the longitudinal, lateral, and vertical motion of the vehicle. The in-wheel motor provides propulsion, allowing for both acceleration and deceleration, complemented by friction brakes when additional braking force is needed . The steering system allows for lateral motion control, while the suspension manages vertical dynamics. These subsystems are controlled via electro-mechanical actuators and a control system that interfaces with the driver through various operational devices, facilitating x-by-wire (XBW) technology . This integration enhances vehicular motion control and enhances the potential for advanced maneuvering capabilities in WCM-equipped vehicles.

Traditional vehicles typically use mechanical linkages connected to a steering wheel and pedals to control vehicular motion, with inputs translated directly through systems like steering columns and internal combustion engine (ICE) components . Conversely, Wheel Corner Module (WCM) vehicles leverage x-by-wire technology, replacing mechanical linkages with electronic systems for control. In WCM systems, operational input mechanisms might include conventional steering wheels and pedals, or alternatives such as joysticks. These inputs are interpreted electronically by control units that manage the electro-mechanical actuators directing the vehicle's movement . This switch to electronic control enhances precision and allows more flexible and responsive vehicle handling. Moreover, WCM vehicles potentially include advanced feedback systems to simulate traditional driving sensations, integrating haptic feedback to improve driver intuition and vehicle control .

Regenerative braking in Wheel Corner Modules presents both benefits and limitations when considered in vehicle design. A significant advantage is energy efficiency; regenerative braking allows the energy typically lost as heat in conventional braking systems to be captured and converted back into electrical energy, which can recharge the vehicle's batteries, thus improving overall energy usage and reducing fuel consumption . This conversion can extend the driving range of electric vehicles and contribute to a reduction in emissions. However, the limitations include the complexity and cost associated with incorporating regenerative systems, which require sophisticated electronic controls and integration with in-wheel motors . There is also a challenge of effectively blending regenerative braking with traditional braking systems to ensure smooth and consistent braking performance under varying driving conditions . These factors must be carefully balanced to optimize the benefits of regenerative braking in WCM-enabled vehicles.

Sensors play a critical role in the functioning of Wheel Corner Module (WCM) vehicles by providing essential data inputs that enable precise control and operation of the different actuators involved in the vehicle’s motion. These sensors include position sensors, velocity sensors, acceleration sensors, force and torque sensors, pressure sensors, flow meters, and temperature sensors . They continually supply the vehicle's control units with information regarding its position, state, and movement dynamics such as yaw rate, lateral acceleration, and wheel velocity . The integration of these sensors ensures that the electronic control systems can accurately interpret the driver’s commands and the vehicle’s current state, allowing for dynamic adjustments and maintaining safety and performance levels. This robust data framework is crucial for the high precision and fault tolerance demanded by x-by-wire systems, providing real-time feedback necessary for decision-making and adjustment in various driving scenarios .

The increased unsprung mass in vehicles equipped with Wheel Corner Modules (WCMs) can pose significant challenges, particularly affecting ride comfort and handling performance. Unsprung mass refers to the parts of a vehicle that are not supported by the suspension, primarily the wheels and anything attached directly to them. As WCMs include in-wheel motors and additional electronic components, they increase this unsprung weight, which can adversely affect the vehicle's responsiveness to road surfaces, reduce shock absorption capability, and thus decrease ride comfort . Furthermore, handling dynamics and stability might be compromised as higher unsprung mass can lead to slower response times in suspension systems, affecting the vehicle's traction and cornering abilities . Such impacts necessitate careful design considerations and potential trade-offs when integrating WCMs into vehicle designs.

X-by-wire (XBW) technology involves the substitution of mechanical and hydraulic linkages with electronic controls for vehicular motion, setting it apart from traditional systems that rely on physical connections like steering columns and pedals . This shift allows for a more flexible and responsive control system, as inputs from the driver are sent to control units via sensors and processed electronically to manage motion control functions. The advantages of XBW include the potential for improved safety and handling through overactuation, where the system exceeds the degrees of freedom with more actuators than necessary, allowing more precise control . Additionally, XBW reduces the weight and complexity of the vehicle, enhances fault tolerance, and supports advanced safety features by enabling new handling and error management solutions .

Axial Flux Permanent Magnet (AFPM) motors enhance the performance of in-wheel propulsion systems in Wheel Corner Module (WCM) vehicles through several key attributes. They are known for their high efficiency and high torque density, making them particularly suitable for the compact and constrained space of in-wheel applications . The geometry of AFPM motors, which allows for a large diameter and a high number of poles, is advantageous for maximizing torque output within the confines of a wheel . This design enables the motor to produce high torque at low speeds and maintain a broad speed range, which is crucial for the direct drive applications needed in WCM configurations . These characteristics of AFPM motors contribute to enhanced vehicle acceleration and power delivery, leading to better overall performance, including quicker response times and smoother drive experiences.

You might also like