Dynamic Stability Simulation of a Counter Balanced Lift Truck

Joshua Hogg, PE, M.Sc., Project Engineer at Hyster-Yale Group

Unrestricted Siemens AG 2016 Realize innovation.

 Dynamic Stability Simulation
of a Counter Balanced Lift Truck
Presented by: Joshua Hogg

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About Hyster-Yale Group

Hyster-Yale Group is a global manufacturer of lift trucks.

Produces a full range of electric and internal combustion
engine lift trucks under the Hyster and Yale name brands.
Product ranges from small warehouse pallet movers to
large shipyard container trucks.

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 3
EN16203:2014

EN16203:2014 [1] introduces new dynamic

lateral stability test requirements for trucks
with capacities of 5000kg or less being sold
into the European market.
Test consists of navigating a 90 turn within
A: Accelerating Area
a specified lane at 90% of maximum travel B: Entrance Corridor
speed. C: Maneuvering Area
D: Exit Corridor
Failure is defined by lift-off of an inside rear E: Deceleration Area
tire (for conventional 4 wheel truck)
Cross line 1 at 90%
New standard allows use of computer maximum speed
modeling given physical test validation is
Exit line 7 without lift off or
performed. crossing outline lanes.

w2 Exit corridor lane size

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 4
Anatomy of a Lift Truck

Anatomy of a Lift Truck

Rigidly mounted axles; zero suspension.
Rear steering with an Ackerman type
steering linkage
Large variation in front end equipment
based on customer specifications.
Lift Height
Attachments
Capacity

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 5
Developing the Dynamic
Model

6 6
Developing The Dynamic Model

Model topology consists of a TRUCK mass body, rigidly

attached to a MAST mass body.
Primary function of the initial model has been to physically
test a base truck, and use simulation to evaluate multiple
mast options.
Articulating steering axle, and tires represented as
discrete bodies
Tires were modeled using the native Complex Tire
element in LMS VL Motion.
An open differential was modeled explicitly using a
kinematic assembly of revolute joints and relative
constraints. Vehicle was propelled by a constant RPM
applied to the input shaft of the differential.

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 7
Developing The Dynamic Model

Model topology is driven by

parameters defined in a data
table.
Linked Spreadsheet tool houses in-
house tire stiffness and weight
data for all tire options available.
Lane size definition is controlled
by parametric axis systems.
Vehicle position is monitored via
sensor axis systems defining the
lane as well as at the vehicle drive
and steer wheels.

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 8
Developing The Dynamic Model
Model topology is driven by
parameters defined in a data
table.
Linked Spreadsheet tool houses in-
house tire stiffness and weight
data for all tire options available.
Lane size definition is controlled
by parametric axis systems.
Vehicle position is monitored via
sensor axis systems defining the
lane as well as at the vehicle drive
and steer wheels.
Dynamic Stability Simulation of a Counter Balanced Lift Truck
Expressions:
Lane_Boundary_Distance_DT_X=DIST(SAS2,SAS5,SAS2,X)
Exit_Boundary_Distance_ST_Z=DIST(SAS3,SAS4,SAS3,Z)
Lane_Boundary_Flag_DT_X=TEST(Lane_Boundary_Boolean_1,1,0)
Parameters:
Lane_Boundary_Boolean_1=EVAL_EXPR(Lane_Boundary_Distance_DT_X)<0
AND EVAL_EXPR(Lane_Boundary_Distance_ST_Z)<0
X Z
SAS1
Z X
SAS2
SAS4
SAS5
X Z
Z X
SAS3
Siemens Simcenter Symposium 2016 9
Developing The Dynamic Model

A Visual Basic script copies results plot images and

model parameters to a scratch directory and kicks off
a Python Program to Generate an MS Word Report

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 10
Developing The Dynamic Model

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 11
Quantifying Model
Uncertainty

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Quantifying Model Uncertainty

Using simulation in conjunction with physical

testing significantly reduces the total testing
required.
Acceptable?
However, relying on the simulation entirely is a Experiment Simulation
logical progression.

PDF
This requires a more detailed validation. For
example ASME V&V.
Assessing model correlation requires
understanding model uncertainty due to input
variation.
Measurement

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016
Quantifying Model Uncertainty

We have a parametric MBS Model Model Input Standard

Solve time is ~5 seconds Uncertainty [%]
Sweep simulation inputs, and evaluate response Front track 0.52 %
variance. Rear track 0.50 %
Drive tire width 2.6 %
1. Determine Standard Deviation () for each simulation input quantity.
Steer tire width 2.9 %
2. Normally vary inputs about their mean value within their respective Truck mass (no mast) 0.14 %
variance. Truck HCG (no mast) 0.30 %
3. Vary exit corridor within a range large enough to capture a failure. Truck VGG (no mast) 2.9 %
4. Generate design table with 5000 configurations for a given truck. Steer axle articulation stop gap 7.4 %
5. Using solution manager, run configurations and output Steer Tire
Speed 0.10 %
Normal Force, and Exit Corridor.
6. Determine variance in Exit Corridor at zero Steer Tire Normal Force
Inertia roll 5.0 %
7. Determine each inputs contribution to total input variance. Inertia yaw 5.0 %
Inertia pitch 7.5 %

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 14
Quantifying Model Uncertainty

Take exit corridor and minimum steer

tire force output for each trial.
Develop a linear model of response.
Extract mean prediction and standard
deviation at Steer Tire Force = 0.
Repeat for multiple truck configurations.
Develop conservative estimate for
model variance based on input +1
variation.

-1

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 15
Preliminary Comparisons to
Physical Testing

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Preliminary Comparisons to Physical Testing

2
Measures for Comparison =

Lateral acceleration was chosen as a
parameter for comparison, as it is
=
theoretically proportional to overturning 2
Overturning Moment
moment causing tip-over.
Test failure occurs when the inside rear
tire lifts off the ground Assumption:
This occurs when the reaction force on
the inside rear tire goes to zero.
Simulation confirms proportionality
between lateral acceleration and steer
tire normal force.
Additionally, a test witness would observe
whether lift-off occurred during each test
trial.

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 17
Preliminary Comparisons to Physical Testing

Experimental Setup
Vehicle instrumented with motion
capture sensor and accelerometer
Test track is laid out with multiple
target exit corridors
Array of 8 motion captures
cameras distributed around
perimeter lanes
Vehicle top speed set in software

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 18
Preliminary Comparisons to Physical Testing

w2=7.368 m w2=6.368 m

Physical Test: No Lift-Off (3/3) Physical Test: No Lift-Off (3/3)

Simulation: No Lift-Off Simulation: No Lift-Off

w2=5.368 m w2=4.368 m

Physical Test: No Lift-Off (3/3) Physical Test: Lift-Off (1/3)

Simulation: No Lift-Off Simulation: Lift-Off

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 19
Implementation

20
Implementation

_ _ _

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016
Implementation

103 Simulated
1 Physical Test
Variants

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016 22
Next Steps

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Next Steps

Accurate Parametric Model can be used to

extract critical statistical relationships from
an otherwise stochastic event.
Using LMS simulation to develop statistical
predictive model to eliminate physical
testing completely.
Use simulation based statistical analysis as
a development tool.

Dynamic Stability Simulation of a Counter Balanced Lift Truck Siemens Simcenter Symposium 2016
Thank you!
Contact Information:
Joshua.Hogg@hyster-yale.com
Hyster-Yale Group
4000 NE Blue Lake Road, Fairview, OR 97024 25