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Research Paper

An Integrated Systems Engineering Method


for Conceptual Design of Vehicle Handling
Dynamics
Mandar Hazare∗ and Paul Venhovens

Department of Automotive Engineering, Clemson University, 4 Research Dr, Greenville, SC 29607

Received 1 September 2014; Revised 11 September 2015; Accepted 19 December 2015, after one or more revisions
Published online in Wiley Online Library (wileyonlinelibrary.com).
DOI 10.1002/sys.21333

ABSTRACT
The handling characteristics of road vehicles are important attributes that define a major part of its unique
selling proposition. The engineering process of tuning vehicle handling dynamics is a challenging process
due to the multitude of competing design requirements/parameters and requires a well-defined system-
atic approach. The primary objective of this publication is to describe an integrated system engineering
method for the conceptual design of vehicle handling dynamics early in the product development process.
A systems engineering-based simulation framework is described that connects subjective, customer-
relevant handling expectations to higher-level, objective vehicle engineering targets and consequently
breaks these targets down into subsystem-level requirements and component-level design specifications.
A case study supporting this proposed system engineering method for vehicle handling design is also
described in detail. The integrated systems engineering approach guides the engineering development
process and provides insight into the compromises involved in vehicle handling layout, ultimately saving
product development time and costs and helping to achieve a higher level of product maturity early in the
design phase. C⃝ 2016 Wiley Periodicals, Inc. Syst Eng 18: 659–675, 2015

Key words: Systems Engineering; Vehicle Handling Design

1. INTRODUCTION (relevant to the consumers), and reflects brand’s strategic


preferences regarding relative importance of the attributes.
The handling characteristics of road vehicles are important at- Vehicle handling can be broadly defined as the interaction
tributes that define a major part of the vehicle’s unique selling between driver, vehicle and environment, which takes place
propositions. For vehicle manufacturers with specific focus during transportation of people and goods [Bergman, 1969].
on driving dynamics (emphasizing for example fun/joy of It is an indicator of driver’s ease of controlling the motions
driving), on-road vehicle handling is an important attribute of of the vehicle while driving. The roots of vehicle handling
the strategic brand “DNA.” The vehicle brand specific DNA design theory can be traced to mid 1950s, when the first
(shown in Fig. 1) represents the different vehicle attributes comprehensive understanding of both the theory and practice
of the linear handling response of the automobile was
∗ Author to whom all correspondence should be addressed (e-mail: mhaz- introduced [Olley, 1946–1947, Segel, 1993; Crolla, 1995].
are@g.clemson.edu). Since then, the field of vehicle handling dynamics design
has come a long way, with a plethora of research activities
Systems Engineering Vol. 18, No. 6, 2015
C⃝ 2016 Wiley Periodicals, Inc.
in almost all areas of vehicle handling including, theories

659
660 HAZARE AND VENHOVENS

Figure 1. Brand specific DNA or vehicle attributes.

explaining nonlinear limit handling behavior [Ono et al., Fig. 1) allows for a visual representation of important
1998], use of computer simulations [Allen et al., 1999], vehicle attributes and also show the relative importance
complex multibody models [Pacejka, 2005; Blundell and of the attributes.
Harty, 2014], specialized handling measurement devices, • Trial and error approaches to find the best compromise
vehicle characterization test rigs [Garrott et al., 1988], can lead to suboptimal solutions, resulting in increased
application of active control systems [Statistical Analysis of product cost and weight and the prolongation of product
the Effectiveness of Electronic Stability Control (ESC) 2007; development time.
Browalski et al., 2010], etc. It should be pointed out that
even with these significant advances in the field of vehicle To address the challenges above, it is important to establish
handling and objectification of the handling characteristics, a well-defined and systematic approach toward handling dy-
subjective testing of the vehicle by trained test drivers still namics design to ensure that the final product meets customer
dominates the final chassis setup and sign-off process. expectations. Most vehicle manufacturers follow their own set
The domain of vehicle handling engineering is focused on of unique, proprietary methods to design a vehicle’s handling
developing and applying methods to qualify (and quantify) characteristics. Commonly, current best practice design meth-
the directional behavior of the vehicle during different driv- ods [Kinstle, Hassler, and Johnson, 2009]:
ing maneuvers. Studying handling dynamics involves under-
standing the controllability and stability of the vehicle, and • Benchmark competitor vehicles to develop vehicle-level
is also closely associated with driver’s subjective interaction targets and component design specifications. Compet-
with the vehicle. The engineering process of tuning the vehi- itive benchmarking can lead to products with perfor-
cle handling dynamics is a challenging task due to the mul- mance levels that go beyond customers’ expectations
titude of (competing) design requirements and parameters. and lead to unnecessary engineering effort, higher prod-
Some of the key challenges involved in the process are listed uct costs and weight, and product performance that
below: might not be perceived by the end-user.
• Rely heavily on the application of physical prototypes
during the initial development phase. Early-stage vehi-
• It is difficult to understand the voice of the customer cle prototypes are very expensive, not infinitely tunable
(i.e., interpret the driver’s expectations/perception of the (such as the setup of static and dynamic body-in-white
vehicle’s handling behavior) and translate these expecta- stiffness), and frequently of insufficient build quality to
tions into meaningful objective metrics to be used in the address competing vehicle properties like acoustics.
vehicle product development process. • Focus on physical testing of prototypes. Repetitive phys-
• It is challenging to find a unified chassis setup that meets ical testing can be time-consuming and costly.
the expectations of various segments of drivers interested • Practice “trial-and-error” and “test-and-tune” philoso-
in the same vehicle. Drivers of different age group, such phies, which can be time-consuming if not supported
as young enthusiast and aging drivers, might have dif- by sufficient system behavior knowledge. This approach
ferent expectations regarding handling behavior for one- can also lead to an oversight of conflicting design objec-
and-the-same vehicles. tives, resulting in a sub-optimal final setup.
• Different aspects of vehicle handling—such as steady- • Lead to expensive design changes late in the develop-
state handling, transient handling, straight-line stability, ment process, especially if the interaction with and de-
parking, and emergency handling—are often in conflict pendency of the handling on other vehicle properties and
with one another. design parameters is not properly understood.
• The vehicle’s handling properties by themselves as part
of the overall brand specific DNA (Fig. 1), are often in The objective of this research is to address the challenges
conflict with competing properties aspects, such as ride described in the previous section by developing a method
comfort, acoustic comfort, or passive safety. The vehi- for conceptual vehicle/chassis layout based on a systems
cle brand specific DNA spider/radar diagram (shown in engineering approach. A system engineering process provides

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SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 661

Figure 2. Systems engineering process “V” diagram.

a comprehensive, sequential, and top-down approach for decomposition-based approach helps to better understand and
the successful realization of complex systems. According explore the compromises and trade-offs involved between the
to International Council of Systems Engineering (INCOSE) different subsystems and hence provides valuable insights for
[International Council on Systems Engineering Systems the system engineer. Once the system is decomposed, the tar-
Engineering Handbook, 2006], systems engineering seeks to gets, or specifications for top levels, are identified first. These
focus on the definition of customer needs and requirements targets are propagated, or cascaded, systematically to the rest
early in the development process and subsequently proceed of the system (i.e., the subsystems and smaller components.
with design synthesis and systems validation. The systems en- The actual design tasks are executed locally at subsystem and
gineering process inputs focus primarily on the stakeholder’s component level, and interaction with the rest of the system
(i.e., the customer, legislator, manufacturer, or retailer) needs, is revisited only when a target cannot be met. This often
objectives, expectations, requirements, project target visions, leads to an iterative target cascading process. When the design
and business objectives. These process inputs are used to decisions can be modeled analytically, the process can be
derive system-level, functional, and performance targets, formalized as a multilevel optimization problem referred to
which are then realized by the systematic development of as Analytical Target Cascading (ATC) [Kim et al., 2003, Li,
subsystem-level requirements and component-level specifi- Lu, and Michalek, 2008].
cations. The systems engineering approach is often described In this publication, a simulation based design method for
with a “V” diagram, shown in Figure 2. The left-hand side conceptual design of vehicle handling characteristics is de-
of the “V” diagram deals with decomposition and definition scribed using decomposition based target cascading process
of requirements, the bottom with product design using the and systems engineering principles.
defined requirements, and the right with the integration and
verification of the requirements through testing.
Successful implementation of a system engineering
method for the design and development of complexly 2. PROPOSED METHOD FOR DESIGN
engineered systems is in itself challenging. For example, OF VEHICLE HANDLING DYNAMICS
it is often not straightforward to systematically decompose
and define the requirements and specifications for the Systems engineering approach toward product design always
different design and development levels due to “build-in” begins with understanding the customer’s expectations from
system trade-offs and competing properties. Furthermore, the a particular product, to make sure that the final product meets
implementation method must be concurrent and consistent the end-user’s expectations as best as possible. Equally im-
(concurrent here implies that the individual tasks at different portant for the product developer is to understand the com-
levels are carried out separately in parallel, and consistent pany’s brand essence and how the branded products need to
implies that the key interactions among different design tasks be designed for and aligned with the brand strategy in mind
are identified, observed, and enforced until the concurrent to ensure consistency in the message and product experience.
design process results in a final product [Kim et al., 2003]). Translating these general ideas to vehicle handling design
One approach to assuring concurrency and consistency is targets requires a target setting process that is in alignment
the use of a decomposition-based target cascading method- with the brand essence (or DNA) and a target realization and
ology [Kim et al., 2003]. In a decomposition-based target tracking process that assures that higher-level specific cus-
cascading methodology, the entire complex problem is par- tomer expectations are met during the vehicle development
titioned or decomposed into smaller and simpler problems. A process.

Systems Engineering DOI 10.1002/sys


662 HAZARE AND VENHOVENS

Figure 3. Systems engineering method for conceptual design of vehicle handling dynamics.

Systems engineering recommends a systematic top-down between customer’s handling expectations brand
approach toward product design where the customer require- DNA targets, and objective metrics.
ments are cascaded step-by-step from overall high-level vehi-
cle targets into subsystem level requirements and component The first step is to understand the customer’s relevant ve-
level specifications. The targets, requirements and specifi- hicle handling expectations. The average consumer often de-
cations must be validated at each step during the product scribes handling highly subjectively with attributes such as
engineering and build phase as part of multiple design review “fun to drive,” “sporty,” or “safe”. Translation of these subjec-
processes. For the specific application of conceptual design tive attributes into the engineering domain is a big challenge
of vehicle handling dynamics, the five steps involved in this in itself. Customers with different lifestyles and backgrounds
process are: (i.e., age groups, income levels, and hobbies) might have
very different expectations with respect to vehicle handling
Step 1: Define driving maneuvers and qualitative metrics behavior, which makes the qualification and quantification of
of vehicle handling based on correlative anal- customers’ vehicle handling requirements even more difficult.
yses between customers’ handling expectations, A possible approach to understanding customer’s han-
brand DNA targets, and objective metrics. dling expectations is based on the use of marketing research
Step 2: Quantify handling metrics. and clinics to better understand the product characteristics and
Step 3: Develop a set of knowledge-based lower-order features desirable for customers. Clinics, driving events, and
models as the basis for engineering design opti- marketing surveys aimed at understanding end-user prefer-
mization. ences and expectations of vehicle handling can be used as the
Step 4: Develop and apply a multiobjective, multisce- first step in the vehicle dynamics development program.
nario optimization framework to drive the prod- Customer handling expectations should be defined and
uct design. quantified with respect to the various domains of vehicle han-
Step 5: Validate and verify the recommended design con- dling. The vehicle handling domains are formulated consider-
figurations to ensure customer satisfaction. ing the handling performance requirements of a driver during
Figure 3 schematically shows the application of system different scenarios of vehicle operation. Step 1 requires the
engineering process for conceptual design of vehicle handling development of statistically relevant correlations between
dynamics. customer expectations and qualitative objective metrics,
which can then be used by chassis engineers for the develop-
Step 1: Define driving maneuvers and qualitative metrics ment of vehicle handling targets used in the product design
of vehicle handling based on correlative analyses phase. Table I shows the qualitative overview of vehicle-

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SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 663

Table I. Vehicle Handling Domains and Objective Metrics

Handling Domains Description of Handling Domains Handling Objective Metrics


Steady-State Handling Scenarios of constant speed; constant steer angles with vehicle Understeer Gradient, Yaw Rate
turning along a constant radius of curvature Gain, Roll Gain, Side Slip Angle
Gain
Transient Handling Scenarios of changing yaw velocity, side-slip velocity, and path Yaw Rate Time Constant, Lateral
curvature; represents vehicle’s response during dynamic situations Acceleration Phase Lag, Yaw
(i.e., turn-entry and turn-exit); evaluated with metrics: agility, Rate Damping Ratio, Roll Angle
responsiveness and damping Overshoot, Roll Angle Response
Time
Steering Feedback Steering system response, described in terms of steering-wheel torque Steering Torque Feel (Torque vs.
(Off-Center) feedback, of vehicle during normal driving scenarios Angle, Torque vs. Lateral
Acceleration Gradient)
On-Center Steering Steering system response during straight-line driving at highway Steering Torque Time Lag (vs.
speeds steering angle) at Low Lateral
Accelerations
Emergency (Limit) Vehicle’s response during critical maneuvers such as obstacle Yaw Stability, Roll Stability
Handling avoidance
Parking Ease of vehicle maneuverability during low-speed, high-steer angle Static Parking Torque, Turn Circle
maneuvers Diameter, Lock-to-Lock Steering
Turns
Coupled Dynamics Vehicle’s directional stability in scenarios where cornering is coupled Yaw Rate Increment
with other dynamic motions such as braking or acceleration
Road Adaptability Handling behavior of vehicle on different road surfaces (i.e., rough Yaw Rate Increment
roads, bumps, or low friction surfaces).
Straight-Line Stability Pull and drift behavior of vehicle (i.e., tendency of vehicle to deviate Pitch Gradient, Straight-Line
from intended path during straight-line cruising, acceleration, and Stability Index
braking scenarios); vehicle’s response during acceleration and
braking on split-mu surfaces.
Disturbance Sensitivity Vehicle’s straight-line performance in presence of external Yaw Moment Sensitivity
environmental disturbances such as winds, road crown, and road
roughness.

In this research, all handling domains described in


Table I contribute to the total objective vehicle handling
DNA of a vehicle (see Fig. 4).The handling DNA represents
one arm of the overall vehicle DNA (shown in Fig. 1) and
provides a more detailed representation of vehicle handling
characteristics (and the relative importance of the different
vehicle handling domains). It is important to note that there
are dependencies and trade-offs among the different domains
of vehicle handling. For example, designing a vehicle for
stability during emergency handling usually results in an
understeered vehicle that customers may perceive as less
agile and sporty during normal driving scenarios. Making
a vehicle more agile, and thus oversteered, will result in a
vehicle setup that is more nervous with regard to straight-line
stability. Making a vehicle easier to turn using a low steering
ratio leads to high steering effort and torque during parking.

Figure 4. Typical vehicle handling DNA. Step 2: Quantify handling metrics.

Once the various vehicle-handling scenarios and objective


handling domains associated with different, everyday driving metrics associated with different everyday driving tasks are
tasks (scenario). As part of the systems engineering process, identified, the next step is to quantify objective metrics with
each scenario should be quantified with objective metrics that realistic numbers. These metrics can then be used in the prod-
captures the driver’s assessment of vehicle handling behavior. uct development process.

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664 HAZARE AND VENHOVENS

Figure 5. Target cascading flow diagram.

There are three traditionally different approaches for quan- near-constant closed-loop driver-vehicle system perfor-
tifying objective handling related metrics: mance. The gains and lead time-constants are indicators
of the driver’s perception of handling quality. A range
1. Physical testing of vehicles using highly trained pro- of gains exists that are perceived as enjoyable by the
fessional test engineers (Bergman [1969, 1978], Weir driver. Gains that are too high (perceived as “twitchy”
and DiMarco [1978], Mimuro et al. [1990], King et al. by customers) or too low (“sluggish”) lead to degraded
[2002], Xia and Willis [1995], Chen [1997], Lincke, perception of handling quality. Although this method
Richter, and Schmidt [1973], and Good [1977]). The seems very attractive, uncertainty associated with the
subjective feedback of trained test engineers using qual- human driver simulation model has restricted this
itative engineering descriptions such as “progressive approach.
handling,” “predictable behavior,” “cornering traction,” 3. Clinics and analytic research. This approach isolates
“overall grip,” “direct steering response,” etc., corre- the driver’s preferences and perceptions of particu-
lates with objective responses measured by sensors in- lar vehicles and brands by conduction-driven events
stalled on the vehicle. This approach assumes that the with nonexpert target consumers to help manufactur-
nonexpert target customer’s expectations can be suffi- ers understand customer expectations and preferences.
ciently described by expert test engineers’ subjective Drivers’ preferences are then correlated with objective
judgments. This approach, although most widely used metrics using statistical tools (i.e., regression and cor-
within the industry, can lead to over-engineered prod- relation techniques). These objective metrics can be de-
ucts tuned for expert professional test engineers/drivers rived from vehicle responses measured during physical
instead of “normal” end-users. testing of the vehicles or by the use of simulated vehicle
2. Simulation-based strategies (McRuer and Klein [1978], dynamics models.
Venhovens and Hazare [2012], Horiuchi and Yuhara
[2000], and Ishio, Ichikawa, Kano and Abe [2008]). The quantification of vehicle handling objectives with re-
This approach relies on simulation methods and re- alistic targets requires understanding both the brand essence
quires synthesized vehicle dynamics and driver models and brand DNA targets. The brand image closely relates to the
to predict and assess the driver’s perception of vehi- customer’s perception of a particular brand in comparison to
cle handling dynamics. A simulated driver model is the other brands; for example, the customer might perceive a
used in conjunction with a vehicle dynamics model, certain brand to be “sportier” or more “comfortable” than an-
and the adaptive parameters of the driver model are other brand. Brand DNA targets provide a way to realistically
used as indicators of the vehicle’s handling quality. account for trade-offs between different conflicting attributes
According to McRuer and Klein [1978], drivers adapt (i.e., sportiness vs. comfort) relevant to the customer while
their driving control in such a way that they maintain emphasizing certain attribute more than others.

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SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 665

Table II. Handling Performance Metrics Vehicle A and B

Objective Handling
Handling Domains Metrics Unit Vehicle A (FWD) Vehicle B (RWD)
Steady-State Handling (v = 80 km/h) Understeer Gradient deg/g 0.727 1.197
Yaw Rate Gain 1/sec 0.491 0.307
Side-Slip Angle Gain deg/g −1.29 −1.34
Roll Angle Gain deg/g 2.39 3.57
Transient Handling (v = 80 km/h) Yaw Rate Time Constant ms 113 105
Yaw Rate Damping Ratio − 0.994 0.918
Lateral Acceleration deg −44.1 −43.4
Phase Lag
Roll Angle Overshoot % 1.9 8.0
Steering Feedback (v = 80 km/h) Steering Torque Gain (per Nm/deg 0.391 0.308
Steering Angle)
Steering Torque Feel (per Nm/g 20.1 25.4
Lateral Acceleration)
On-Center (v = 80 km/h) Steering Torque Time Lag ms 86 63
(@ 0.2 Hz)
Parking Lock-to-Lock Steering − 2.3 3.2
Rotations
Turn Circle Diameter m 10.52 10.47
Parking Static Torque Nm 13.2 10.3
Disturbance Sensitivity (v = 80 km/h) Yaw Moment Sensitivity deg/kN m-sec 3.327 2.301
Coupled Dynamics (v = 80 km/h) Yaw Rate Increment % −1.47 3.54
(Acceleration out of
Turn)
Road Adaptability (v = 80 km/h) Yaw Rate Increment % −0.85 −1.95
(Cornering on Rough
Roads)
Straight-Line Stability Straight-Line Stability Nm/N 1.197 1.518
Index
Pitch Gradient deg/g 1.99 1.79
Emergency Handling (Roll Stability) Static Stability Factor − 1.416 1.499
NHTSA Stars − 4 5

Step 3: Develop a Set of Knowledge-Based Lower-Order component specifications that are generally not available dur-
Models as the Basis for Engineering Design Op- ing the initial stages of the conceptual vehicle design, sec-
timization. ondly, having highly nonlinear and complex models make
the simulation (and numerical optimization) process very
The next step is to develop suitable vehicle handling mod- computationally expensive, and thirdly, some commercially
els (physics-based, knowledge-based), which can capture and available simulation tools are of a black-box nature which
connect the different vehicle handling scenarios and metrics means that the chassis engineer has no clear insight into the
(described in Step 1). These “hybrid” lower-order models descriptive language of the model make-up and models of
with appropriate amount of complexity must be able to sim- such nature often do not allow access to model parameters
ulate vehicle behavior at each level (vehicle, subsystem and by 3rd party optimization routines.
component). Since these models will be used in an iterative
optimization framework (Step 4) it is important to ensure
Step 4: Develop and Apply a MultiObjective, Multi-
that the models are easy to characterize, computationally in-
Scenario Optimization Framework to Drive the
expensive, transparent and insightful for the chassis design-
Product Design.
ers.
Note that there are several highly complex vehicle dy-
namics models available (as part of commercially available Systematically following Steps 1 and 2 will lead toward
software packages). These commercially available handling the development of quantifiable engineering metrics that cor-
packages/models are often not suitable during the vehicle relate to customers’ vehicle handling expectations. As de-
concept development phase. Firstly, the detailed vehicle han- scribed in Step 1, to comprehensively describe customers’
dling software packages (such as multibody dynamics simu- vehicle handling requirements, a variety of scenarios and
lation tools) requires building elaborate models with detailed corresponding objective metrics are needed. These objective

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666 HAZARE AND VENHOVENS

Figure 6. Vehicle handling DNA performance spider diagram, higher value on handling spider diagram is better (indicates improvement).

handling metrics can be analytically computed using vehicle gether in the optimization framework. An iterative optimiza-
handling models developed in Step 3. tion scheme has been established, which aims at reducing
Step 4 requires the availability of a multiscenario, the discrepancy between targets (from higher levels) and re-
multiobjective optimization framework to balance competing sponses (from lower levels) in order to achieve a consistent,
customer relevant vehicle handling requirements; that will optimized chassis design solution with respect to constraints
drive the product design development and optimization. at the subsystem and component levels. Figure 5 shows the
This optimization framework should account for the overall target cascading flow diagram proposed.
interaction between various aspects of vehicle handling and Genetic Algorithms (GA) [Deb, 2001], a type of stochastic
supports developing chassis subsystem- and component- optimization method is used at each level. As the vehicle
level design specifications with respect to realistic design handling design process is complex and possibly multimodal
constraints. The framework can be applied in two consecutive in nature, the use of stochastic optimization approaches will
steps: in the first step, objective vehicle-level handling targets ensure that the final optimal solution is not restricted to a
derived from customer handling expectations are translated local minimum as with traditional gradient-based optimiza-
into subsystem-level engineering requirements and balanced tion methods. Note that it is possible to use other stochastic
against various competing design objectives using an optimization methods for solving the vehicle handling design
optimization method. In thesecond step, the subsystem-level problem. For example, Haghiac, Haque, and Fadel [2004]
requirements are translated into component-level design used GA to solve a more simplified vehicle handling design
specifications where an optimization algorithm searches for problem and compares the results obtained from using Ge-
the best set of design parameters. netic Algorithms against other optimization methods such
In this research, the chassis design problem is decom- as Monte Carlo [Scarlat et al., 2002; Chakravartula, Haque,
posed into a meaningful subsystem-level—such as sus- and Fadel, 2005] and Simulated Annealing [Chandramoulli,
pension, steering and tires—and component-level—such as 2002]. The results and conclusions from their research indi-
kinematics and bushing compliances—design problem. The cate that the GA approach has some distinct advantages over
desired vehicle-level targets are cascaded systematically to the other methods.
lower levels (i.e., subsystems) and components are rebalanced The optimization framework has been implemented using
upwards based on lower-level designs. Analytical models a decomposition-based Analytical Target Cascading (ATC)
for subsystems and components are identified and tied to- methodology [Kim et al., 2003, Li et al., 2008]. ATC is an

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SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 667

Table III. Customer Relevant Subjective Handling Attributes effective hierarchical multilevel optimization-based design
and Objective Vehicle Handling Metrics methodology; it applies a decomposition approach wherein
the overall system is split into subsystems, which are then
Customer Relevant solved separately and coordinated via target-response consis-
Subjective Handling tency constraints [Li et al., 2008].
Attributes Objective Handling Metrics In the most general form, ATC problem can be represented
Sporty 5 Metrics to be Higher Yaw Rate Gain, as follows ([notations and formulations adapted from Li et al.
Maximized and 8 Higher Steering Torque Gain, [2008] and Tosserams, Etman, and Rooda [2006])
Metrics to be Higher Steering Torque Feel,

N ∑ ∑
N ∑
Minimized Higher Damping Ratio, 𝑚𝑖𝑛 f i j (x i j ) + 𝜋(ti j − ri j ) (1)
Higher Yaw Rate Increment x ...,x 𝑁𝑀
11 i=1 J =𝜀i i=1 J =𝜀i
(Acceleration-in-Turn).
For Augumented Lagrangian ATC Formulation:
Lower Understeer Gradient,
Lower Side-Slip Gain, 𝜋(ti j − ri j ) = 𝜆iTj (ti j − ri j ) + ||w i j ∙ (ti j − ri j )||22
Lower Roll Gain, s.t. gi j (x i j ) = 0
Lower Pitch Gradient, h i j (x i j ) = 0
(2)
Lower On-Center Lag, ti j − ri j = 0
Lower Yaw Rate Time Constant, w her e x i j = [x i j , t(i+1)k ∀k ∈ Ci j ]
Lower Lateral Acceleration Phase Lag, ri j = ai j (x i j )∀ j ∈ 𝜀i , i = 1, . … , N
Lower Roll Angle Overshoot.
Here, the system is decomposed into N levels with M
Fun-to-Drive 2 Metrics Higher Yaw Rate Damping Ratio, elements each. The subscript i j represents thejth element
to be Maximized Higher Steering Torque Feel. of the system in the ith level. The variable f i j represents
and 6 Metrics to be the scalar objective function, and gi j ≤ 0, h i j = 0 are
Minimized the inequality and equality constraints respectively. Local
Low Side-Slip Gain, variables of element j are denoted by xi j . The variable
Lower Roll Gain, ri j is the response of element j calculated by analysis
Lower Pitch Gradient, model ai j . ∈i is the set of elements at level i, and Ci j is
Lower On-Center Lag, the set of children of element j. ti j represents target vari-
Lower Time Constant, able created for each shared variable. 𝜋 denotes the con-
Lower Lateral Acceleration Phase Lag. sistency constraint relaxation function. In the case of the
Augmented Lagrangian (AL) method, applied to ATC for-
Safety 2 Metrics to be High Understeer Gradient (Yaw mulation, the consistency constraint function, 𝜋, is formu-
Maximized and 4 Stability), lated as a combination of the quadratic penalty function,
Metrics to be Higher Static Stability Factor (Roll w =∥ w i j⋅(ti j −ri j ) ∥22 , w = [w i j , ∀ i, j] and the Lagrangian
Minimized Stability).
function, 𝜆iTj (ti j − ri j ), 𝜆 = 𝜆i j , ∀ i, j ].
Lower Yaw Rate Increment In this work, ten different scenarios of vehicle handling
(Accelerating in Turn), dynamics are considered (see Table I). The vehicle handling
Lower Yaw Rate Increment (Rough objective metrics from each scenario are grouped under four
Road Cornering), customer-specific brand attributes derived from market data
Lower Roll Angle Overshoot, (i.e., Sporty, Fun to Drive, Safety, and Comfort). The fitness
Lower Straight-Line Stability Index function at the first layer (vehicle-level) of the optimization
(i.e., Higher Straight-Line Stability). framework is based on customer-relevant brand attributes.
The design variables used in the first layer of the optimization
Comfort 2 Metrics to Higher Yaw Rate Time Constant, framework can be grouped into three separate subsystems—
be Maximized and 6 Higher On-Center Delay. tires, suspension, and steering.
Metrics to be In the second layer of the optimization framework, the sus-
Minimized pension subsystems are analyzed using separate kinematics
Lower Yaw Moment Disturbance and compliance modules. The suspension kinematic charac-
(i.e., Higher Side Wind Stability), teristics are represented by eight design variables namely, sus-
Lower Steering Torque Gain, pension roll camber, roll steer, roll center height, mechanical
Lower Steering Torque Feel, trail, scrub radius, king pin inclination, caster angle, and anti-
Lower Parking Torque, dive geometry. The suspension compliance characteristics are
Lower Lock-to-Lock Steering Turns, represented with three design variables: namely, suspension
Lower Turn Circle Diameter. lateral force compliance steer, lateral force camber compli-
ance, and aligning moment compliance steer. The suspen-
sion kinematic characteristics are a function of suspension
geometry, and the suspension compliance characteristics are
a function of the suspension geometry and bushing stiffness.

Systems Engineering DOI 10.1002/sys


668 HAZARE AND VENHOVENS

Figure 7. Analytical target cascading flow diagram for design of vehicle handling dynamics.

In the proposed ATC optimization framework, a suspension kinematics and compliance behavior validate suspension sub-
geometry model and a suspension compliance model work system targets, such as the compliance steer of an entire axle.
separately to achieve the desired kinematics and compliance The simulation models can also be used to simulate different
targets set at the first layer of the optimization framework. vehicle handling scenarios to ensure that vehicle-level targets
Note that both suspension kinematics and compliance mod- derived during Step 2 are achieved. Real world testing with
els use suspension pickup points—three-dimensional spatial physical prototypes can be used to complete the validation
coordinates—as common design variables and hence are rep- process.
resented as linking variables in the ATC framework.

Step 5: Validate and Verify the Recommended Design 3. CASE STUDY


Configurations to ensure Customer Satisfaction.
In this section, a case study based on the proposed systems
In a typical system engineering process, the derived engineering framework for the systematic design of vehicle
subsystem-level and component-level specifications are vali- handling characteristics will be carried out. The case study
dated by physically building and testing systems at each level. comprises of two vehicles: vehicle A (compact FWD hatch-
(Refer to the right-hand side of the “V” diagram shown in Fig. back) and vehicle B (sporty RWD coupe).
2.) The upward process ensures that the final product meets In our case study, a vehicle customer satisfaction survey
all desired vehicle level targets and end-user expectations. from AutoPacific [2013] is used to understand customer’s
For the conceptual design of vehicle handling dynamics vehicle satisfaction with attributes that relate to vehicle han-
described in this research, it is recommended that the valida- dling. The survey (2013 New Vehicle Satisfactory Survey)
tion process be performed virtually - potentially with higher- consists of around 56,000 responses from consumers who
order, higher-quality simulation models. The component de- purchased a new vehicle within 6 months of filling out the
sign specifications derived using the optimization framework questionnaire. The survey captures new vehicle owners’ sat-
(Step 4) can be used to characterize commercially available isfaction with their purchases with respect to different ve-
higher-order simulation tools, which usually have a higher hicle attributes. From the general survey responses, four
degree of correlation with real vehicle behavior. For exam- key attributes—Sporty, Fun to Drive, Safety, and Comfort—
ple, the suspension pick-up points generated from the opti- related to vehicle handling behavior were selected to correlate
mization algorithm can be used to characterize a multibody the customer’s satisfaction to the various scenarios and objec-
simulation model, which can then be used to simulate the tive metrics of vehicle handling.

Systems Engineering DOI 10.1002/sys


SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 669

Figure 8. Vehicle handling DNA performance spider diagram, higher value on handling spider diagram is Better (indicates improvement).

From the survey, it was found that customers perceived include: steady-state handling, transient handling, on-center
vehicle B to be more Sporty, Fun-to-Drive, and slightly more handling, emergency handling, parking, steering feedback,
Comfortable than vehicle A. The customers also perceived handling on different road surfaces, coupled dynamic corner-
vehicle A to be much Safer than vehicle B. In this scenario, ing, disturbance sensitivity, and straight-line stability.
the challenge for a chassis engineer would be to develop a new Table II illustrates the differences in the handling char-
chassis setup solution for vehicle B, such that it improves its acteristics of vehicle A (compact FWD hatchback) and ve-
Safety behavior without excessively sacrificing its Sporty, Fun hicle B (sporty RWD coupe), described with respect to the
to Drive and Comfort attributes. ten scenarios of vehicle handling. The four key customer-
relevant vehicle handling attributes (i.e., Sporty, Fun to Drive,
Safety, and Comfort) were correlated with the various han-
3.1. Objectives and Scope of the Case Study dling objective metrics shown in Table II. Table III shows
To limit the scope of this case study, it is assumed that the the higher-level relationship between the customer-relevant
manufacturer (or the chassis engineer) would like to redesign handling attributes and the objective handling metrics used
the chassis setup for vehicle B such that the new concept (say, for this case study. Figure 6 shows a relative performance
optimized-vehicle B), handles similar to vehicle A. It is also spider diagram comparing the handling performance DNA
assumed that the vehicle manufacturer can only redesign the (expressed in terms of customers’ subjective expectations) for
steering system, front and rear tires, and front-axle suspension vehicles A and B.
characteristics of vehicle B. Thus, the objective of this case Figure 6 is based on the numerical values of objective
study is to illustrate a systematic chassis design process that metrics shown in Table II and empirical associations shown
will attempt to give vehicle B the handling characteristics—or in Table III. These correlations have been developed such that
the DNA—of vehicle A within realistic design constraints. a higher value of a metric on the spider diagram represents
an improvement of the attribute. The first step in developing
these correlations is to calculate the normalized values of the
3.2. Quantification of Vehicle Handling vehicle handling objective metrics. The normalized values
Characteristics are calculated by dividing the handling objective metrics by
values for a reference vehicle. In this case a best-in-class ve-
The handling requirements are grouped and categorized with hicle was considered as the reference. The next step involves
respect to the various scenarios of vehicle handling. These either addition or subtraction of these normalized metrics,

Systems Engineering DOI 10.1002/sys


670 HAZARE AND VENHOVENS

Table IV. Handling Performance Metrics for Vehicle A, B and Optimized Vehicle B

Handling Objective Handling


Domains Metrics Units Vehicle A Vehicle B Optimized - Vehicle B
Steady-State Handling (v = 80 km/h) Understeer Gradient deg/g 0.727 1.197 1.171
Yaw Rate Gain 1/sec 0.491 0.307 0.352
Side-Slip Angle Gain deg/g −1.29 -1.34 −0.77
Roll Angle Gain deg/g 2.39 3.57 2.32
Transient Handling (v = 80 km/h) Yaw Rate Time Constant ms 113 105 85
Yaw Rate Damping Ratio 0.994 0.918 0.983
Lateral Acceleration deg −44.1 −43.4 −30.0
Phase Lag
Roll Angle Overshoot % 1.9 8.0 1.9
Steering Feedback (v = 80 km/h) Steering Torque Gain (per Nm/deg 0.391 0.308 0.327
Steering Angle)
Steering Torque Feel (per Nm/g 20.1 25.4 23.5
Lateral Acc.)
On−Center (v = 80 km/h) Steering Torque Time Lag ms 86 63 36
(@ 0.2 Hz)
Parking Lock−to−Lock Steering 2.3 3.2 2.8
Rotations
Turn Circle Diameter m 10.52 10.47 10.50
Parking Static Torque Nm 13.2 10.3 11.5
Disturbance Sensitivity (v = 80 km/h) Yaw Moment Sensitivity Deg/kN m−sec 3.327 2.301 1.937
Coupled Dynamics (v = 80 km/h) Yaw Rate Increment % −1.47 3.54 2.62
(Acceleration out of
Turn)
Road Adaptability (v = 80 km/h) Yaw Rate Increment % −0.85 −1.95 −0.83
(Cornering on Rough
Roads)
Straight−Line Stability Straight−Line Stability Nm/N 1.197 1.518 1.471
Index
Pitch Gradient Deg/g 1.99 1.79 2.12
Emergency Handling (Roll Stability) Static Stability Factor − 1.416 1.499 1.499
NHTSA Stars − 4 5 5

depending upon whether they need to be maximized or steering wheel. The tire force model is based on Pacejka’s
minimized, to calculate the relevant handling attribute based Magic Formulae [Pacejka, 2005] and includes a simple tran-
on associations shown in Table III. Figure 6 clearly indicates sient tire side force model extension based on a first-order lag
that the vehicle B is Sportier than vehicle A; on the other hand, using the tire’s relaxation length as the time constant. The in-
vehicle A is perceived as much Safer than vehicle B. Although fluence of steering system compliance, suspension kinematics
not very apparent from the figure, it is found that vehicle B is and compliance, weight transfer due to height of the center
slightly more Fun-to-Drive and Comfortable than vehicle B. of gravity, roll stiffness, and centrifugal forces are included
in the tire force calculations using effective axle cornering
characteristics [Pacejka, 2005]. Such effective cornering char-
3.3. Vehicle Handling Models acteristics include tire properties based on Pacejka’s Magic
Formulae, incorporate tire force dependency on slip angle
The key idea at this step is to develop models with an appro- and vertical load, and provide mechanisms for combined cor-
priate amount of complexity and that are easy to character- nering and braking with tire force saturation. The suspen-
ize, computationally in-expensive, transparent, and insightful sion elasto-kinematic characteristics are modeled by using
for chassis engineers. The models applied must be effec- the suspension compliance matrix formulations described by
tive/efficient when used in an iterative optimization frame- Knapczyk and Dzierżek [1995].
work.
The vehicle handling model used for this case study is
based on a vehicle model with roll, yaw, and lateral motion as 3.4. Optimization Framework
the three Degrees of Freedom (DOF). This is coupled with a
steering system model, which adds another DOF and accounts A multiscenario, multiobjective optimization framework nec-
for steering system compliance between the road wheel and essary to account for customers’ conflicting vehicle handling

Systems Engineering DOI 10.1002/sys


SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 671

Table V. Optimized Vehicle Design Variables (Suspension, Steering and Tires)

Vehicle Design Variables

Suspension Parameters

Variables Units Vehicle B Optimized −Vehicle B % Change


Roll Stiffness (Total) Nm/deg 1,641 2,522 53.7
Roll Stiffness Distribution (Front) % 65.3 78.1 19.5
Roll Stiffness (Front) Nm/deg 1,072 1,969 83.7
Roll Stiffness (Rear) Nm/deg 569 554 −2.7
Front Wheel Rate (Suspension Stiffness, Front) N/mm 26.60 39.55 48.7
Rear Wheel Rate (Suspension Stiffness, Rear) N/mm 18.40 11.09 −39.7
Roll Stiffness (sway bar, Front) Nm/deg 573 1,194 108.3
Roll Stiffness (sway bar, Rear) Nm/deg 129 336 160.6
Shock Damping (Front) N−sec/mm 2,420 1,970 −18.6
Shock Damping (Rear) N−sec/mm 1,746 1,592 −8.8
Lateral Force Compliance Steer (Front) deg/N −1.01E−04 −4.65E−05 −53.8
Lateral Force Compliance Steer (Rear) deg/N 5.90E−06 5.90E−06 0.0
Lateral Force Camber Compliance (Front) deg/N 1.18E−04 9.04E−05 −23.4
Lateral Force Camber Compliance (Rear) deg/N 6.35E−05 6.35E−05 0.0
Roll Camber (Front) deg/deg −0.620 −0.907 46.5
Roll Camber (Rear) deg/deg −0.637 −0.637 0.0
Roll Steer (Front) deg/deg 0.035 0.037 6.1
Roll Steer (Rear) deg/deg −0.044 −0.044 0.0
Roll Center Height (Front) mm 57.00 38.59 −32.3
Roll Center Height (Rear) mm 99.7 99.7 0.0
Anti−Dive Angle (Front) deg 2.00 2.09 4.3
Anti−Dive Angle (Rear) deg 14 14 0.0
Steering Parameters
Steering Ratio − 16.4 14.8 −9.9
Mechanical Trail mm 30.00 25.83 −13.9
King Pin Inclination Angle deg 12.39 9.54 −23.0
Caster Angle deg 7.50 8.53 13.8
Scrub Radius mm 34.00 −5.15 −115.2
Aligning Torque Compliance Steer (Front) deg/Nm 2.83E−04 1.33E−04 −52.8
Aligning Torque Compliance Steer (Rear) deg/Nm 3.34E−04 3.34E−04 0.0
Tire Parameters
Cornering Stiffness (Front, per tire) N/deg 1,279 1,520 18.8
Cornering Stiffness (Rear, per tire) N/deg 1,145 1,349 17.9
Cornering Stiffness Load Dependence Coefficient a3 2,203 3,076 39.6
BCD = a3 * sin (2 * atan (Fz ./ a4)) a4 11.21 13.61 21.3
Camber Stiffness (Front, per tire) N/deg 191.9 227.9 18.8
Camber Stiffness (Rear, per tire) N/deg 171.7 202.4 17.9
Relaxation Length mm 422.50 146.02 −65.4
Pneumatic Trail mm 27.70 22.33 −19.4

requirements has been developed for this case study. The op- subsystem-level requirements are passed on as targets to the
timization framework is implemented using a decomposition- second layer of optimization and the second layer attempts to
based, Analytical Target Cascading (ATC) [Kim et al., 2003, derive component-level specifications from subsystem-level
Li et al., 2008] methodology. The ATC optimization frame- requirements derived in the first step. The second layer
work developed for this research works in a two-layer opti- optimization utilizes component level design variables and
mization schedule. GA [Deb, 2001], a type of evolutionary analysis models and attempts to minimize the difference
optimization algorithm, are used at each layer of the frame- between the targets transferred from the vehicle level and
work. response generated from the component level analysis. An
The first layer is used to derive subsystem-level iterative loop is set up with an objective to minimize the
requirements from overall vehicle level targets. These target/response consistency constraints, that is, the targets

Systems Engineering DOI 10.1002/sys


672 HAZARE AND VENHOVENS

Figure 9. Optimized suspension geometry configuration for vehicle B and optimized-vehicle B.

Table VI. Optimized Front Suspension Bushing Stiffness

Bushing Radial Stiffness (N/mm)

Vehicle B Optimized-Vehicle B % Change


Link 1 (Lower A Arm (F)) 3,305 5,126 55.1
Link 2 (Lower A Arm (R)) 1,885 2,935 55.7
Link 3 (Upper A Arm (F)) 7,831 1,801 −77.0
Link 4 (Upper A Arm (R)) 3,531 9,741 175.8
Link 5 (Tie Rod) 1.0E + 09 1.0E + 09 0

at the vehicle level are constantly rebalanced to achieve a suspension kinematics and compliance models use suspen-
consistent and feasible solution. sion pickup points—three-dimensional spatial coordinates—
Figure 7 shows the ATC flow diagram illustrating the op- as common design variables and hence are considered as
timization process used in this study. As described earlier in linking variables in the ATC framework.
the paper, the first layer (vehicle-level) of the optimization
framework is based on customer-relevant brand attributes.
The design variables used in the first layer of the optimization
3.5. Results from the Optimization Process
framework can be grouped into three separate subsystems—
tires, suspension, and steering. In the second layer of the The objective of the optimization process is to derive a new
optimization framework, the suspension subsystems are an- chassis configuration for vehicle B (called “optimized-vehicle
alyzed using separate kinematics and compliance modules. B”) such that it has handling characteristics are similar to
The suspension kinematic characteristics are represented by those of vehicle A. Most importantly, the objective was to
eight design variables namely, suspension roll camber, roll improve the Safety characteristics of vehicle B without ex-
steer, roll center height, mechanical trail, scrub radius, king cessively sacrificing its Sporty, Fun-to-Drive and Comfort
pin inclination, caster angle, and anti-dive geometry. The attributes. The steering system, front and rear tires, and front
suspension compliance characteristics are represented with axle suspension characteristics were set as design variables in
three design variables: namely, suspension lateral force com- the optimization process.
pliance steer, lateral force camber compliance, and aligning Figure 8 shows a relative performance spider diagram com-
moment compliance steer. The suspension kinematic char- paring the handling performance DNA, expressed in terms
acteristics are a function of suspension geometry, and the of customers’ subjective expectations, for vehicle A, vehicle
suspension compliance characteristics are a function of the B, and optimized-vehicle B. The handling spider diagram is
suspension geometry and bushing stiffness. Note that both based on correlations described in Table III and uses a ranking

Systems Engineering DOI 10.1002/sys


SYSTEMS ENGINEERING METHOD FOR VEHICLE HANDLING DESIGN 673

Figure 10. Optimized suspension kinematic characteristics (bump steer, bump camber).

Figure 11. Tire cornering stiffness (N/deg) vs. normal load (N).

scheme where a higher value on the spider diagram repre- Safe than vehicle A. Although not very apparent in the figure,
sents improvement in the handling attribute. From Figure 8 it was also observed that the optimized-vehicle B was the least
it is observed that the optimized-vehicle B is slightly less Comfortable among the three vehicles.
Sportier than vehicle B but is Sportier than vehicle A; it is Table IV shows the final vehicle handling performance
also more Fun-to-Drive than both vehicle A and vehicle B. metrics for the optimized configuration obtained from this
The optimized-vehicle B is Safer than vehicle B but still less case study. The proposed system engineering framework

Systems Engineering DOI 10.1002/sys


674 HAZARE AND VENHOVENS

ensures that the proposed vehicle-level solution can always ing design requirements and parameters and requires a well-
be realized with feasible subsystem and component-level defined systematic approach.
specifications. Table V compares the subsystem-level design The primary objective of this publication is to describe
variables for the optimized vehicle configuration (optimized- an integrated system engineering method for the conceptual
vehicle B) and the original vehicle (vehicle B). Note that only design of vehicle handling dynamics early in the product
front suspension design variables were independent for this development process. A systems engineering-based
case study (i.e., only the front suspension of vehicle B was simulation framework is described that connects subjective,
redesigned). customer-relevant handling expectations to higher-level,
Figure 9 shows the optimized suspension geometry config- objective vehicle engineering targets and consequently
uration (i.e., the re-designed suspension pick-up points). In breaks these targets down into subsystem-level requirements
this case study, only wheel-side points of suspension assem- and component-level design specifications. A case study
bly were optimized, that is, only the front wheel knuckle was supporting this proposed system engineering method for
redesigned. Figure 10 shows the suspension kinematic curves vehicle handling design is described in detail.
for the optimized suspension configuration. Table VI shows Such an integrated systems engineering approach will
the optimized bushing stiffness obtained from the optimiza- guide the engineering development process and provides in-
tion schedule. Figure 11 shows the tire cornering stiffness sight into the compromises involved in vehicle handling lay-
characteristics obtained from the optimized schedule. Note out, ultimately saving product development time and costs
that both front and rear tires are assumed to have identical and helping to achieve a higher level of product maturity early
characteristics in this case study. in the design phase.
The results of the case study indicate that the optimized-
vehicle B can only partially attain the handling character-
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Dr. Mandar Hazare is vehicle dynamics researcher and a motorsports professional. He received his PhD in Automotive Engineering from
Clemson University International Center for Automotive Research (CU-ICAR) in 2014. His research interests include vehicle dynamics,
control systems, tire mechanics, and suspension design.

Dr. Paul Venhovens is the BMW Endowed Chair in Automotive Systems Integration at CU-ICAR and comes to CU-ICAR from BMW’s
Research and Development headquarters in Munich, Germany, where he worked in the field of systems integration since joining the company
in 1995. Dr. Venhovens received his Ph.D. in mechanical engineering in 1993 from Delft University of Technology in his home country of
the Netherlands. Before joining BMW, he conducted post-doctoral research at the University of Michigan Transportation Research Institute
(UMTRI) in Ann Arbor, Mich., in the area of simulation and control design for ITS (lane departure warning and control) applications. At CU-
ICAR his research focuses on vehicle dynamics, new vehicle architectures and automotive systems engineering tools that balance multiple,
often competing aspects, including markets, policies, brand, geometry, functions, weight, costs, and manufacturing.

Systems Engineering DOI 10.1002/sys

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