Strojniški vestnik - Journal of Mechanical Engineering 63(2017)1, 35-44 © 2017 Journal of Mechanical Engineering. All rights reserved. D0l:10.5545/sv-jme.2016.3639 Original Scientific Paper Received for review: 2016-04-04 Received revised form: 2016-09-12 Accepted for publication: 2016-11-29 Robust Fault-Tolerant Control of In-Wheel Driven Bus with Cornering Energy Minimization Andras Mihaly1 - Péter Gaspar12 - Balazs Németh12 Budapest University of Technology and Economics, Department of Control for Transportation and Vehicle Systems, Hungary 2Hungarian Academy of Sciences, Institute for Computer Science and Control, Hungary The aim of this paper is to design fault-tolerant and energy optimal trajectory tracking control for a four-wheel independently actuated (FWIA) electric bus with a steer-by-wire steering system. During normal driving conditions, the architecture of the proposed controller enables the bus to select an energy optimal split between steering intervention and torque vectoring, realized by the independently actuated in-wheel motors by minimizing the cornering resistance of the bus. In the case of skidding or a fault event of an in-wheel motor or the steering system, a high-level control reconfiguration using linear parameter varying (LPV) techniques is applied to reallocate control signals in order to stabilize the bus. The main novelty of the paper is the control reconfiguration method based on the specific characteristics of the in-wheel bus which enables introducing such scheduling variables, with which the safety and efficiency of the FWIA bus can be enhanced. Keywords: In-wheel motor, FWIA bus, reconfigurable control, cornering resistance Highlights • Reconfigurable velocity and trajectory tracking in-wheel electric vehicle control. • High-level LPV design and low-level control allocation using constrained optimization. • Development of a reconfiguration technique with scheduling variables. • Consideration of actuator failure and energy optimal cornering. 0 INTRODUCTION As economical and environment-friendly hybrid/ electric vehicles become increasingly popular, researchers and automotive companies also focus on the development of in-wheel electric vehicles, which have several benefits in comparison to conventional vehicles. From a vehicle dynamic point of view, the fast and precise torque generation of the hub motors lends torque vectoring capability to the vehicle with which manoeuvrability can be enhanced significantly [1] and [2]. The electric in-wheel motors must also be integrated with friction brakes, as proposed in [3]. By knowing the characteristics of the in-wheel engines and the hydraulic brake system, energy optimal torque distribution can be achieved as proposed by [4] and [5]. Moreover, high-efficiency regenerative braking can be implemented [6]. The capabilities of a four-wheel independently actuated (FWIA) vehicle enable novel techniques to improve safety and economy. Recently, a sliding mode control has been developed by [7] to deal with a faulty in-wheel motor by rearranging steering geometry depending on the location of the fault. Furthermore, the steer-by-wire steering system failures can be handled more effectively in an FWIA vehicle by using differential drive-assisted steering, as presented in [8]. The performance degradation of both the steering system and the in-wheel motors were addressed in a more general manner in [9]. The aim of the paper [10] was to design a trajectory and velocity tracking reconfiguration control method for FWIA vehicle, in which both types of actuator failures and cornering resistance minimization are handled simultaneously in order to enhance the economic performance of the vehicle. The novelty of the proposed method in this paper lies in the high-level linear parameter varying (LPV) control reconfiguration strategy based on the specific design of weighting functions' handling actuator selection. The method enables the vehicle to dynamically modify the prescribed control values best suited for the actual vehicle state and the corresponding priority regarding safety and economy. The paper is organized as follows: Section 1 introduces the vehicle model used for the control of the FWIA bus. Section 2 presents the control design found on an LPV framework and the structure of the fault tolerant and energy efficient control reconfiguration. Section 3 defines the allocation of the high-level control signals based on vehicle dynamics. Section 4 demonstrates the effect of the introduced method in a software-in-the-loop (SIL) simulation environment. Finally, some concluding statements are listed in Section 5. *Corr. Author's Address: Budapest University of Technology and Economics Department of Control for Transportation and Vehicle Systems, H-1111 2. Stoczek street, Budapest, Hungary, mihaly.andras@mail.bme.hu 35 Strajniski vestnik - Journal of Mechanical Engineering 63(2017)1, 35-44 1 CONTROL-ORIENTED MODEL OF THE BUS The goal of the design is to ensure trajectory and velocity tracking for the FWIA bus, taking longitudinal and lateral dynamics into account while neglecting the vertical behaviour of the bus. Thus, for the modelling of the FWIA bus dynamics, the well-known two-wheeled bicycle model is used, see Fig. 1. Fig. 1. Single track bicycle model The motion equations in the planar plane can be written as follows: Jy = IF - l2 Fyr + Mz , m£(Y + 0) = Ff + Fyr, (1) m k = Fi - Fd, where m is the bus mass, J is the yaw inertia, Ff = cxax and Fyr = c2a2 are the lateral tyre forces on the front and rear axle, c1 and c2 are the tyres' cornering stiffness. The distances measured from the centre of gravity to the front and rear axles are denoted by l1 and l2. The side slip angles of the front and rear wheels are ax= S - p -ylx / i and a2 = -p +yl2 / £ . The yaw rate of the bus is denoted with , the bus side-slip angle is ft and £ is the longitudinal displacement of the FWIA bus. The high-level control inputs of the bus are the longitudinal force noted with Fb the yaw moment Mz generated by torque vectoring, and the steering angle 8 of the front wheels. The disturbance force Fd contains the drag, rolling and road slope disturbances: F = Fdl + Fd2 + Fd3. Here, the aerodynamic drag is a function of the drag coefficient cw, the air density Paero, the frontal area size AF and the velocity of the bus: Fd1 = 0.5cwpaeroAF^2. The rolling resistance force depends on vehicle mass m, rolling resistance coefficient f and road slope angle 6: Fd2 = mgf cosd , where g is the gravitational constant. Finally, the road slope disturbance is calculated as: Fd 3 = mg sin0. Since the nonlinearity of the system described by the differential equations of Eq. (1) is caused by the velocity | of the bus, choosing it as a scheduling variable p1= | the nonlinear model is rewritten as an LPV model. Note that another scheduling variable p2 is also introduced responsible for the high-level control allocation between steering and yaw moment generation. The main goal of the proposed method presented in the paper is to determine the value of P2 in such way that the energy efficiency and safety of the FWIA bus can be guaranteed. Thus, a real-time calculation is carried out to define p2 z and ps2 related to safety and p2e related to energy efficiency, while simple decision logic sets the value of P2 considering priorities. The state-space representation of the LPV model can be written as follows: x = A(p1) x + B1w + B2u , (2) where the state vector x = % y contains the bus velocity, the displacement, the yaw rate and the side-slip angle. Note that the input vector u = [[ 5 Mz ]r contains the high-level control inputs, the output vector y = |contains the measured velocity and the yaw rate, while the disturbance vector is w = \Fd ] . 2 DESIGN OF ENERGY OPTIMAL AND FAULT TOLERANT CONTROLLER For the nonlinear model of the FWIA bus, a gain scheduling LPV controller is necessary to guarantee a global solution. The reference signals for the bus to follow are the reference velocity and the yaw rate. The former is set by the driver, while the latter is also given by the driver steering intervention 8d as follows [11]: yref = d ■ e~"T ■8d, where t is the time constant, d is a parameter depending on the bus geometry and velocity. With £,ref denoting the reference velocity set by the driver, the two signals are put in a reference vector R = [^ref yref ]T. Thus, the control task is to follow the signals given in vector R, for which two optimization criteria must be satisfied at the same time. Both the velocity error ^ =1 Lf - i 1 and yaw rate error Zf = \ Vref \ must be minimized with the consideration of the optimization criterion z^^ 0 and zw ^ 0 . These are represented with the performance vector Z = |z^ Zy J , while the limitation of the control inputs connected to the physical set-up of the in-wheel 36 Mihäly, A. - Gäspär, P. - Nemeth, B. Strajniski vestnik - Journal of Mechanical Engineering 63(2017)1, 35-44 motors and steering system are defined by a second performance vector z2 = [[ S Mz ]r . 2.1 High-Level Controller Design The proposed high-level controller is based on the closed-loop P-K-A architecture, as depicted in Fig. 2. Here, P is the augmented plant in which uncertainties given by A are taken into consideration and K is the controller. The design is based on selecting relevant weighting functions representing control objectives, disturbances, and sensor noises. Weighting functions Wp ensure the accommodation of performances defined in zj, serving as penalty functions. Disturbances and sensor noises are considered with Ww and Wn, while the neglected dynamics of the bus are represented by Wu. The focus of the paper is connected to the weighting function Wa, responsible for the control reconfiguration between actuators. The goal of the design is to ensure an optimal split between steering and torque vectoring for the bus, considering both the efficiency and safety of the FWIA bus. These criteria are realized by the scheduling parameter p2 e [0.01,1], which holds for the scaling of the actuators. Thus, the weighting function of the steering WaS = (Smax%l)/(p2) and the differential torque generation WaMz = (p2)/ (Mzmax%2) are dependent on p2, with dmax and Mzmax representing the maximal steering angle and yaw moment, X\ and x2 are design parameters tuned to achieve an appropriate control reallocation. Fig. 2. Closed-loop structure The consideration of safety and efficiency described later in Section 2.2 and Section 2.3 are implemented by the defining the value of p2 based on the calculated parameters p2 z, p2 and p2e. The minimization task for the LPV performance problem already described in [12] is written as follows: infsup sup K peFpHj*0,weL2 H| \\z\ 12 H| 12 (3) The goal of the design is to select a parameter-varying controller in order to guarantee quadratic stability, while the induced L2 norm from the disturbance w to the performances z remains smaller than y. The LPV control synthesis is detailed in [13]. 2.2 Consideration of Fault Events and Wheel Slip The reconfiguration method in the case of a faulty in-wheel electric motor or the skidding of one of the wheel is based on the specific property of the in-wheel motor construction. The fast and accurate torque generation of the electric motors and the direct link to the wheels enables a precise estimation of the transmitted longitudinal wheel forces for each wheel of the FWIA bus. For this purpose, the wheel dynamics must be considered, given as follows: J.xb.- = Tmo'°r - R fF '1'1 '1 eff i] (4) where Jh i e [ f = front, r = rear] j e [L = left, R = right] is the wheel inertia, d>is the measured angular acceleration, Reff is the effective rolling radius of the wheels, Tj""or is the torque produced by the in-wheel engines, which can be measured. Thus, assuming no wheel slip the transmitted longitudinal drive or brake force Flfam can be calculated. When longitudinal wheel slip X occurs, the friction force F*am can still be estimated as described in [14] by considering the relation of the friction coefficient and wheel slip ^ -X given by the Pacejka Magic Formula, see [15]. Thus, by using the estimated transmitted torque of each wheel T^ = R.effF'tjans and assuming a small steering angle S of the front wheels the transmitted yaw moment of the in-wheel bus can be given as follows: rptrc trans _ f M where T*ans = -T'/ram ■ J JL b R tr f + Tr b eff rp trans -l/R R (5) eff -V -VL 1 -VR are the transmitted torque at the front and rear concerning M*am, moreover, bf and br are the front and rear track. Hence, the relation of the desired yaw moment given by the high-level controller Mz and the achieved Robust Fault-Tolerant Control of In-Wheel Driven Bus with Cornering Energy Minimization 37 Strajniski vestnik - Journal of Mechanical Engineering 63(2017)1, 35-44 yaw moment M'2mm of the FWIA bus serves as the indicator for the bus dynamic state related to the trajectory-tracking task. For example, when the transmitted yaw moment M'zram becomes significantly smaller than the prescribed value Mz , the bus is skidding, or an internal failure has occurred in one of the electric motors. Thus, the cornering manoeuvre can only be evaluated by using more steering and less yaw moment; therefore, the negative effect of a wheel slip or motor failure can be eliminated. Hence, one of the aims of the reconfiguration presented in the paper is to reallocate the high-level control signals in such cases, by introducing the variable p^2 as follows: P2 M - M Mz (6) Accordingly, if the bus can transmit the prescribed yaw moment during a cornering manoeuvre, the value of p^ z remains small and the value of p2 responsible for the high-level control allocation is that set by the result of the energy optimization method detailed later in Section 2.3 or the value of ps2 due to a steering system failure. In the case of a faulty electric motor or wheel slip due to critical bus dynamics, the value of p2 z increases and the energy optimal split between steering and yaw moment generation is overwritten by the safety critical distribution with altering the value of p2 to be equal with p^2 . Thus, with modification of the weighting function Wa of the LPV controller, steering intervention becomes more pronounced to overcome the effect of lateral dynamic performance degradation due to faulty electric motor or wheel spin. Fault-tolerant control methods for steer-by-wire steering systems have already been presented by researchers. Although faulty steering occurs rarely in comparison to the performance degradation or wheel slip related to the in-wheel motors, this present paper also deals with such event to guarantee bus stability. Here, the aim of the fault tolerant design is to substitute the effect of the steering in case of a fault event by reconfiguring the high-level controller, with which additional differential torque is generated by the in-wheel motors. The fault of the steering is assumed to be detected by FDI, as proposed by [16]. When the fault is detected, the scheduling variable p\ = 0 is applied overwriting the value of the actual p2. Thus, weighting function Wa of the LPV controller is modified in such a way, that the highlevel controller prescribes solely yaw moment signal for the FWIA bus. Thus, in the case of a steering system failure, the cornering manoeuvres are evaluated using only the precise torque vectoring ability of the in-wheel bus. 2.3 Consideration of Cornering Resistance The efficiency of the FWIA bus can be enhanced by optimizing the high-level control inputs of the bus, i.e. the steering angle 8 and yaw moment Mz. The aim of this procedure is to minimize cornering forces, i.e. the longitudinal disturbances affecting the bus related to the cornering manoeuvre. Using the two-wheeled bicycle model, the cornering force Fc is calculated, omitting forces related to the drag, road slope and rolling resistance of the wheels as follows: Fc = 2Fyf sin(aj +5) + 2F sin(a2). (7) Thus, during a cornering manoeuvre the power loss of the bus related to the cornering is P = F£ + . Assuming no energy recuperation, the cornering energy of the FWIA bus can simply be calculated. Using small angle approximation sin(aj) ~ a1 and sin(a2) ~ a2, the following formula can be derived: P = (2clal(a +5) + 2c2(a2)2)% + Mzy . Ignoring af and a22 given their small values, the power loss related to cornering can finally be expressed as follows, see [17]: P =(2c1a1S)i+ Mzy. (8) Note that in the calculation of the power loss al= 8 - ft -ylj i need to be known. This requires the knowledge of the bus side slip angle p, which can be estimated with different methods, as proposed by [18]. The role of the control allocation in the power loss due to cornering is well represented, as the power loss is a function of several bus dynamic states and the values of the control inputs 8 and Mz. Thus, the objective of the cornering resistance minimization task is to create an optimal steering angle 8e and yaw-moment Mez, with which the power loss expressed in Eq. (8) can be minimized. Note, that the total yaw moment induced by the steering intervention and differential torque generation must be unchanged. Thus, using the torque Eq. (1) and assuming the steady state of the bus dynamic parameters (P, and |), the following constraint can be defined: (c1l1Se + Mez) - (c1l18 + Mz) = 0. (9) Since the steer-by-wire steering system has constructional limitations Smin 1 where s is a scaled value based on the ratio of Mez and Me. The value of p2e thus represents the energy optimal control allocation, by which the weighting function Wa is set in such way that the LPV controller prescribes a steering angle and yaw moment that minimizes the power loss P = (2c1a1S)i^ + M\(r related to the cornering manoeuvre. However, in safety critical situations due to the failure of an in-wheel electric motor, wheel slip, or steering system failure, the reconfiguration is based on the variables p2 z and p\ . The strategy of the hierarchical control along with the scheduling variable selection will be presented in the following section. 3 IMPLEMENTATION OF THE CONTROL SYSTEM The energy optimal and fault tolerant reconfigurable controller design of the in-wheel bus is implemented in a hierarchical structure. The multi-layer layout of the proposed control scheme is shown in Fig. 3. In the first layer, the high-level LPV controller calculates the inputs of the FWIA bus based on the driver reference signals, the measured bus signals regarding the velocity and yaw rate and the value of scheduling variable p2. Note that p2 is derived from the energy optimal and fault-tolerant methods. For this purpose, a decision logic has been created with giving priority to the safety of the in-wheel bus. Hence, p2 is defined as follows: Fig. 3. Hierarchical structure of the reconfigurable control system Robust Fault-Tolerant Control of In-Wheel Driven Bus with Cornering Energy Minimization 39 Strajniski vestnik - Journal of Mechanical Engineering 63(2017)1, 35-44 P2 ' p2, if p2> p2z and p2 = 1 P2 z, Pp, if pi -10 -15 ! _ ! ■i ! A i / 7 --- _........ _ \ \ Y / — In-wheel fault ---No fault 50 a) 100 150 200 Distance [m] 250 300 b) c) Distance [ Fig. 11. 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