Volvo GTT Brake Simulation Tool : Virtual vehicle using data driven approach for rapid testing

Abstract: The project has been conducted in collaboration with the company Volvo Group Truck Technology and deals with the area of ​​brake development. The purpose of this thesis is to develop a simulation tool to perform rapid testing of the brake system.  The brake system is introduced, where an explanation of what the brake systems role is in the vehicle and which kinds of brakes can be found in commercial trucks. Different trucks depend on different braking systems, a truck doing long-hauls will have different braking needs than a worksite transporter. It is important to have a customizable tool to be able to cover the different truck braking systems.   Simulations cannot replicate reality perfectly; the results will always deviate from the actual value. There are countless of variables that can affect the braking torque, everything from mechanical efficiency to weather conditions. It is important to set limitations and boundaries for the tool.  Four different methods have been used to develop the simulation tool. MATLAB pulls information from component test data stored in Excel sheets, then inserts it into the block diagram calculations in Simulink where the model has been created using a data driven method with a physics base. The tool has also been validated compared to component performance data and old truck dynamometer tests.   The project presents how the development cost can be reduced by using the simulation tool instead of traditional testing. A simulation can be done in one minute, as opposed to the 14 days it takes to perform a physical test, this means that decisions can be taken quicker with minimal resource investments. The virtual vehicle customization is also presented, where the user can choose which specific components to test. Making the tool useful for different braking scenarios and different truck setups.