Electrification and control of a 1:5 scale vehicle for automotive testing methodologies

The design and testing of innovative components and control logics for future vehicular platform represents a challenging task in the automotive field. The use of scale model vehicles constitutes an interesting alternative for testing assessment by decreasing time and cost efforts with a potential benefit in terms of safety.The target of this research work is the development of a customized scale vehicle platform for verifying and validating innovative control strategies in safe conditions and with cost reduction. Consequently, the electrification of a radio-controlled 1:5 scale vehicle is carried out and a customized remote real-time controller is installed onboard. One of the main features of this commercial product is its modular characteristics that allows the modification of some component properties, such as the viscous coefficient of the shock absorbers, the stiffness of the springs and the suspension geometry. The original vehicle is equipped with a 2-stroke internal combustion engine, whose throttle command is provided by a common radio transceiver/receiver unit. The original configuration is commonly adopted for radio-controlled race car competitions, but the presence of a noisy combustion engine is not well suited for implementing a precise and accurate control logic based on onboard sensor measurements; hence, the conversion into an electric vehicle represents the adopted solution in this research activity.In particular, the electrification process accounts for the replacement of the internal combustion engine and fuel tank with a brushless DC motor, a battery pack, and a planetary gearbox. CAD tools are exploited for the selection of the replacement components and the design of the mounting systems. Additionally, a Speedgoat Baseline Real-Time Target Machine is installed for implementing the customized control logic, developed in MATLAB/Simulink environment, for controlling the traction electric motor and the steering servomotor.After a preliminary bench testing phase, a remote control is implemented for the validation of the system through maneuvers typically carried out for vehicle handling analysis.