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Need for Advanced Suspension Systems

Suspension systems have significantly contributed to vehicles safety as well as in the enhancement of its life span. A good suspension system protects vehicle from undue wear & tear, which in turn increases the life-span of the vehicle. In this context, vehicles application is very useful for providing its availability. Moreover, it proactively plays an active part in rendering comfort to vehicle occupants. In modern times, the significance of suspension systems is much valued than it was decades ago. Today, the manufacturers have certainly prioritized incorporating advanced suspension systems in its vehicles, in order to render controllability, stability and many other component attributes onto its vehicle occupants. Also, patenting of its suspension system design is carried out by certain vehicle makers. Future trends of advanced suspension systems could be reflected from representative patents and innovations in the arena of suspension systems.

Achieving State of Art Suspension systems Driving comfort and safety is one of the functionalities of vehicle suspension system. A good suspension system is the efficient carrier of the vehicle body or its framework, so as to proportionately distribute all forces between the road and the vehicle body. In order for the suspension system to suit any driving conditions, introduction of active and semi-active components is mandatory. Fixed setups of suspension should be technically enhanced by making alterations in variable shock absorber or springs so attached to it. For instilling efficacy in vehicle suspension systems, the control behavior of its components ought to be studied. Also, adapting to certain parameters in relevance to driving excitations must be understood. It is equally pertinent to identify as well as detect if any faulty components persist, in order to accommodate design of suspension system. As

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any discussions on suspension systems brings forth the essence of driving safety and driving comfort, it would be optimal to elaborate these two widely used terms.

Driving Safety It is meant to signify an optimal suspension design with harmonious combination of springing, braking, and steering as well as wheel suspension. A quantitative value of safety can be evaluated by variation in Tire load indication.

Driving Comfort A quantitative value of Driving comfort can be evaluated by cars quantity for motion and vibration of its body. Moreover, in determining Driving comfort level of any suspension system, it is optimal to keep the external values such as climate conditions, external noises and vibrations to lowest possible limit, so as to effect an optimal evaluation of its quantitative value.

The following depict key pointers so as to achieve optimal performance from suspension systems:

1) It is essential to decrease the frequency sensitive to human body by decreasing sprung mass peak to near 1 Hz. while attempting to isolate the sprung mass from other road disturbances. In doing so, suspension system can achieve greater scalability in the ride quality.

2) For improving stability of the ride, it would be optimal to decrease resonance frequency of the wheel to around 10 Hz., while essentially keeping the contact between the road and the tire intact.

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3) A larger deflection in suspension can be sought by using road disturbances to effect sprung mass to isolate better in relevance to a suspension spring.

4) It is necessary to note that unnecessary suspension deflections, if prevented with appropriate damping, could enable achieve better road contact.

5) Driving stability and quality thus demand criteria which are pretty conflicting to each other. It is suggested that for any set of data input in specific stress and road conditions, comfort and safety will always be compromised where the passive suspension system is fixed

6) It is also suggested that active or semi-active suspension systems strive to lessen the conflict.

7) Semi-active suspension systems are based on the theory of meeting the actual demands by making stiffness of spring and/or damping adapting to them

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8) However, the mechanism of active suspension system requires an addition or input of extra force to the already existing passive systems. Thus, active suspension system is based on mechanism of addition, rather than adaptation unlike semi-active suspension systems.

9) Any unnecessary loss in performance of active or semi-active suspension can be prevented by taking changes in parameters such as wear & tear, temperature, variation in certain other external factors, during process of designing controller for the aforesaid suspensions. This can also be prevented by adapting a robust controller by which changes in system behavior could be controlled by its signals

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Ensuring safety through the concept of Brake-friendly Suspension Controllable suspension and advanced brake control systems are incorporated in most of the vehicles in higher segments. Semi-active dampers are the chosen controllable suspension systems for these purpose. The switching between emergency modes and normal operative is the presumption in active safety chain for effectuating real integration of suspension controls. The comfort objectives shall be the parameters considered to control vehicle suspension in operative mode. The application of specialized optimized algorithms has to be considered for control of suspension in emergency mode. Advanced algorithms which have ability to trace the full potential of vehicle controllable suspension will be used for manoeuvres as emergency braking.

Concept of Brake-Friendly Suspension Emergency braking manoeuvre includes Tires which play intermediary or as a interface between the road and the vehicle. The nonlinear attribute of the coupling dictates its dependence on varied parameters. The vertical load Fz and the longitudinal slip : = (Fz,), which carries the coefficient between tire and a given road, causes fluctuation in vertical tire to have influence on breaking distance. The extension of stopping distance arises as a result of nonlinearity from the oscillations of vertical force. In the case where braking is completely interrupted, the decrease in scenario of losing contact between tire and road is effectuated by controlled suspension. ABS algorithms depict these undesirable situations in worst scenarios. That the vehicle has not braked during the interval of losing and gaining contact, is the direct consequence of ABS algorithm and its sampling.

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The mere tradeoff between comfort and road handling are satisfied by current vehicle suspension designs. Active and Semi-active systems are suggested to increase performance in suspension systems, considering that passive suspension design has been almost pushed to its limits. Semi-active systems propose the use of fail-safe and low energy demands. Certain undesirable vibrations and shortening of braking distance can be suppressed by optimization of braking manoeuvre and with the aid of efficiently controlled vehicle suspension system. This is what brakefriendly suspension can mean to be, so achieved by eradicating the vertical forces of fluctuation between road and tire. This objective has to be achieved in order to ensure safety via advanced suspension systems.

Global Trend towards vehicle weight reduction The EU regulatory authorities have proposed that 2020 vehicle manufacturing targets fulfil requirement of having lighter cars. The regulatory authorities have endorsed one of the technical requirement of 2020 fleet of passenger cars would be to have emissions of not more than 95g CO2/km. This restriction in carbon emission would in fact set trend for every manufacturer indirectly lower the weight of the car.

Manufacturers have adhered to the proposed regulatory requirement by bringing innovative tools to effect weight reduction in cars. In the process of doing this, CFRP structures are going to replace metal structural components in cars seating arrangement, thereby effecting 20% reduction in weight via polyamide structures used in seats. Moreover, plastic and certain other materials which are suggested to replace PU foams will further reduce weight in overall seating. Along with innovative materials, the market is pampered with innovative designs such as TU Delft and BMW massage system in order to adhere with weight reduction requirement.

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With European commission striving to make Europe a zero carbon society by 2050, vehicle manufacturers will have to adhere to certain stringent regulatory targets, which in fact would enable production of lighter cars by using innovative materials and design. This is sure to benefit the consumers who will get the best of both the worlds - Quality and Performance.

Determinants of Advanced Suspension systems Vehicle manufacturers are constantly striving new ways to quench their customer needs in advanced suspension systems, by optimizing manufacturing standards and improve applications of manufacture. In fact, the type of suspension to be used on vehicle will be decided by the application of the vehicle. Moreover, whether suspension would be a spring or an air will be determined by different performance metrics, roll stability and durability aspects as well.

Although application of vehicle is one of the determinants in choosing suspension system, it is unanimously agreed that the key determinant of suspension system is their ability to handle pressures of different environment. For e.g. spring suspensions are optimal for highway trailer but could be not so useful on a BMW. Different company manufacturers think of different priorities in manufacture of advanced suspension systems. For some it is still the old process manufacturing suspensions that is important, so long as the suspensions are proven to fulfil their customer needs. While for some others, the manufacturing line focuses on productivity and zero maintenance to its end users. Such manufacturers make suspensions which offer its customers minimal initial investment and almost negligible long term maintenance. Yet for some others, it is the type of suspension which makes important part of its customers choice. For instance, certain manufacturers thrive on manufacturing Air suspensions on the basis of it comprising

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of air systems which along with air bags can be susceptible to break downs. Air suspensions are termed essentially to be highway applications, which are appropriate for fast cars to render comfort to its passengers and drivers preferring high speed dynamics from suspension. Moreover, irrespective of whatever the chassis load is, Air suspension with its optimized spring rate assists vehicle optimally on on-highway trail. However, for vehicles that have high center of gravity and which are more or less of off-road nature, Air suspension may not suffice.

Certain manufacturers prefer manufacturing suspensions that would enable eliminate the need of certain other components within suspension systems. For e.g. the mechanics involved in spring suspensions, eradicate the necessity for shock absorbers via process of self-damping. Moreover, these suspensions maintain a constant spring rate. Irrespective whether the vehicle is loaded or not, the spring rate will be constant. However, for some spring suspensions lack good roll stability attributes for enabling a free flowing smooth ride. The maintaining of constant spring rate is not always good as this attribute of spring suspensions causes an uncomfortable or stiff ride for operators. Therefore to overcome this problem its manufacturers have introduced rubber spring suspensions. As these provide highly variable spring rate, the ride provided by them is better than the ordinary spring suspensions.

Lighter weight suspensions Suspension companies are now optimizing their product line by introduction of lighter weight suspension systems. For doing this, the use of higher strength steel is made. Higher strength steel enables the same durability and desired carrying capacity from manufactured suspension systems. In fact the use of higher strength steel saves the company of the amount of steel being used in suspensions

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manufacture, thus aiding in reducing the manufacturing costs. This innovative technique is used for manufacturing lighter weight suspension springs as well as the frame. The weight of suspensions can also be reduced by using rubber spring technology. In fact, the rubber springs weigh much less, although they have the endurance to carry the same weight as higher steel suspensions. While a rubber spring weighs less than 900 lbs., a steel spring could weigh between 1200 to 1400 lbs. Reduction in suspension weight can be also effected by post vulcanized bonding process as well. The PV bonding process eradicates the need for clamps or bolts, thereby causing in overall reduction of suspension weight.

Future trends in Suspension systems Suspension design will continue to face optimization and innovation from manufacturers. For e.g. efforts taken by manufacturers to reduce weight is due to benefits derived from weight reduction as well as compliance with regulatory authorities. Likewise, suspension systems will continue to face investigations for entry of new technologies or to aid existing technologies enables other process applications. As aforesaid, advanced suspension systems does not necessarily mean new innovative technologies or its applications, but also mean to perceive what the manufacturers or the end users perceive it to be. However, it is essential to find the right suspension for particular applications enable its function rather than searching for a new technology suspension system without reference to vehicle application or its end user. It will although be optimal for a manufacturer to produce suspension system providing safety, comfort, durability, with minimum costs and weight.

---------------------------------------------------------------------------------------------------------------------------IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de

References: http://www.carbibles.com/suspension_bible.html www.frost.com www.benthamscience.com http://autoshepherd.com/category/Steering-Suspension/1072

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---------------------------------------------------------------------------------------------------------------------------IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de

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