Optimized design for a MacPherson strut suspension with side load springs

Undesired lateral force inevitably exists in a MacPherson suspension system, which is liable to damper rod’s side wear and promotes the damper’s inner friction decreasing the ride performance from the suspension system. Substituting a new side load spring with curved centerline for the conventional coil spring has been proven able to solve these problems and Multi-body Dynamics combining with Finite Elements Analysis may be an efficient method in optimizing its design. Therefore, taking a passenger car as example, a detailed multi-body dynamics model for the suspension system is built to simulate forces exerted on the damper and the minimization of its lateral component is selected as the design target for the spring. When the structure optimization of the side load spring is performed using FEA software ANSYS, its vertical and lateral elastic characteristics, supported by test data, are analyzed. After importing FEA results back to the suspension system, the dynamics simulation can be performed to validate the optimization result.     

麦弗逊悬架侧载螺旋弹簧优化设计

以某轿车为例,建立了麦弗逊悬架多体动力学模型,将减振器侧向力仿真结果作为侧载弹簧设计目标,应用有限元方法进行结构优化设计,并进行了试验验证。研究结果表明,采用优化设计的侧载螺旋弹簧后可显著降低悬架侧载,为悬架系统及其元件的优化提供了一种参考方法。     

A new solution for two-bag air suspension system with leaf spring for heavy-duty vehicle

The design problem of a two-bag air suspension system for heavy-duty vehicles is formulated as a two-level (suspension system level and component level) optimization problem. At the suspension system level, optimal stiffness matrix of leaf spring, characteristics of damper and upper rod layout are determined by solving a multi-objective constrained optimization problem with response surface. At the component level, shape and thickness of the leaf spring are formed using cubic-spline curves to make the stiffness matrix as close to the target values cascaded from suspension system level as possible. Simulations using a vehicle model described by multi-body model and FEM of the novel leaf spring validate the suspension system thus derived.     

Computational model for analyzing the kinematics and compliance characteristics of a commercial vehicle’s front suspension system

This paper develops a computational model that can analyze the kinematics and compliance characteristics of the front suspension of a commercial vehicle. This computational model is called the flexible multi-body dynamic model because it is developed by interfacing the finite element model of the multi-leaf spring with the dynamic model of the front suspension. In this paper, the bump mode and roll mode tests are performed with a suspension parameter measuring device (SPMD). An excitation load for creating the bump mode and roll mode motion is applied on the left and right tires slowly in in-phase and out-of-phase modes. In the test, wheel rate, toe angle change, caster angle change, and camber angle change, which together represent the wheel alignment, are measured along with the longitudinal and lateral wheel center loci which together represent the wheel center trajectory change. The reliability of the developed computational model is verified by comparing the simulation results with the SPMD test results. The developed flexible multi-body computational model will provide useful information on kinematics and compliance characteristics in the earliest stages of the commercial vehicle design process.     

Robust design optimization of suspension system by using target cascading method

This study presents the robust design optimization process of suspension system for improving vehicle dynamic performance (ride comfort, handling stability). The proposed design method is so called target cascading method where the design target of the system is cascaded from a vehicle level to a suspension system level. To formalize the proposed method in the view of design process, the design problem structure of suspension system is defined as a (hierarchical) multilevel design optimization, and the design problem for each level is solved using the robust design optimization technique based on a meta-model. Then, In order to verify the proposed design concept, it designed suspension system. For the vehicle level, 44 random variables with 3% of coefficient of variance (COV) were selected and the proposed design process solved the problem by using only 88 exact analyses that included 49 analyses for the initial meta-model and 39 analyses for SAO. For the suspension level, 54 random variables with 10% of COV were selected and the optimal designs solved the problem by using only 168 exact analyses for the front suspension system. Furthermore, 73 random variables with 10% of COV were selected and optimal designs solved the problem by using only 252 exact analyses for the rear suspension system. In order to compare the vehicle dynamic performance between the optimal design model and the initial design model, the ride comfort and the handling stability was analyzed and found to be improved by 16% and by 37%, respectively. This result proves that the suggested design method of suspension system is effective and systematic.     

Sensitivity analysis and optimisation of suspension bushing using Taguchi method and grey relational analysis

In this paper, a novel method is presented for investigating suspension bushing based on mechanical properties of the bushing, their effective directions, spring stiffness and damping coefficient of bushing. The vehicle vibration model and suspension geometry parameters are used to optimise the vehicle suspension based on multi-body dynamics simulation (ADAMS/CAR) initially. Several experiment tests based on ISO 4128 and ISO 7401 have been performed in one of main Iranian automaker (SAIPA) in order to verify the ADAMS/CAR model. The grey relational analysis based on using Taguchi L27 orthogonal array is used to obtain the optimum suspension. Then the bushing characteristics are optimised considering the indicated method. This method considers a combination of ride comfort and handling qualities of vehicle as objective functions simultaneously. The results of optimum suspension are compared with typical Renault Logan which declares the accuracy and efficiency of this method in optimising suspension bushing.     

类菱形概念车中悬架优化设计

以多刚体系统动力学理论和虚拟样机技术为基础,采用UG软件建立新概念车的中悬架刚体模型,运用机械系统动力学仿真软件ADAMS中的V iew核心模块和Insight模块对中悬架模型进行运动学分析和优化设计研究。     

Hierarchical optimisation on scissor seat suspension characteristic and structure

Scissor seat suspension has been applied widely to attenuate the cab vibrations of commercial vehicles, while its design generally needs a trade-off between the seat acceleration and suspension travel, which creates a typical optimisation issue. A complexity for this issue is that the optimal dynamics parameters are not easy to approach solutions fast and unequivocally. Hence, the hierarchical optimisation on scissor seat suspension characteristic and structure is proposed, providing a top-down methodology with the globally optimal and fast convergent solutions to compromise these design contradictions. In details, a characteristic-oriented non-parametric dynamics model of the scissor seat suspension is formulated firstly via databases, describing its vertical dynamics accurately. Then, the ideal vertical stiffness-damping characteristic is cascaded via the characteristic-oriented model, and the structure parameters are optimised in accordance with a structure-oriented multi-body dynamics model of the scissor seat suspension. Eventually, the seat effective amplitude transmissibility factor, suspension travel and the CPU time for solving are evaluated. The results show the seat suspension performance and convergent speed of the globally optimal solutions are improved well. Hence, the proposed hierarchical optimisation methodology regarding characteristic and structure of the scissor seat suspension is promising for its virtual development.     

Kineto-dynamic design optimisation for vehicle-specific seat-suspension systems

Designs and analyses of seat-suspension systems are invariably performed considering effective vertical spring rate and damping properties, while neglecting important contributions due to kinematics of the widely used cross-linkage mechanism. In this study, a kineto-dynamic model of a seat-suspension is formulated to obtain relations for effective vertical suspension stiffness and damping characteristics as functions of those of the air spring and the hydraulic damper, respectively. The proposed relations are verified through simulations of the multi-body dynamic model of the cross-linkage seat-suspension in the ADAMS platform. The validity of the kineto-dynamic model is also demonstrated through comparisons of its vibration transmission response with the experimental data. The model is used to identify optimal air spring coordinates to attain nearly constant natural frequency of the suspension, irrespective of the seated body mass and seated height. A methodology is further proposed to identify optimal damping requirements for vehicle-specific suspension designs to achieve minimal seat effective amplitude transmissibility (SEAT) and vibration dose value (VDV) considering vibration spectra of different classes of earthmoving vehicles. The shock and vibration isolation performance potentials of the optimal designs are evaluated under selected vehicle vibration superimposed with shock motions. Results show that the vehicle-specific optimal designs could provide substantial reductions in the SEAT and VDV values for the vehicle classes considered.     

基于近似模型的车辆操纵稳定性及平顺性的优化研究

简述了基于近似模型的车辆操纵稳定性及平顺性的优化设计方法.利用多体动力学软件ADAMS/Car建立了某轿车整车多体动力学模型,并确定了车辆操纵稳定性及平顺性的评价目标.以悬架弹簧刚度、减振器阻尼特性和横向稳定杆刚度为设计变量,利用近似优化数学模型对该轿车进行了操纵稳定性和行驶平顺性的多目标优化计算.结果表明,近似模型技术对于汽车性能的平衡优化是一种十分有效的方法.     

燃料电池大客车车身疲劳寿命仿真分析

应用M atlab生成路面激励载荷并检验其特性,结合整车多体动力学模型,获取车身疲劳分析的激励载荷;采用瞬态时域法计算出车身的动应力,利用MSC/Fatigue软件分析和预测燃料电池大客车车身的疲劳部位和寿命,为结构设计与修改提供参考。     

车辆操纵稳定性及平顺性的协同优化研究

利用车辆多体动力学模型与多目标优化工具,对悬架弹簧、减振器及横向稳定杆特性进行操纵稳定性与行驶平顺性的协同优化仿真.结果表明汽车的操稳性和行驶平顺性的各项性能指标均得到了改善.     

汽车悬架多刚体动力学分析及九点控制

汽车机械系统的建模、分析与求解始终是动力学的关键问题,为快速准确地求解分析,文章借助多刚体系统动力学的拉格朗日法对汽车悬架进行分析,建立了基于多刚体系统动力学的主动悬架系统模型,并采用九点控制策略进行了理论分析和计算机仿真。仿真结果表明,以多刚体动力学方法同九点控制策略相结合的汽车悬架系统性能良好。     

基于ADAMS与Matlab的ABS模糊控制仿真研究

将多体系统动力学与智能控制理论相结合对汽车制动防抱死控制系统进行了研究，利用ADAMS／CAR建立了汽车整车的多体力学模型，模型包含了前后悬架、动力总成、转向系统、稳定杆、制动系、轮胎力学模型以及车身，同时也考虑了轮胎、衬套、弹簧、减震器等部件的非线性，准确地表达了车辆的动态特性；利用Matlab／Simulink模糊控制工具箱建立了制动防抱死控制系统的模糊控制策略，利用ADAMS／Control接口进行模型的集成、协同仿真，并将仿真结果与另一种控制策略一逻辑门限值控制的仿真结果进行了比较和分析，仿真反映出模糊控制在整车制动防抱死控制系统上的应用效果，结果表明该控制算法稳定好并具有较强的鲁棒性。     

基于ADAMS的大型客车空气弹簧前悬架仿真分析与比较

利用虚拟样机技术,在ADAMS软件环境下建立了ZF、DANA和SCANIA3种大型客车空气弹簧前独立悬架的多体运动学计算模型,并进行了刚体运动学和弹性体运动学仿真分析研究。在车轮跳动条件下对这3种大型客车空气弹簧前悬架定位参数的变化规律进行了比较研究,并对后两者的前束角进行了优化设计,为同类型空气弹簧前悬架系统设计提供了参考。     

基于正交试验的虚拟样车平顺性分析及参数选择

利用多体力学理论,在机械系统动力学分析软件ADAMS中建立了某车的整车多体力学模型。将虚拟样车在三维空间道路上进行平顺性仿真试验,通过正交试验方法研究了前、后悬架弹簧刚度及相关主要衬套等性能参数对汽车行驶平顺性的影响,并根据正交试验的结果优选了相应的设计参数。     

基于ADAMS的某悬架系统运动特性分析及结构优化

根据多体动力学理论,运用ADAMS／car软件对某微型轿车悬架系统建立了模型并进行仿真分析;使用ADAMS／Insight以轮胎横向滑移量、主销偏距和四个车轮定位参数为设计目标对悬架的结构关键点进行了优化分析,使该悬架的运动学特性更符合理想设计值。     

Vibration path analysis and optimal design of the suspension for brake judder reduction

Brake judder is abnormal vibration, which is mainly generated by uneven contact between the brake disc and pad. The abnormal vibration from BTV (Brake Torque Variation) is transferred to the suspension and the steering system during braking. In this paper, judder simulation is carried out using a multi-body dynamic analysis program to analyze the relationship between judder and the transfer mechanism, which consists of the suspension and the steering system. In order to verify the analytical model, test results are compared with the simulation results. A sensitivity analysis is also carried out. In addition, an optimization method is presented for judder reduction, using the design of experiments.     

四轮转向车辆多体仿真与试验研究

以四轮转向原理样车为对象,运用多体动力学理论对四轮转向车辆的转向特性进行了计算机仿真研究和试验验证。对建立整车多体模型的方法进行了论述。通过对仿真数据与样车试验结果的对比分析,证明了四轮转向多体模型各类参数和控制方法的正确性和适用性。最后利用建立的整车多体模型,仿真分析了前后悬架刚度对操纵稳定性的影响,以及制动转向时的转向响应特性。     

基于ADAMS的空气悬架客车平顺性仿真与试验

以多体系统动力学理论为基础,应用机械系统仿真分析软件ADAMS,创建空气悬架客车前悬架、后悬架的多体系统动力学模型,包括转向系、发动机、车身、前后轮胎等在内的整车虚拟样机模型。并通过编制路面谱文件对虚拟模型进行平顺性仿真和悬挂系统固有频率仿真试验,结果显示该车的平顺性能比较理想。将仿真结果与样车道路试验结果进行对比,发现二者比较吻合,从而验证了所创建的虚拟样机模型的可靠性。研究结果表明虚拟试验可以有效地分析汽车的平顺性。