F2010B043
Innovative Suspension with Wheel Guiding Transverse Leaf Spring
Tightened cost targets and increased requirements for handling and ride comfort were initial reasons for creating a new and innovative suspension concept, with a higher degree of integrated functionality, for compact class vehicles such as the VW Golf, Opel Astra, Toyota Auris, among others. An attractive concept with a wheel guiding transverse leaf spring was developed based on the availability of new materials and a thorough analysis of existing suspension systems.
Functional integration is accomplished through a novel wheel guiding leaf spring made of glass fiber reinforced plastic (GRFP) that performs typical wheel control, spring and stabilizing functions. The leaf spring replaces a stabilizer bar with mounts, two stabilizer links, two control arms and two conventional coil springs, respectively. Through specific dimensioning of the leaf spring cross-section and placement of the mounts, required properties such as precise wheel control, as well as desired parallel and opposite spring rates can be met.
A hybrid multi-body model (i.e. a multi-body model with integrated finite element components) was developed to investigate kinematics, elasto-kinematics, load cases and full vehicle characteristics. Special care was taken with the nonlinear finite element implementation of the composite leaf spring because of elasto-kinematic effects of the part. Parallel to the simulations, the concept was designed as digital mock-up for packaging and clearance analysis. All components were optimized with regard to stiffness and strength and paying consideration to manufacturability as well as costs. After successful design completion, the rear suspension was prototyped and prepared for physical testing on a kinematic and compliance test rig to validate the suspension targets. Subsequent to the K&C test, durability and vehicle tests were also performed to prove the potential of the innovative suspension system.
The concept fulfils the requirements and demonstrates additional advantages, such as: - Economy facilitated by the integration of functionality correlated with substitution of parts - Weight reduction through functional integration and innovative materials - Optimized packaging as a result of part reduction - Higher damping achieved by the use of composite leaf spring versus a steel leaf spring
This abstract is supplemented by a PDF, which can be viewed here.