Axiomatic design of customizable automotive suspension systems

Abstract

The design of existing suspension systems typically involves a compromise solution for the conflicting requirements of comfort and handling. For instance, cars need a soft suspension for better comfort, whereas a stiff suspension leads to better handling. Cars need high ground clearance on rough terrain, whereas a low center of gravity (CG) height is desired for swift cornering and dynamic stability at high speeds. It is advantageous to have low damping for low force transmission to vehicle frame, whereas high damping is desired for fast decay of oscillations. To eliminate these trade-offs, a novel design for a customizable automotive suspension system with independent control of stiffness, damping and ride-height is proposed in this thesis. This system is capable of providing the desired performance depending on user preference, vehicle speed, road conditions and maneuvering inputs. The design, fabrication and control of the customizable suspension prototype are discussed. The application of variable stiffness and variable ride-height suspension system to achieve improved vehicle dynamics is studied. Application to control of vehicle dynamics parameters required bandwidth and power input beyond the capability of the first prototype.

(cont.) To eliminate the bandwidth restrictions of the prototype, a variable-stiffness pneumatic suspension system capable of instantaneous stiffness change with essentially no power input and no ride-height change, is developed. This is done by supporting the vehicle on air springs and connecting each air spring volume to multiple auxiliary volumes through On-Off valves. By adequately choosing N unequal auxiliary volumes, this system can achieve 2N stiffness settings. This suspension has been incorporated in a car suspension. The design, fabrication, and testing of the suspension system are reported in this thesis. A detailed frequency-domain model for the air-spring with auxiliary volumes is developed. Based on this modeling and testing, the performance limits and practical applicability of this system are discussed. The proposed variable stiffness isolator is capable of instantaneous stiffness change with no power input and no dimension change; moreover the isolator is inexpensive, robust and light. As a result, it is readily applicable to several other vibration isolation applications with conflicting stiffness requirements (such as a precision motion stages) or time-varying stiffness requirements (such as prosthetic limbs) and these applications are discussed.