Active suspension technologies are well known for improving ride comfort and handling of ground vehicles relative to passive suspensions. They are ideally suited for mitigating single-event road obstacles. The work presented in this thesis aims to develop a structured approach for finding the peak force and bandwidth requirements of actuators for active suspensions, to mitigate single-event road obstacles. The approach is kept general to allow for application to different vehicle models, ride conditions and performance objectives. The current state-of-art in active suspensions was first evaluated. Based on these findings, the objectives of the simulation models and approach was defined. A quarter-car model was developed in Matlab to simulate the behavior of active suspensions over unilateral boundary conditions due to different road obstacle profiles. The obstacle profiles were obtained from existing standards and literature and then processed to replicate the interaction of tires on road. A least-mean-squares (LMS) algorithm for adaptive filtering, with the help of look-ahead preview was used to determine the ideal control force profile to achieve the performance objective of the active suspension. A case study was conducted to determine the requirements of the actuator in terms of bandwidth and peak force for different single-event road obstacle profiles, vehicle speeds and look-ahead preview distances. The results of the study show that the vehicle velocity and type of road obstacle have a strong influence on the required peak force and bandwidth of the actuator, while look-ahead preview will be much more important for real time controller implementation. / Master of Science

In this study a real-time open loop estimate of the disturbance displacement input to the tire and an external disturbance force, representing handling and aerodynamic forces, acting on the sprung mass of a quarter-car suspension test rig was generated. This information is intended for use in active control methods applied to vehicle suspensions. This estimate is achieved with two acceleration measurements as inputs to the estimator; one each on the sprung and unsprung masses. This method is differentiated from current disturbance accommodating control, bilinear observers, and preview control methods. A description of the quarter-car model and the experimental test rig is given. The equations of motion for the quarter-car model are derived in state space as well as a transfer function form. Several tests were run in simulation to investigate the performance of three integration techniques used in the estimator. These tests were first completed in continuous time prior to transforming to discrete time. Comparisons are made between the simulated and estimated displacement and velocity of the disturbance input to the tire and disturbance force input to the sprung mass. The simulated and estimated dynamic tire normal forces are also compared. This process was necessary to select preliminary values for the integrator transfer function to be implemented in real-time. Using the acceleration measurements from the quarter-car test rig, a quarter-car parameter optimization for use in the estimator was performed. The measured and estimated tire disturbance input, disturbance input velocity, and dynamic tire normal force signals are compared during experimental tests. The results show that the open loop observer provides estimates of the tire disturbance velocity and dynamic tire normal force with acceptable error. The results also indicate the quarter-car test rig behaves linearly within the frequency range and amplitude of the disturbance involved in this study. The resultant access to the disturbance estimate and dynamic tire force estimate in real-time enables pursuit of novel control methods applied to active vibration control of vehicle suspensions. / Master of Science

For controller design, design of experiments, and other dynamic simulation purposes there is a need to be able to predict the dynamic response and joint reaction forces of a quarter-car suspension. This need is addressed by this study through development and system identification of both a linear and a non-linear multibody dynamics McPherson strut quarter-car suspension model. Both models are developed using a method customary to multibody dynamics so that the same numerical integrator can be used to compare their respective performances. This method involves using the Lagrange multiplier form of the constrained equations of motion to assemble a set of differential algebraic equations that characterize each model's dynamic response. The response of these models to a band-limited random tire displacement time array is then simulated using a Hilber-Hughes-Taylor integrator. The models are constructed to match the dynamic response of a state-of-the-art quarter-car test rig that was designed, constructed, and installed at the Institute for Advanced Learning and Research (IALR) for the Performance Engineering Research Lab (PERL). Attached to the experimental quarter-car rig was the front left McPherson strut suspension from a 2004 Porsche 996 Grand American Cup GS Class race car. This quarter-car rig facilitated acquisition of the experimental reference data to which the simulated data is compared. After developing these models their optimal parameters are obtained by performing system identification. The performance of both models using their respective optimal parameters is presented and discussed in the context of the basic linearity of the experimental suspension. Additionally, a method for estimating the loads applied to the experimental quarter-car rig bearings is developed. Finally, conclusions and recommendations for future research and applications are presented. / Master of Science

Recently, active suspension has been applied to many commercial automobiles. To develop the control algorithm for active suspension, a quarter-car test bed was built by using a direct-drive tubular linear brushless permanent-magnet motor (LBPMM) as a force-generating component. Two accelerometers and a linear variable differential transformer (LVDT) are used in this quarter-car test bed. Three pulse-width-modulation (PWM) amplifiers supply the currents in three phases. Simulated road disturbance is generated by a rotating cam. Modified lead-lag control, linear-quadratic (LQ) servo control with a Kalman filter, and the fuzzy control methodologies were implemented for active-suspension control. In the case of fuzzy control, asymmetric membership functions were introduced. This controller could attenuate road disturbance by up to 78%. Additionally, a sliding-mode controller (SMC) is developed with a different approach from the other three control methodologies. While SMC is developed for the position control, the other three controllers are developed for the velocity control. SMC showed inferior performance due to the drawback of the implemented chattering-proof method. Both simulation and experimental results are presented to demonstrate the effectiveness of these four control methodologies.

Recently, active suspension has been applied to many commercial automobiles. To develop the control algorithm for active suspension, a quarter-car test bed was built by using a direct-drive tubular linear brushless permanent-magnet motor (LBPMM) as a force-generating component. Two accelerometers and a linear variable differential transformer (LVDT) are used in this quarter-car test bed. Three pulse-width-modulation (PWM) amplifiers supply the currents in three phases. Simulated road disturbance is generated by a rotating cam. Modified lead-lag control, linear-quadratic (LQ) servo control with a Kalman filter, and the fuzzy control methodologies were implemented for active-suspension control. In the case of fuzzy control, asymmetric membership functions were introduced. This controller could attenuate road disturbance by up to 78%. Additionally, a sliding-mode controller (SMC) is developed with a different approach from the other three control methodologies. While SMC is developed for the position control, the other three controllers are developed for the velocity control. SMC showed inferior performance due to the drawback of the implemented chattering-proof method. Both simulation and experimental results are presented to demonstrate the effectiveness of these four control methodologies.

This thesis deals with the examination of damper characteristics and influence of individual parameters on vehicle handling, primarily with the use of computer program Matlab Simulink.

The purpose of this study has two parts directed toward a common goal. First, a state-ofthe-art quarter-car test platform has been designed and constructed to offer increased testing flexibility at a reasonable cost not found commercially. With this new test rig completed, the second objective is a proof-of-concept evaluation of a well known adaptive control algorithm applied to this new quarter-car test rig for the purpose of replicating the dynamic suspension response, such as a response that was recorded during a road test. A successful application of this control algorithm on the quarter-car rig is the necessary first step toward its application on an 8-post test rig for a direct comparison to current practices. Before developing a new test rig, the current state-of-the-art in quarter-car rigs was first evaluated as well as indoor vehicle testing in general. Based on these findings, a list of desired functional requirements was defined for this new design to achieve. The new test rig was built and evaluated to determine how these goals were met and what the next steps would be to improve the rig. The study then focused on evaluating control policies used for reproducing dynamic responses on vehicle road simulators such as 4- post and 7-post shaker rigs. A least-mean squares (LMS) adaptive algorithm is introduced and applied first in software using a linear two-mass quarter-car model, and then to the actual hardware-in-the-loop quarter-car rig. The results of the study show that the resulting quarter-car test rig design is quite flexible in its ability to test a multitude of suspension designs and also its ability to accommodate new hardware in the future such as a body loaders. The study confirms that this particular implementation of the LMS algorithm is a viable option for replicating test vehicle response on an indoor quarter-car test rig. Thus, a future study to compare the use of this algorithm to the current industry standard batch processing method is possible. / Master of Science

The suspension system is one of the most sensitive systems of a vehicle as it affects the dynamic behavior of the vehicle with even minor changes. These systems are designed to carry out multiple tasks such as isolating the vehicle body from the road/tire vibrations as well as achieving desired ride and handling performance levels in both steady state and limit handling conditions. The damping coefficient of the damper plays a crucial role in determining the overall frequency response of the suspension system. Considerable research has been carried out on semi active damper systems as the damping coefficient can be varied without the system requiring significant external power giving them advantages over both passive and fully active suspension systems. Dampers behave as non-linear systems at higher frequencies and hence it has been difficult to develop accurate models for its full range of motion. This study aims to develop a velocity sensitive damper model using artificial neural networks and essentially provide a 'black-box' model which encapsulates the non-linear behavior of the damper. A feed-forward neural network was developed by testing a semi active damper on a shock dynamometer at CenTiRe for multiple frequencies and damping ratios. This data was used for supervised training of the network using MATLAB Neural Network Toolbox. The developed NN model was evaluated for its prediction accuracy. Further, the developed damper model was analyzed for feasibility of use for simulations and controls by integrating it in a Simulink based quarter car model and applying the well-known skyhook control strategy. Finally, effects on ride and handling dynamics were evaluated in Carsim by replacing the default damper model with the proposed model. It was established that this damper modeling technique can be used to help evaluate the behavior of the damper on both component as well as vehicle level without needing to develop a complex physics based model. This can be especially beneficial in the earlier stages of vehicle development. / Master of Science / The suspension system is one of the most sensitive systems of a vehicle as it affects the dynamic behavior of the vehicle with even minor changes. These systems are designed to carry out multiple tasks such as absorbing shocks from the road as well as improving the handling of the vehicle for a smoother and safer drive. The level of firmness of the shock absorber/damper plays a crucial role in determining the overall behavior of the suspension system. Considerable research has been carried out on semi active damper systems as the damper stiffness can be varied quickly and easily as compared to other passive and fully active damper systems. Dampers are complex systems to model especially for high speed operations and hence it has been difficult to develop accurate mathematical models for its full range of motion. This study aims to develop an accurate mathematical model for a semi active damper using artificial neural networks. A semi active damper was fabricated and tested on a shock dynamometer at CenTiRe for multiple speeds and stiffness values. Thistest data obtained was used for training of the mathematical model using the computer software MATLAB. The developed model was evaluated for its accuracy and further analyzed for feasibility of use in computer simulations. It was established that this damper modeling technique can be used to help evaluate the behavior of the damper with high accuracy while still running the simulations relatively quickly whereas in current simulations compromise has to be made on at least the accuracy of the model or the simulation speed. This can be especially beneficial in the earlier stages of vehicle development.

The ability of a Formula SAE sports car to negotiate a turn in a race is influenced by many parameters which include car's overall geometry, its shape, weight distribution, type of suspension used, spring and shock absorber characteristics that are used in the tire properties, static and dynamic loading. Steady-state cornering implies that the forces acting on the vehicle are unchanging for a given time. The suspension uprights form a connection between the wheel assembly and the suspension linkages. The criticality of the upright is that it is considered an un-suspended body, but in fact, it is subjected to very high stresses. The dynamic load imposed on the vehicle from various road conditions, cornering, braking and suspension assembly constraints generate stress on the upright body. The equations of motion generally govern vehicle dynamics. For a kinematic and rigid body dynamics analysis, a multibody dynamics (MBD) approach is popular. The results of the dynamic analysis yield internal loads which are used to analyze suspension components for structural stiffness and strength. Automotive companies with relatively lower structural loads have made the MBD approach popular because it is supposed to be computationally less expensive. Elastodynamics is an alternative approach to solving dynamics equations while considering the components to be elastic. This approach can capture the inertial and elastic responses of the components and the load path with varying positions of the components in a mechanism. In this research, a quarter-car suspension is modeled in a finite element code (Abaqus®), focusing on the vehicle upright but still modeling the connections and interactions of the quarter-car suspension system of a FSAE vehicle. The BEAM element modeling used for the suspension members captures the bending response. The overall model is created by making computationally conscious decisions, debugging and refining the interactions and connections to be representative. The modeling technique to create elastodynamic models is explored and established with a versatile set of suspension components and interactions providing a good experience with finite element modeling. The models are created with incremental steps and early steps are verified with hand calculations. A further vehicle verification and validation plan is the next immediate priority to gain confidence in the model for accurate simulations which can be used to predict accurate structural and dynamic results. With extending the model capabilities and computational capabilities, a quarter-car suspension model is powerful enough to run the entire track simulations for formula races and even durability load cases for commercial vehicles. Fatigue loading and abusive test cases would be the load cases to investigate possible failure modes. The quarter-car suspension model is a framework with different interactions, connections, components, boundary conditions and loads that are representative for different suspension configurations in different vehicles. The best practices of this modeling exercise are established and scalability to defeature or add details while preserving the connection behavior is achieved. / Master of Science / Automotive suspension analysis includes analysis the design of suspension components. In automotive parlance, suspension includes the wheel subassembly, brakes, tires, shock absorbers, subframes and the steering system. A quarter-car model is incorporated in this research to analyse a Formula SAE suspension. The quarter-car model is representative of relevant vehicle dynamics within the scope of this research. The suspension of the vehicle governs the “attitude” of the vehicle; it is a foundation on which the behavior of the car is built when it responds to operator wishes and terrain. Necessary but not sufficient for a great car is addressing multiple issues around strength and stiffness of the components during vehicle maneuvers. These issues are pulled against cost and packaging issues as jelly sets for engineering design with only a small number of physical iterations. Finite element analysis employs its powerful solving capabilities to run an elastodynamic simulation. The representation of the component’s elasticity yields elastic responses that can be observed and evaluated virtually for engineering design. Current state-of-the-art methods rely on rigid body analysis to develop dynamic simulations which do not show elastic response or response due to complex interactions between the components. The elastodynamic model built for this research is scalable to include detail or defeatured components without losing their interactions and connection behaviors – examples include – rod end joints, bearing interference fits and bell crank connections for a pull rod suspension. Several finite element modeling practices are established as part of this research to build a popular problem in the automotive industry – quarter-car suspension model. The elastodynamic model is verified along the journey by building simpler building-block models. Further validation of the elastodynamic model is required for complete confidence – the path to which is covered in this thesis.

This thesis deals by the design of 1/4 car model for testing vehicle dampers, which can be used to simulate the real suspension of a vehicle wheel (up to a maximum car weight of 1,970 kg) and the so-called linear wheel suspension. A linear mathematical 1/4 car model with 2 DOF (Degrees Of Freedom) and data from literature search are used to design and derive the basic parameters of the device. The thesis contains a description of the linear mathematical model and its outputs (acceleration of the sprung mass and forces acting on the sprung mass), description of designed device, descriptions of created simulations (static, modal and harmonic analysis in ANSYS Workbench 2020 R2) and conceptual design of the modifications this device for another possible use for testing of bicycles.