Magnetic bearings have recently begun to be employed in rotating machinery for vibration reduction, elimination of oil lubrication problems and prevention of failures. This thesis presents an analysis and design of an experimental model of a magnetic suspension system. The magnetic bearing, its control circuit and the supported object are modeled. Formulas are developed for the position and current stiffness of the bearing and the analogy with a mechanical system is shown. The transfer function is obtained for the control and experimental results are presented for the double pole one axis magnetic support system. / Applied Science, Faculty of / Electrical and Computer Engineering, Department of / Graduate

A racing vehicle suspension system is a kinematic linkage that supports the vehicle under complex loading scenarios. The suspension also defines the handling characteristics of the vehicle. Understanding the loads that the suspension carries in a variety of loading scenarios is necessary in order to properly design a safe and effective suspension system. In the past, the Formula SAE team at Virginia Tech has used simplified calculations to determine the loads expected in the suspension members. This approach involves several large assumptions. These assumptions have been used for years and the justification for them has been lost. The goal of this research is to determine the validity of each of the assumptions made in the method used for calculating the vehicle suspension loads by hand. These assumptions include modeling the suspension as pinned-pinned truss members to prevent bending, neglecting any steering angle input to the suspension, and neglecting vertical articulation of the system. This thesis presents an approach to modeling the suspension member loads by creating a finite element (FE) model of the entire suspension system. The first stage of this research covers the validation of the current calculation methods. The FE model will replicate the suspension with all of the current assumptions and the member loads will be compared to the hand calculations. This truss-element-based FE model resulted in member loads identical to the hand calculations. The next stage of the FE model development converts the truss model to beam elements. This step is performed to determine if the assumption that bending loads are insignificant is a valid approach to calculating member loads. In addition to changing the elements used from truss to beam element, the suspension linkage was adapted to more accurately model the methods by which each member is attached to the others. This involves welding the members of each control arm together at the outboard point as well as creating a simplified version of the pull rod mounting bracket on the upper control arm. The pull rod is the member that connects the ride spring, damper, and anti-roll bar to the wheel assembly and had previously been mounted on the upright. This model reveals reduced axial components of load but increases in bending moments sizable enough to reduce the resistance to buckling of any member in compression. The third stage of model development incorporates the steer angle that must be present in loading scenarios that involve some level of cornering. An analysis of the vehicle trajectory that includes the effects of slip angle is presented and used to determine the most likely steer angle the vehicle will experience under cornering. The FE model was adapted to include the movement of the steering linkage caused by driver input. This movement changes the angle of the upright and steering linkage as well as the angle at which wheel loads are applied to the suspension. This model results in a dramatic change in member loads for loading cases that involve a component of steering input. Finally, the FE model was further enhanced to account for vertical movement of the suspension as allowed by the spring and damper assembly. The quasi-static loading scenarios are used to determine any member loading change due to vertical movement. The FE model is also used to predict the amount of vertical movement expected at the wheel center. This data can be used by the suspension designer to determine if changes to the spring rate or anti-roll bar stiffness will result in a more desirable amount of wheel movement for a given loading condition. This model shows that there is no change in the member loads due to the vertical movement of the wheel. This thesis concludes by presenting the most important changes that must occur in member load calculations to determine the proper suspension loading under a variety of loading scenarios. Finally, a discussion of future research is offered including the importance of each area in determining suspension loads and recommendations on how to perform this research. / Master of Science

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.

A need for a cost effective, versatile and easy to use suspension component testing method has arisen, following the development of a four-state hydro-pneumatic semi-active spring-damper system. A method known as hardware-in-the-loop (HiL) was investigated, in particular its use and compatibility with tests involving physical systems – previously HiL was used predominantly for Electronic Control Unit (ECU) testing. The suitability of HiL in the development of advanced suspension systems and their control systems, during which various vehicle models can be used, was determined. A first step in vehicle suspension design is estimating a desired spring and damper characteristic, and verifying that characteristic using software simulation. The models used during this step are usually low-order, simple models, which hampers quick development progress. To predict vehicle response before vehicle prototype completion, many researchers have attempted to use complex and advanced damper models to simulate the vehicle’s dynamics, but these models all suffer from some drawback – it is either based on empirical data, giving no indication of the physical parameters of the design sought; it may be overly complex, having many parameters and thus rendering software impractical; or it may be quick but based on the premise that there is no hysteresis in the damping character. It can be seen that an obvious answer exists – use a physical commercially available or prototype damper in the software simulation instead of the mathematical model. In this way the suspension deflection, i.e. the true motion of the damper is used as excitation, and the true damper force is measured using a hydraulic actuator and load cell. The vehicle mass motions are simulated in a software environment. This is basically what HiL simulation does. The HiL method was verified by comparing HiL simulations and tests to globally accepted testing methods, employing widely-used vehicle models: linear single-degree-of-freedom (SDOF) and two-degrees-of-freedom (2DOF) or quarter-car models were used. The HiL method was also compared to a non-linear physical system to verify that the method holds for real vehicle suspension geometries. This meant that HiL had to perform adequately at both ends of the suspension-testing spectrum – base software and real system simulation. The comparison of the HiL and software/real system simulation was done using the “Error Coefficient of Variance” (ECOV) between the compared signals; this quantitative measure proved very sensitive and performed dubiously in the presence of signal offsets, phase lags and scaling errors, but remains a tangible, measurable parameter with which to compare signals. Visual confirmation was also obtained to back the ECOV values. It was found that even using a relatively low-force actuator, the HiL simulation results followed the software/real system responses well. Phase lags and DC offsets in the HiL simulation’s measured signals (as well as the real systems responses) has an adverse effect on the performance of the HiL simulation. Special attention must thus be paid to the zeroing of equipment and the amount/type of filters in the system, as these affect the HiL results dramatically. In all, HiL was proven to be a versatile and easy to use alternative to conventional mass-based suspension testing. / Dissertation (MEng (Mechanical Engineering))--University of Pretoria, 2006. / Mechanical and Aeronautical Engineering / unrestricted

Additive manufacturing (AM), also known as 3D printing, has emerged as a rapidly growing manufacturing technique with numerous advantages over traditional methods. This thesis project investigates the application of AM in suspension design. The aim is to explore the advantages of AM, suitable product selection, and the potential for gaining a competitive edge by leveraging AM effectively. Through this research, a printable part specifically designed for AM will be developed. The project's results demonstrate the advantages of AM when the technique is harnessed effectively. Merely switching manufacturing techniques without considering AM's value-added aspects is unlikely to yield the desired benefits. However, designing components with AM in mind from the initial stages can unlock numerous advantages. The findings of this thesis project contribute to understanding how AM can be leveraged to optimize mountain bike suspensions. By evaluating the advantages and disadvantages of the designed parts, valuable insights are provided for Öhlins and the wider biking industry. This knowledge enables informed decision-making for strategic integration of AM in future product development and manufacturing processes. This research underscores the significance of thoughtful design considerations and effective integration of AM to harness its full potential in enhancing the performance, cost-efficiency, and functionality of mountain bike suspension. / Additiv tillverkning (AM), även känt som 3D-printning, har framträtt som en snabbt växande tillverkningsteknik med flertalet fördelar gentemot traditionell tillverkningsteknik. Detta examensarbete undersöker tillämpningen av AM inom design av stötdämparsystem. Målet är att utforska fördelarna med AM, lämpligt urval av produkter samt potentialen att få en konkurrensfördel genom att effektivt utnyttja AM.  Genom denna forskning blir en printbar produkt framtagen speciellt designad för AM. Projektets resultat demonstrerar sedan fördelarna med AM när tekniken utnyttjas på ett effektivt sätt. Genom att endast byta tillverkningsmetod utan att ta i beaktning de värdeskapande delar AM erbjuder är produkten osannolik att kunna dra nytta av de önskade fördelarna. Om produkten designas med AM från ett tidigt stadie kan detta bredda vägen för utnyttjandet av de flertalet fördelar som kommer med AM.  Resultaten av detta examensarbete bidrar till djupare förståelse om hur AM kan utnyttjas för att optimera en mountainbikes stötdämpare. Genom att utvärdera för- och nackdelar av de designade delarna förseddes Öhlins och även den bredare cykelindustrin med värdefull insikt. Denna kunskap möjliggör för framtida informerade strategiska beslut i hur produktutveckling och tillverkningsprocesser ska tillämpas.  Denna forskning understryker betydelsen av att göra designval noggrant igenom effektiv integration av AM för att fullt utnyttja den potential och fördelarna AM kan ge för förbättrad prestanda, kosteffektivitet samt funktionalitet av stötdämparsystem för mountainbikes.

Arbetets syfte var att göra ett motiverat val av däck till bilen som KTH Formula Student planerar att utveckla till 2025. Detta gjordes genom att använda däckdata från FSAE TTC och utifrån den modellera alla däck med däckmodellen Magic Formula TNO MFTyre/MF-Swift 6.1. Denna modell innehåller variationer i däcktryck, camber och vertikal last. Därefter simulerades varvtid vid olika grenar som skidpad, autocross och endurance för att jämföra alla däcks prestanda. Dessutom kunde flera andra värden värda att jämföras beräknas utifrån däckmodellen och datan från FSAE TTC. Dessa var hållbarhet, däcktemperatur, däckens massa, sidkraftskoefficient, camberkänslighet och däckens fjäderkonstant. Alla dessa värden jämfördes till sist där varvtid och hållbarhet prioriterades. Tre däck fanns kvar i slutet vilka rekommenderades.