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Springs
Support the weight of the vehicle, maintain ride height, and absorb road shock bounce : vertical movement of suspension jounce : compression, upward movement rebounce : extension, downward movement The spring bounces at its natural frequency. Sprung Mass : Mass carried by the spring, like the vehicle body, transmission, frame Unsprung Mass : Mass that is not carried by the springs, like the tyre, wheels.
TYPES OF SPRINGS
COIL SPRINGS
LEAF SPRINGS
TORSION BAR
AIR SPRINGS
Coil springs
Diameter and length determine whether the spring is strong or flexible No inter-leaf friction therefore smoother ride Variable rate achieved by varying
Materials of different thickness Progressive winding of the spring
Leaf springs
Multi leaf
Stacked steel plates of different lengths Spring compress to absorb road shocks Leaf springs bend and slide for suspension movement
Mono leaf
Tapered leaf spring- thick in middle and tapers toward sides Composite material
Mounting configuration
Longitudinally in pairs Single traverse mounted leaf spring
Torsion Bar
Torsion bar straight or L-shaped bar of spring steel Torsion bar twists to provide suspension Mounting configuration
Longitudinally mounted solidly to the frame at one end and other end to the moving part of the suspension Traverse mounting possible.
Air springs
Air spring is a rubber cylinder filled with compressed air Movement of the piston attached to lower control arm affects the air compression to provide the spring action On board compressor provides air through a valve at the top of air bag Valve opens to add or release air according to the load requirements Most popular on passenger cars, buses, and heavy trucks
Turns K.E thermal/ heat and dissipates though hydraulic fluid Located in pressure tube and at the end of suspension which forces the fluid in to the piston of shock absorber Has a piston with orifices to control flow of hydraulic fluid Resistance to the flow depends on:
Number and size of orifices Speed of movement of the suspension
Types of damping
Viscous Coulomb Structural
Viscous damping
Fd
Damping force linearly dependent on velocity Pure viscous damping force is an ellipse w.r.t displacement
x
With the spring force added, the Damping force is inclined forming a hysteresis. Fd = cwx
Coulomb Damping
Fd
Damping force dependent on direction of velocity Pure coulomb damping force is a rectangle w.r.t displacement
x
Struts
Second job:
Structural support support the spring hold tire in aligned position Bear side load placed on suspension Affect riding comfort, steering, braking, wheel alignment and wear on suspension
Suspension types
Ability of opposite wheels to move independent of each other Dependent Independent Semi dependent
Dependent: A live axle holding both wheels parallel to each other and perpendicular to the axle Change in Camber of one will affect the same in other Independent: Not connected at all or connected through universal joints with a swing axle Allows wheels to rise and fall without affecting opposite wheels Anti roll bars are classified as independent Semi-dependent: Swing axle is used, but the wheels are also connected with a solid tube deDion axle
Ride Control
Objectives of a suspension steering stability good handling Maximize passenger comfort Limits of vibration Exposure Limit Fatigue Reduced comfort boundaries Design aspects Vibration isolation Suspension travel Road Holding
Ride Control
Vibration isolation
Response of sprung mass to the excitation from the ground Judicious selection of damping required for control over the natural frequency of sprung mass and ride comfort
Suspension travel
The deflection of the suspension spring or the relative motion between the sprung and the unsprung mass
Road Holding
Vibration effects normal load acting b/w the tire & road In turn effects the cornering force, tractive effort and the braking force developed by the tire
Evolution
Fixed suspensions Leaf spring suspensions Christie suspension: coil springs inside armor hull and bell crank Horstmann suspension combination of bell crank and exterior coil springs Torsion bar suspension Hydro-pneumatic suspension
Hydro-pneumatic suspension
Advantages:
Progressive spring rate
softer rate around the static position and a stiffer rate near full deflection
Totally independent System is external more space inside the vehicle Better cross-country performance Sensitive equipment subjected to lower acceleration levels Reduced shock loads vary the gas pressures of each unit
Variants:
Hydro strut Hydrogas Tandem hydro strut for torsion suspension Variable damper & spring
Static Test
Load at Rebound,
Load, Tons
Dynamic Test
250 100 mm, 0.8 Hz
Displacement, mm
Temperature, C
120 100 80 60 40 20 0 0
60
120
180
240
300
Time, min
Germany
Leopard 2 55.15 t 7x7 Torsion bar suspension and advanced friction dampers Torsion bar& hydraulic shock absorbers Torsion bar & hydraulic shock absorbers Torsion bar
40t
7x7
Leopard2 MBT
42.2t
7x7
30.5
6x6
India
Vijayanta: 40,4tonnes and 6x 6 configuration with torsion bar suspension Indian production of Vickers MBT, UK
CI Ajeya: 43.5 tonnes and 6x 6 configuration with torsion bar suspension Indian production and upgraded T-72M1
India
Arjun: Combat weight of 58.5 tonnes Hydro- mechanical Suspension . 7 x7 road wheel configuration
Ex-tank: Combat Weight 47tonnes has Suspension type Torsion bar with Hydrogas struts. Indian production of T-72M1 series tank chassis fitted with the complete turret of the Arjun MBT
Israel
60 t
6x6
Horstmann suspension with helical spring concentric coil springs and have a hydraulic rotary damper
63t
6x6
MK4 Merkava
65t
6x6
United Kingdom
Challenger 1 MBT weighs around 62 t and has hydro pneumatic suspension The In-arm suspension is for high-performance system with minimal space claim and weight Vickers MBT MK1weighs around 38.6tonnes and MK3 weighs around 38.7 tonnes have six road wheels on each side with torsion bar suspension
United Kingdom
Hydro strut are used in Centurion, M109, and Cheiftian
Khalid MBT weighs 58 tonnes has hydro pneumatic suspension with 6 road wheels on each side
United States
The suspension systems of M48, M60 and centurion and T-series are being retrofitted with in-arm suspensions developed by Textron Marine called 14k, 10k and 6k systems (In-arm suspension)
M1A2 Abrams with combat weight of 63,086 kg has advanced torsion bar suspension
Russian federation
T-72 S MBT
46.5 t
6x6
torsion bar suspensions with hydraulic rotary shock absorbers torsion bar suspension torsion bar suspension &hydraulic shock absorbers
42.5 t 46 t 46.5 t
6x6 6x6
BAE Systems Land Systems OMC (previously Reumech Ermetek) of South Africa and Horstmann Defense Systems of the UK teamed to develop, as a private venture, the Adaptive Damping System (ADS).
In-arm suspension
A compact light weight design to meet the requirements of air portable tracked vehicles
Options for in-arm suspension include variable height , Adaptive damping system, and suspension lockout as well as the development of super light weight with extensive use of titanium.
sensor
Sprung mass
Variable Damper
Un-sprung mass
sensor
Sprung mass
Force actuator
sensor
Un-sprung mass
high
high High
Variable damping
Electro-rheological fluid
mixture of dielectric base oil and fine semi conducting particles Its resistance to flow is related to the electric voltage across it
Magneto-rheological fluid
smart material --mixing fine particles in a fluid of low viscosity The particles form into fibrous chain like structures in the presence of a magnetic field
MR Damper
MR Fluid MR valve
Accumulator
The fluid must pass through the MR valve for flow MR valve is a fixed size orifice with the ability to apply a magnetic field results in an apparent change in viscosity of the MR fluid Imparts pressure differential for the flow of fluid proportional to the flow required to move the damper rod. The accumulator is used to avoid cavitation in the low pressure side of the MR valve
Control strategies
The Conventional PID Optimum Control And Ricatti Equation Predictive Control Robust Control / L1-Optimal Control Skyhook Damping Control
Setting parameter: Relative velocity (Rv) b/w sprung mass and unsprung mass Rv is in the direction of absolute velocity of sprung mass damping is set to maximum Robust and simple
Penalty function J = (XT Q X + UT R U) dt Objective function is linear quadratic Ricatti solution X = AX +B An optimum control strategy is one that minimizes the following:
rms value of the sprung mass acceleration the rms value of the suspension travel the rms value of the dynamic tyre deflection
Predictive Control
Input obtained by solving an open-loop optimal control problem over a fixed prediction horizon into the future Applied input is determined online at the recalculation instant Implemented until new measurements become available As applied input is based on an optimal control problem, it is possible to take specifications into account
for plants with parametric or dynamic uncertainties time-invariant and time-varying controllers Norm-based optimization is used to address robustness and performance issues of the control system Criteria: H, H2 and in particular the L1 norms, as well as multi-objective synthesis problems
Csky
An optimum control strategy, followed for suspension control problems The damper is considered to be positioned such as to connect its one end to the sprung mass and the other end to an inertial reference in the sky, instead of the unsprung mass.
Base wheel
Specimen
Filter
Accumulator
Control Room
Actuator
Controllers
Vertical actuator
300mm stroke Load: 25T dynamic, 50 t static Frequency: 0.1 Hz/ 250mm, 0.8 Hz/ 100mm
Measurements:
Load cell Pressure: 0-1000 bar Surface temperatures: 0-200C
Test specifications
Test Cycle 1 Cycle 2 Frequency (Hz) 0.1 0.8 Amplitude (mm) 200 100
Conclusion
State of the art is the passive type, hydropneumatic suspension, for the AFV Current research actively pursued on semi-active and active suspension Korea, USA. etc., are ready to field AFV with semiactive Hybrid (passive suspension for some stations and other with active suspension/semi-active) is the next option CVRDE fully prepared to take up development of semi-active suspensions for AFVs