Design and Development of Suspension Test rig

1. INTRODUCTION

The main functions of an automotive suspension system are to provide vehicle support,
stability and directional control during handling maneuvers and to provide effective isolation
from road disturbance. These different tasks result in conflicting design requirements.
Directional control and stability requires a suspension that is neither very stiff nor very soft.
Insensitivity to external loads requires a stiff suspension, whereas good ride comfort demands
a soft suspension. In a conventional passive suspension system, the designer is faced with the
problem of choosing the suspension stiffness and damping parameters, which inevitably
involves a difficult compromise in view of the wide range of conditions over which a vehicle
operates.

Ride and handling performances of a vehicle suspension system often present engineers
conflicting design goals. For decades, engineers have studied active control for vehicle
suspension systems to resolve this conflict. The intent of the system is to replace the classical
passive elements by a controlled system that can supply unlimited force to the system. This
type of active suspension system has proven capable of achieving improvement over passive
systems The different methods of measurement of vibrations in cars is studying the dynamics
of motions, preparing the state space equations, conversion of acceleration inputs in velocity
and displacement and analyze the frequency response in graphical form and also simulating
the system using the matlab software. Measurement of tire dynamics, degrees of freedom of
the suspension components such as Mcpherson strut, control rods, lower arm, upright, car
body frame. A car suspension system is the mechanism that physically separates the car body
from the wheels of the car. The performance of the
uspension system has been greatly increased due to increasing vehicle capabilities. Various
performance characteristics to be considered in order to achieve a goodsuspension system.
Suspension consists of the system of springs, shock absorbers a nd linkages that connects a
vehicle to its wheels. In other meaning, suspension system is a mechanism that physically
separates the car body from the car wheel. The main function of vehicle suspension system is
to minimize the vertical acceleration transmitted to the passenger which directly provides road
comfort

Any suspension system has the ability to store, dissipate and to introduce energy to the
system. It may vary its parameters depending upon operating conditions. There are three types

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of suspension system; passive, semi-active and active suspension system. Traditional

suspension consists springs and dampers are referred to as passive suspension, then if the
suspension is externally controlled it is known as a semi active or active suspension.

The passive suspension system is an open loop control system. It only designs to achieve
certain condition only. The characteristic of passive suspension are fix and cannot be adjusted
by any mechanical part. Therefore, the performance of the passivesuspension depends on the
road profile. In other way, active suspension can gave better performance of suspension by
having force actuator,which is a close loop control system. The force actuator is a mechanical
part that added inside the system that control by thecontroller. Controller will calculate either
add or dissipate energy from the system, from the help of sensors as an input. Sensors will
give the data of road profile to the controller.

1.1. OBJECTIVE

Currently, the desired functions of a quarter-car rig include the ability to mountseveral
different designs of actual car suspensions, having the ability to perform a wide range of tests,
which include body loads on the sprung mass.

The objective for this work is to study and develop a test facility that can improve the state -
of-the-art in indoor vehicle suspension simulation testing on a quarter-car vehicle.
•The objective is to design and develop a quarter car suspension test rig model and to perform
its simulation.In summary, a new quarter-car test rig has been designed and built. In an
attempt to prove the concept, a well known control scheme, not currently used for this
application, is applied to the problem of replicating vehicle response signals. Finally the
comparison of both analytical simulation and experimental results was done.

The primary objective of this project is to create a state-of-the-art shock absorber test rig that
can simulate real-world conditions and provide comprehensive data on the performance of
shock absorbers. The specific goals include:
 Enhancing the accuracy and repeatability of shock absorber testing.
 Expanding the range of testing parameters and conditions.
 Improving data acquisition and analysis capabilities.
 Reducing testing time and human intervention.

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1.2. METHODOLOGY

To achieve these tasks the following approach is taken. Current quarter-car test rigsand the
state of indoor testing in general are first evaluated. The approach is to develop a quarter-car
test rig that addresses many of the shortcomings found with the state-ofthe-art while trying to
minimize expense. Before this with known data the analytical simulation is carried out on
Matlab and t he results were recorded. Then comparison is to be done with the actual test
results.

Since the days of horse-drawn spring carriages people have strived for making rides
comfortable by isolating the car body from road irregularities. Today's "carriage" isolation
could consist of passive and/or active spring and dashpot elements. The aim is to study linear
spring-dashpot road vehicle suspension system with respect to ride comfort.
The suspension of a two-degree-of-freedom (2-DOF) vehicle traveling on a road surface is
studied and is simulated with respect to test rig design.
In the proposed work, a 2-DOF linear quarter car is modeled to carry out computer
simulations. During simulations, a vehicle is assumed to run at certain speed while it hits a
step or a p othole or a bump or a random road profile defined by PSD(Power Spectral Density
Vehicle response corresponding to above mentioned road disturbances is obtained for ride
quality and comfort.

Quarter Car suspension system is modeled and simulated for above mentioned road
disturbances to analyze performance

The work involves –

•Study of suspension systems.

•Modeling of a vehicle suspension system – A linear quarter car model. K

•Deriving the equations for the quarter car model and formulation of Transfer Function and
State Space equations for vehicle suspension system.

•Mathematical modeling for the actuator system.

•Simulation of suspension system using road surface disturbances as input at the tire to
analyze the vehicle performance.

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•Repeating the simulations over wide range of road surfaces and vehicle speeds and analyzing
the performance of the vehicle in terms of Body Displacement, Body Vertical acceleration ,
Suspension working Space or Rattle Space, Controller Force, etc
•Mechanical Design and Development of a Quarter Car Test Rig.
•Simulation of a Quarter Car Test Rig.

•Design, Implementation and Simulation of Suspension System on a Quarter Car Test Rig.

•Validation of simulation and Quarter Car Test Rig results.

1.3. Suspension System

An automobile suspension system is a crucial component that plays a key role in providing a
comfortable and stable ride for vehicles. It is designed to absorb shocks and vibrations from
the road surface, ensuring that the tires maintain contact with the road while minimizing the
impact on the vehicle and its occupants.

Fig.1.1. Automobile Suspension System

1.3.1. The primary functions of an automobile suspension system include:

1.3.1.1. Shock Absorption:

The suspension system absorbs and dampens the impact of irregularities on the road, such as
bumps, potholes, and uneven surfaces. This helps to provide a smoother and more controlled
ride.

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1.3.1.2. Vehicle Stability:

The suspension system contributes to the stability of the vehicle by minimizing body roll
during cornering, ensuring that the tires maintain optimal contact with the road. This enhances
overall handling and maneuverability.

1.3.1.3. Tire Traction:

By maintaining consistent contact between the tires and the road, the suspension system plays
a crucial role in maximizing tire traction. This is essential for effective braking, acceleration,
and overall vehicle control.

1.3.1.4. Comfort:

A well-designed suspension system enhances ride comfort by isolating the vehicle occupants
from harsh vibrations and jolts. This is achieved through the use of various components that
work together to absorb and dissipate energy.

1.3.2. Key components of an automobile suspension system.

1.3.2.1. Springs:

These are responsible for supporting the weight of the vehicle and absorbing shocks. Common
types of springs include coil springs and leaf springs.

Fig.1.2. Suspension Coil Spring

1.3.2.2. Dampers (Shock Absorbers):

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Dampers control the motion of the springs by absorbing and dissipating kinetic energy. They
help prevent the vehicle from bouncing excessively after encountering a bump.

Fig.1.3. Damper

1.3.2.3. Anti-roll Bars:

These components help reduce body roll during cornering, enhancing the stability and
handling of the vehicle.

Fig.1.4. Suspension anti-roll Bar

1.3.2.4. Suspension Linkages:

Control arms, bushings, and other linkages connect various parts of the suspension system,
allowing for controlled movement and flexibility. Modern vehicles often feature advanced
suspension systems with electronic components, such as adaptive damping systems and air
suspension, to further enhance performance and adjust to varying driving conditions. In
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summary, the automobile suspension system is a critical aspect of vehicle design, contributing
to ride comfort, stability, and overall safety by managing the interaction between the vehicle
and the road surface.

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2. LITERATURE REVIEW

Anil Shirahatt[1] studied a suitable optimizing technique is applied at design stage to obtain
the suspension parameters of a passive suspension and active suspension for a passenger car
which satisfies the performance as per ISO 2631 standards. A number of objectives such as
maximum bouncing acceleration of sprung mass, root mean square (RMS) weighted
acceleration of seat and sprung mass as per ISO 2631 standards, jerk, suspension travel, road
holding and tyre deflection are minimized subjected to a number of constraints. The vertical
weighted RMS acceleration of seat and sprung mass is reduced from 0.3032 m/s2 to 0.0534
m/s2 and 0.2834 m/s2 to 0.0492 m/s2.While searching, space of the parameters is very large,
the solution space is very tight due to the presence of various constraints. Therefore, the
constrained optimization problem is converted into unconstrained one.

Faheem[2] investigates the responses of the quarter car and a half car model as the vehicle
ride performance is generally assessed at the design stage by simulating the vehicle response
to road excitation. His paper provides an insight on the suspension dynamics of the two most
extensively used models in vehicle dynamics with their complete state space realisation
simulated using the Matlab platform. Quarter and Half car models can successfully be used to
analyse the suspension system responses to road inputs but accuracy of the results obtained
will depend on how accurately and effectively the system parameters have been measured (Eg.
sprung mass, unsprung mass, stiffness and damping). Using the models analyzed in this work,
the system responses with different road excit ations can be obtained. With different set of
sprung mass, unsprung and stiffness etc, the suitable damping value can be obtained.

L.J. Zhang[4] analysed a time domain method for solving non-stationary random vibration
caused by vehicle acceleration in which time changing model is established for representing
nonstationary excitation of road. Furthermore a novel frequency domain method called the
transient power spectral density with spatial frequency (TPSD) is presented to obtain response
of vehicle s ystem in frequency domain. This method has been proved to be valid by
comparing numerical results with exact solution.The computational results in time domain
shows that amplitudes of vibration caused by vehicle accelerating with high acceleration are

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smaller than that with low acceleration. The conclusion can be drawn that higher the driver
accelerate the car, the better is the car performance.

Keum-Shik Hong[5] investigated a new model and an optimal pole-placement control for the
Macpherson suspension system. The focus in this new modelling is the rotational motion of
the unsprung mass. The two generalized coordinates selected in this new model are the
vertical displacement of the sprung mass and the angular displacement of the control arm. The
vertical acceleration of the sprung mass is measured, while the angular displacement of the
control arm is estimated for active and semi-active suspension. By changing the length of the
control arm, it is possible to design a wide range of plant models. When the active control law
was applied to the semi-active damper, a small degradation in the vertical acceleration of the
sprung mass was noticed.

S.H.Sawant[6] developed quarter car vehicle model for analysis of vibrational effect when it is
subjected to harmonic excitation by road profile. For this analysis experimental setup for
Hyundai Elantra 1992 front suspension is developed and harmonic road excitations are given
to this with eccentric cam and displacement results are obtained with FFT analyzer. These
results are compared with analytical and Matlab Simulink results.From the results and
discussions it is concluded that there is very less difference between theoretical and Matlab
simulink results, and which may be due to truncation. But there is large difference between
experimental and theoretical or experimental and Matlab simulink results, which may be due
to non linearities in suspension parameters. Therefore it is very much essential to consider the
non linearites in suspension parameters at the time of modelling of vehicle dynamic system for
its vibration analysis.

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3. SUSPENSION TESTING

Automobile suspension testing involves evaluating the performance and characteristics of a

vehicle's suspension system under various conditions to ensure optimal functionality, safety,
and comfort. This testing process is crucial during the development and design phases of a
vehicle, as well as for quality control in manufacturing. Different types of tests are conducted
to assess various aspects of the suspension system:

3.1. Types of Suspension Testing

3.1.1. Ride Comfort Testing:

This involves evaluating how well the suspension system absorbs shocks and vibrations from
the road, providing a comfortable ride for the vehicle occupants. Test engineers use equipment
to simulate different road conditions and measure the response of the suspension system.

3.1.2. Handling and Stability Testing:

These tests assess how the suspension system contributes to the vehicle's stability and
handling characteristics. Dynamic tests, such as slalom tests and skidpad tests, may be
conducted to evaluate how the vehicle responds to steering inputs and maneuvers.

3.1.3. Durability Testing:

This involves subjecting the suspension system to prolonged stress and strain to ensure it can
withstand the rigors of everyday use over an extended period. This may include testing for
durability under various road conditions and over a specified number of miles or kilometers.

3.1.4. Shock Absorber Testing:

Shock absorbers (dampers) play a critical role in the suspension system. Testing may involve
assessing their ability to absorb and dissipate energy effectively. This can include bench
testing, where individual shock absorbers are subjected to controlled conditions, as well as on-
vehicle testing.

3.1.5. Load-Carrying Capacity Testing:

This evaluates how well the suspension system supports the vehicle's weight and handles
varying loads. This is particularly important for different vehicle configurations, such as

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when the vehicle is carrying passengers or cargo.

3.1.6. Noise, Vibration, and Harshness (NVH) Testing:

NVH testing assesses how well the suspension system isolates the vehicle occupants from
unwanted noise, vibrations, and harshness. Engineers use sensors and instruments to measure
and analyze vibrations and acoustics under different driving conditions.

3.1.7. Tire Traction and Alignment Testing:

These tests evaluate how the suspension system contributes to maintaining proper tire traction
and alignment. Misalignment or uneven tire wear can result from issues with the suspension
geometry.

3.1.8. Environmental Testing:

Suspension systems are exposed to various environmental conditions, including temperature

extremes, humidity, and corrosive substances. Testing may involve subjecting components to
environmental chambers or real-world conditions to assess their resistance to wear and
deterioration.

Testing can be conducted using physical prototypes, computer simulations, and a combination
of both. Advanced testing facilities and equipment, such as shaker rigs, test tracks, and
simulation software, are employed to comprehensively evaluate the performance of
automobile suspension systems. The goal is to ensure that the suspension system meets design
specifications, regulatory standards, and provides a safe and comfortable driving experience.

3.2. Suspension Testing Machine

Automobile suspension testing machines are specialized equipment designed to evaluate

the performance and characteristics of a vehicle's suspension system under controlled
conditions. These machines play a crucial role in the development, research, and quality
control of suspension components and systems. Various types of testing machines are used
to simulate different aspects of a vehicle's suspension behavior. Here are some common
types:

3.2.1. Types of Suspension Testing Machine .

3.2.1.1. Shaker Rigs:

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Shaker rigs are dynamic testing machines that simulate road conditionsby subjecting the
vehicle or suspension components to controlled vibrations and forces. This type of testing
helps assess the durability, fatigue resistance, and performance of the suspension system under
various frequencies and amplitudes.

3.2.1.2. Damper (Shock Absorber) Testing Machines:

These machines are specifically designed to test the performance of shock absorbers or
dampers. They can simulate compression and rebound cycles to evaluate how well the shock
absorbers absorb and dissipate energy. Damper testing machines help manufacturers ensure
that these components provide consistent and effective damping over time.

3.2.1.3. Suspension Geometry Testers:

These machines assess the geometry and alignment of the suspension system. They measure
parameters such as camber, caster, toe, and other alignment angles to ensure that the
suspension components are correctly positioned. Proper alignment is essential for vehicle
stability, tire wear, and overall handling.

3.2.1.4. Durability Testing Machines:

Durability testing machines simulate real-world driving conditions to assess the long-term
reliability and endurance of suspension components. These machines subject the suspension
system to repetitive movements, vibrations, and loads to replicate the wear and tear
experienced during the vehicle's lifespan.

3.2.1.5. Tire Testing Machines:

While not strictly focused on suspension, tire testing machines play a role in evaluating how
well the suspension system maintains proper tire traction and influences tire performance.
These machines can simulate different road surfaces, speeds, and loads to assess tire behavior.

3.2.1.6. Hydraulic and Pneumatic Testers:

Some testing machines use hydraulic or pneumatic systems to apply controlled forces to
suspension components. These systems allow for precise testing of components under various
conditions, helping engineers understand how different factors affect performance.

3.2.1.7. Component Test Benches:

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These benches are used to test individual suspension components such as springs, control
arms, and bushings. They simulate the forces and movements these components experience in
real-world driving scenarios, allowing manufacturers to assess their strength, durability, and
performance.

Testing machines contribute significantly to the development of high-quality suspension

systems by providing engineers with controlled environments to assess performance, identify
weaknesses, and optimize designs. They help ensure that suspension systems meet safety
standards, provide comfort, and deliver the desired handling characteristics.

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4. DESIGN OF SUSPENSION TESTRIG

Designing a suspension testing machine involves a systematic procedure to ensure that the
machine effectively evaluates the performance and characteristics of a vehicle's suspension
system. Below is a general design procedure for a suspension testing machine:

Fig.4.1. Suspension Testing Machine

4.1. Functional requirement of system

4.1.1. Dynamic Testing:

Simulate different driving conditions, including bumps, potholes, and turns, to evaluate the
suspension system's response.

4.1.2. Load Application:

Apply controlled loads to simulate the weight of the vehicle and various loading conditions.

4.1.3. Vibration and Frequency Control:

Provide the capability to control the frequency and amplitude of vibrations to simulate
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different road surfaces.

4.1.4. Steering and Handling Tests (optional):

Include features to simulate steering inputs and assess handling characteristics.

4.2. Design

4.2.1. Determine Load Requirements:

Understanding the maximum forces and loads the testing machine will need to withstand. This
includes the forces exerted by the shock absorber during testing and the weight of any
additional components, such as the test rig or actuators.

4.2.2. Select Materials:

Choosing materials for the structural components of the testing machine based on the load
requirements and durability considerations.

Common materials for structural elements include high-strength steel or aluminum alloys.
Ensuring that the selected materials are suitable for the anticipated loads and environmental
conditions.

4.2.3. Frame Design:

Designing the frame structure to provide stability and support for the testing machine.
Considering factors such as rigidity, stiffness, and the ability to absorb vibrations. Using
engineering principles to determine the optimal frame geometry, including the size and
placement of beams and supports.

4.2.4. Mounting Fixtures:

Designing fixtures to securely mount the shock absorbers for testing. These fixtures should be
adjustable to accommodate different sizes and types of shock absorbers. Ensuring that the
mounting system allows for easy installation and removal of test specimens.

4.2.5. Actuator Mounting:

If Electric, hydraulic or pneumatic actuators are used for dynamic testing, design mounting
points that can withstand the forces generated during operation.

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Ensuring proper alignment and stability of the actuators to maintain accurate testing
conditions.

4.2.6. Adjustability:

Incorporate features that allow for adjustability in the testing rig. This might include adjustable
mounting points, fixtures, and testing angles to accommodate various shock absorber
configurations.

4.3. Fabrication and Assembly:

Will be work with experienced fabricators to manufacture the structural components according
to the design specifications. Ensuring that the assembly process follows the design
documentation and that all components are properly aligned and secured.

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5. ADVANTAGES

Suspension testing machines offer several advantages in the development and evaluation of
vehicle suspension systems. These advantages contribute to improved performance, safety,
and comfort in automotive design. Here are some key benefits of using suspension testing
machines:

 Accurate Performance Assessment:

Suspension testing machines provide a controlled environment to accurately assess the

performance of a vehicle's suspension system. This allows engineers to understand how the
system responds to various road conditions, loads, and dynamic forces.

 Ride Comfort Optimization:

By simulating real-world driving conditions, suspension testing machines help optimize ride
comfort. Engineers can fine-tune the suspension system to minimize vibrations, jolts, and
impacts, ensuring a smoother and more comfortable ride for vehicle occupants.

 Handling and Stability Improvement:

Testing machines allow for the evaluation of handling and stability characteristics under
different scenarios. Engineers can adjust and enhance the suspension geometry and
components to improve vehicle stability, responsiveness, and overall handling performance.

 Durability Assessment:

Suspension testing machines subject the suspension system to repetitive and extreme
conditions, allowing for the evaluation of long-term durability. This helps identify potential
weaknesses and ensures that the suspension components can withstand the rigors of everyday
use.

 Load-Carrying Capacity Testing:

These machines enable the assessment of the suspension system's ability to support varying
loads, including different passenger and cargo configurations. This information is crucial for
designing suspension systems that can handle diverse driving conditions.

 Component-Specific Testing:
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Suspension testing machines allow for the testing of individual components, such as springs,
shock absorbers, and control arms. This helps manufacturers evaluate the performance of each
component and optimize their designs for maximum efficiency.

 Efficient Development Process:

By providing a controlled and repeatable testing environment, suspension testing machines

streamline the development process. Engineers can quickly iterate and refine designs, leading
to more efficient and cost-effective product development.

 Data Collection and Analysis:

These machines are equipped with data acquisition systems that collect comprehensive data
during testing. This data enables engineers to analyze the behavior of the suspension system,
identify performance trends, and make informed design decisions.

 Versatility for Various Vehicle Types:

Suspension testing machines are designed to accommodate different vehicle types and
suspension configurations. This versatility allows manufacturers to test a wide range of
vehicles, from passenger cars to trucks and SUVs.

 Compliance with Standards:

Testing machines ensure that suspension systems meet industry standards and regulatory
requirements. This is crucial for ensuring the safety and performance of vehicles in accordance
with established guidelines.

 Safety Testing:

Suspension testing machines can be used to simulate emergency braking, swerving, and other
maneuvers to evaluate the safety of the suspension system under challenging conditions. This
contributes to overall vehicle safety.

 Time and Cost Savings:

Through efficient testing and validation, suspension testing machines help save time and costs
associated with the development process. Identifying and addressing potential issues early in
the design phase reduces the need for extensive rework and expensive modifications later on.

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6. CONCLUSION

The design and development of a suspension testing machine involve a comprehensive and
systematic process aimed at creating a reliable and effective tool for evaluating the
performance of a vehicle's suspension system. This multifaceted undertaking encompasses
various engineering principles, materials science, and considerations for safety and precision.

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[6] S. H. Sawant, Mrunalinee V. Belwalkar, Manorama A. Kamble, Pushpa B. Khot & Dipali
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[8] Kiran Antony “Analysis of Passive Suspension System using Matlab, Simulink and
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[9] Kateřina Hyniova and Antonín Stribrsky and Jaroslav Honcu, “Fuzzy Control Of
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[15] kFeng Tyan and Yu-Fen Hong, Shun-Hsu Tu and Wes S. Jeng, “Generation of Random
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[17] E. J. Haug, Computer-Aided Kinematics and Dynamics of Mechanical System volume 1:

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effect of cubic damping in an automotive Vehicle suspension model.” Other References and
Books:

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[19] Erik Ryan Andersen, “Multibody Dynamics Modelling and System Identification for a
Quarter-Car Test Rig with McPherson Strut Suspension.”

[20] IS 2062, Bureau of Indian Standards, “Hot Rolled Low Medium and High Tensile
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[22] Quarter Car Suspension Model, a random source.

[23] PSG Data Book, Design Data by Mahadevan.

[24] CATIA workbench help.

[25] AutoCAD workbench help

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