Browse Publications Technical Papers 2020-01-0991

Composite Suspension Leaf Springs: The Smart Solution 2020-01-0991

2020 SAE Congress - Technical Paper Abstract "Smart Solutions for Electric Vehicle Suspensions" Session: Steering, Chassis and Suspension Authors: Peter Kuhn, SGL Technologies GmbH, Meitingen, Germany William D. Pinch, SGL Technologies LLC, Charlotte, NC USA Abstract: Battery Electric Vehicles (BEVs) Programs are becoming the vehicle of choice globally. This is driven by heightened vehicle emissions requirements and improved fuel economy performance. Vehicle requirements will be rolled down to Subsystems and Components. Subsystem requirements will be divided into upper and lower control planes with Kinematic performance targets discussed. Various types of front and rear suspensions will be identified and analyzed including MacPherson & Chapman Strut, Short-Long Arm (SLA), and various Multi-link arrangements. At the component level the use of innovative, lightweight composite materials provides a significant advantage. Besides ensuring technical feasibility, implementation on high volume production vehicles is essential for competing with aluminum and steel materials. Within suspension, Carbon Fiber Reinforced Polymer (CFRP) suspension links as well as lateral and longitudinal leaf springs made from Glass Fiber Reinforced Polymer (GFRP) materials are capable solutions. In addition, the low mass offered by composite materials contributes to improved Vehicle handling and ride. Based on the experience of the successful development and series manufacturing of the lateral leaf springs for the Volvo Scalable Product Architecture (SPA) platform, the paper will discuss recent developments in composite leaf springs: • Design for a progressive longitudinal leaf spring made more efficient by eliminating multiple steel leaves in favor of a much more efficient single-leaf structure in GFRP • Holistic approach of GFRP leaf spring development process focusing on material characterization, simulation, manufacturing and component testing • Adjustable Height Suspension with a simple, low mass & cost mechanization Innovation Value The presentation will give a detailed look at evolving EV architectures including new and innovative solutions at the Vehicle, Subsystem and Component levels. Ground breaking applications in component design using composite materials will be highlighted as optimized and tailored solutions for Electric Vehicles. Peter Kuhn William D. Pinch SGL Technologies LLC (313) 648-7816 September 2, 2019


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