Development of a Multi-Component Wheel Force Transducer - A Tool to Support Vehicle Design and Validation

The design and validation process of a new car requires detailed knowledge of the interaction of dynamic forces and moments introduced into the rotating wheel. These forces are measured under operating conditions with appropriate sensors and transducers. Due to the effects of the dynamic masses, the loads should be sensed as close to the tire/road interface as possible using a wheel load transducer. Currently, existing transducers are quite heavy, not very accurate and elaborate calibrations and computations have to be performed. With the newly developed VEhicle LOad Sensor (VELOS), these deficiencies are overcome. Examples of dynamic force and moment calibrations with the original tire are presented, as well as road load data acquisitions comparing results from the VELOS with those of the axle transducers on a passenger car under different driving maneuvers. The effect of the location of the sensor in the suspension system is demonstrated for driving over an obstacle and a rough road. Finally, the application of the VELOS during highly sophisticated road load simulation tests to prove the fatigue life of components and complete vehicles is presented and discussed.