Boosting the development of a BEV Rear Twist Beam suspension through a pioneering approach: ADAMS Real Time on Driving simulator

Twist beam suspensions are widely utilised in passenger vehicles because of their simplicity and cost-efficiency, yet they provide engineers with a complex challenge as their performance depends entirely upon the structural properties of the beam itself. Traditional methodologies rely on the generation of Modal Neutral Files (MNF) based upon vehicle dynamics requirements and packaging constraints, which is a highly time-consuming process that starts failing to fulfil the demands of a market where development times are being exponentially reduced. Besides this, part of flexible body’s real behaviour might be lost in the process of converting multibody models into parametric ones, which, in turn, presents difficulties in modifying compliant-related items. Thanks to a novel approach followed jointly by Mahindra and IDIADA, quick identification and optimisation of key tuneable items is achieved by employing a hybrid solution that combines full flexible and FE elements in ADAMS Car. Additionally, through the integration of ADAMS Real-Time models into IDIADA’s Driving Simulator, it has been possible to capture all the behaviour of the system with a high degree of fidelity. This complete methodology was applied to the rear suspension development for an electric SUV, resulting in a remarkable 70% development time reduction from concept phase to prototype build, along with a notable performance enhancement achieved through a rapid and precise virtual tuning process, meeting all key performance target.