Browse Topic: Suspension systems

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A Frequency-Aware Reinforcement Learning Framework for Suspension Control with Integrated Temporal Features and Expert Guidance2026-01-0209To be published on 04/07/2026
Active suspension systems play a crucial role in improving vehicle ride comfort and handling stability. However, most existing studies focus on the low-frequency range below 20 Hz, leaving the suppression of high-frequency vibrations within 50–500 Hz largely unexplored, even though these vibrations strongly affect in-cabin noise and ride quality. To address this gap, this study introduces a quarter-car suspension model incorporating both bushing dynamics and a rigid-ring tire within a reinforcement learning (RL) framework. A major challenge for RL-based suspension control is its degradation in high-frequency performance. To overcome this issue, we design an innovative training framework that integrates multiple synergistic strategies. First, frequency-domain rewards are incorporated as auxiliary signals to explicitly guide policy optimization in the high-frequency band. Second, long short-term memory (LSTM) networks are embedded in both the Actor and Critic to capture the sequential
zhu, Zhehui, Zhang, Lijun, Meng, Dejian, Hu, Xingyu
A Helical Compression Spring Fracture under Impact Velocity in Pump Operation by Theoretical Study and FEA2026-01-0271To be published on 04/07/2026
Helical compression springs have been used widely in various industries from automotive, aerospace and construction to electronics and medical devices. In the automotive industry, they appear in many places such as suspension, valvetrain, etc., as well in the discharge check valve of Gasoline Direct Injection (GDI) pump, which is the subject of study due to a recent fracture in lab testing. A theoretical study is conducted first to establish the equation governing spring dynamic motion under impact velocity, which can be in high magnitude with surging shock wave along spring axis. A new spring shock wave equation is developed for spring axial motion coupled with coil torsional effect. This newly derived shock wave equation has a broader term than the classic spring formula found in most engineering books. In this paper, it shows that the classic spring shock wave equation is only a special case for the general wave equation newly discovered. Then, a theoretical formula on spring shock
Pang, Michael L., Gunturu, Srinu, Norkin, Eugene
Impact of Instantaneous Center of Rotation Variability on Path Planning and Performance of Park Assist Systems2026-01-0053To be published on 04/07/2026
Parking assist systems are among the most widely adopted driver-assistance features in modern vehicles. A key component of these systems is the path planning module, which ensures accurate vehicle alignment within a parking slot while satisfying various constraints such as maintaining slot centering, avoiding collisions in confined spaces, minimizing maneuver count, and achieving the shortest feasible path. Multiple path generation techniques—such as geometric, polynomial-based, and search-based methods—have been developed to enable safe and efficient parking maneuvers. However, most of these approaches rely on the simplifying assumption that the vehicle’s instantaneous center of rotation (ICR) is fixed, typically located on the non-steering axle. In practice, the ICR is not constant and can vary significantly across vehicles due to several physical and kinematic factors, including steering geometry, tire slip characteristics, suspension configuration, and weight distribution
Awathe, Arpit, Patanwala, Abizer, Jain, Arihant, Varunjikar, Tejas
A Real-Time Capable, Three-dimensional, and Nonlinear Multibody Model of the Mercedes-Benz G-Class for an Efficient Assessment of Off-Road Performance in Early Stages of Vehicle Development2026-01-0217To be published on 04/07/2026
This article deals with the development of a real-time capable, three-dimensional model of the Mercedes-Benz G-Class with flexible ladder frame that considers nonlinear suspension kinematics and force elements. The shift to new drivetrain technologies often results in a significant increase in vehicle weight and requires corresponding design modifications – also applying to off-road vehicles. These modifications result in changed stiffness of elements such as the ladder frame or anti-roll bar, which significantly affect vehicle dynamics and off-road performance. Therefore, strategic, efficient assessments must be made in early development stages, where no detailed information about individual systems and components is available yet, to detect and avoid potential massive, costly changes in later stages. This requires a “handmade” vehicle simulation model specifically tailored to this particular application, since the use of commercial multi-purpose simulation packages is not effective
Riebler, Sandro, Pernsteiner, Samuel, Granitz, Christina, Schabauer, Martin
Modal Analysis Approach on Vehicle Transient Behavior Considering Roll and Pitch Dynamics2026-01-0210To be published on 04/07/2026
When a vehicle performs planar motion, the tire side force induces a jacking-up effect determined by the suspension roll center height governed by suspension geometry. These jacking forces also excite pitching motion. In this study, the pitching degree of freedom, along with roll degree of freedom, was incorporated in the bicycle model of the vehicle motion, hence it becomes four-degree-of-freedom model, and a new analytical method that applies modal analysis method to the model decomposes the motion of the sprung mass of the vehicle into mutually independent vibration modes. Since the superposition of these vibration modes can reproduce vehicle motion, these vibration modes are the fundamental factors governing sprung-mass behavior. Therefore, understanding how these vibration modes respond to design parameters provides a theoretical foundation to design desired vehicle dynamics from the early stage of car development. This report presents, by conducting modal analysis of the four
Kusaka, Kaoru, Yuhara, Takahiro, Koakutsu, Shingo
High Biofidelity Modification of Thoracolumbar Structure in THOR Model for Reclined Occupant2026-01-0196To be published on 04/07/2026
With the rapid development of automated driving and the increasing adoption of “zero-gravity” seats, the crash safety of highly reclined occupants has become a critical issue. The current THOR dummy, designed for frontal impacts in the standard upright posture, exhibits limitations when directly applied to reclined seating configurations, including insufficient spinal flexion capability and excessive posterior pelvic rotation. In this study, the thoracolumbar spine kinematics of the THUMS human body model, reconstructed against post-mortem human subject (PMHS) tests, were analyzed. A two-segment linear fitting was employed to characterize a “dummy-like” spinal flexion response, yielding a virtual rotational hinge located near the thoracolumbar joint of the original THOR model. The characteristic rotation angle obtained from THUMS showed a strong linear correlation with the flexion moment of the T12–L1 vertebrae. Based on this relationship, the rotational joint of the THOR dummy was
Guo, Wencheng, Kuang, Gaoyuan, Shen, Wenxuan, Tan, Puyuan, Zhou, Qing
Reliability-Based Vibration Design of Vehicle Systems with Tuned Mass Dampers (TMD)2026-01-0139To be published on 04/07/2026
Tuned Mass Dampers (TMDs) are widely used in the automotive industry to mitigate Noise, Vibration, and Harshness (NVH) issues across various vehicle systems. These passive devices are particularly effective in reducing structural vibrations in components subjected to resonant excitation. However, real-world applications often face challenges due to manufacturing variability and system-level build differences, which can cause deviations in both the TMD’s tuned frequency (up to ±15%) and the vibration characteristics of the host structure. These uncertainties—in both the TMD properties and the vehicle subsystem dynamics—can be modeled using statistical distributions. This paper presents a generalized methodology for vibration analysis and design under uncertainty, combining reliability engineering with dynamic vibration modeling. The approach formulates a unified mathematical framework that incorporates probabilistic and stochastic modeling to assess TMD performance under a range of
Abbas, Ahmad, Haider, Syed, d'Souza, Suneel
Impact of User-Adjustable Vehicle-Dynamics Tuning on Vehicle Durability2026-01-0194To be published on 04/07/2026
Software-defined vehicles offer customers a greater degree of customization of vehicle controls and driving experience. One such feature is user-adjustable tuning of vehicle ride and handling, where customers can vary ride height, damper stiffness, front-rear torque balance, and other aspects of vehicle dynamics. While promising a great customer experience, such a feature can expose the vehicle to a wider range of structural loads than those in the nominal design condition, particularly when such tuning is extended to cover spirited “sport” mode driving, off-road driving, etc. In this paper we present a novel methodology combining Road Load Data Acquisition (RLDA) data and real-world telemetry data to estimate the impact of user-adjustable vehicle-dynamics tuning on structural durability. In doing so, the method combines the physics of damage accumulation (from RLDA data) with user behavior (from telemetry data) to present an accurate assessment of the impact on durability, moving
Demiri, Albion, Ramakrishnan, Sankaran, Khapane, Prashant, Borton, Zackery, Ramakrishnan, Sankaran, Khapane, Prashant, Borton, Zackery
Target Cascading Kinematics and Compliance Tables to Suspension Design2026-01-0584To be published on 04/07/2026
During the initial design phase, automotive Original Equipment Manufacturers (OEMs) require the adaptability to examine various suspension system architectures while maintaining focus on the specific performance objectives. Those requirements are expressed by Kinematics and Compliance (K&C) look-up tables and represent the footprint of what the suspension should look like in real-world applications. However, translating those requirements into the full geometric hardpoint layout is not straightforward. This process often relies on trial-and-error approaches, making it time consuming and requiring significant expertise. This challenge, known as "target cascading," remains a major hurdle for many engineers. The main objective of this paper is to cascade the suspension requirements from K&C look-up tables to hardpoint locations by adopting an automatic workflow and ensuring respect for constructive and feasibility constraints. Design space exploration was conducted using a robust
Brigida, Piero, Di Carlo, Paolo, Di Gioia, Niccolò, Geluk, Theo, Tong, Son, Alirand, Marc, Gorgoretti, Davide, Occhineri, Marco, Tassini, Nicola, Berzi, Lorenzo
A Research on Driving Performance of Vehicle Body Control using vehicle height adjustment system2026-01-0626To be published on 04/07/2026
Recently, premium cars include a device in the suspension that can adjust the ride height. The main function of this system is to help the vehicle pass through uneven roads by keeping the vehicle body high so that the lower part of the vehicle does not contact the road surface. In particular, the device of the air spring type improves riding comfort by adjusting the vehicle's wheel rate. The proposed system was designed to adjust the ride height by adjusting the position of the spring lower seat up and down. By modeling the machinery topology of the proposed system in detail using a dynamics tool, we would like to investigate the feasibility of implementing driving performance by controlling not only the height adjustment function but also the vehicle body Posture of the vehicle during driving.
Park, Jaeyong, Sang Hoon, Lee, Jong Min, Kim, Choi, Jang Han
Design, Fabrication, and Assessment of a User-Friendly Suspension System for a 2025 BAJA Vehicle2026-01-0588To be published on 04/07/2026
A suspension system was designed, fabricated, and tested following a systems design approach by the Desert Hare Off-road Team from South Dakota State University (SDSU). Compared to previous suspensions, the new suspension system is more reparable and contains a minimal number of custom parts, while still maintaining sufficient strength to withstand dynamic loads experienced when operating the vehicle. Modifications were also made to fit the newly designed vehicle body frame. As an integral part of the team’s 2025 Baja vehicle, the redesigned suspension system contributed to the vehicle’s improved performance during the 2025 SAE (Society of Automotive Engineers) Baja Competition. This paper presents a detailed account of the design, development, and fabrication process of the suspension system. The final design was tested and evaluated via both computer simulations and physical tests, whose efficiency and reliability were finally demonstrated by the team’s improved ranking in the 2025
Liu, Yucheng, Anderson, Matthew, Larson, Cody, Rodgers, Joshua, Seberger, Aaron, Letcher, Todd
Vehicle Test Platform with Experimentally Correlated Tire Model for Torque Vectoring Control2026-01-0622To be published on 04/07/2026
This paper presents a testing platform for torque vectoring controls utilizing a 10 degree of freedom (DOF) vehicle simulation and a ⅕ scale radio control test vehicle. These vehicle simulations or “Digital Twins” have been widely adopted throughout the automotive industry for their lower operating costs and ease of implementation. Virtual models are not perfect representations of reality, however, and physical testing is still necessary to validate systems for use in the real world. This is especially true when testing safety-critical features such as Advanced Driver Assist Systems (ADAS). As a result, a simulation environment working in conjunction with a test vehicle represents an optimal hybrid approach. In this work, a 1/5 scale radio controlled vehicle with torque vectoring capability is designed and assembled. A high fidelity vehicle model is then constructed in the Matlab/Simulink environment to model test vehicle behavior. The test vehicle features independent suspension for
Petersen, Nicholas Conner, Robinette, Darrell
Modular Smart Corner Systems for Next-Generation Electric Vehicle Architecture2026-01-0639To be published on 04/07/2026
The transition to software-defined vehicles (SDVs) necessitates a paradigm shift in both control strategies and vehicle architecture. The EU-funded SmartCorners project addresses this challenge by developing integrated smart corner systems (SCS) that combine in-wheel motor propulsion, brake-by-wire, active suspension, and steer-by-wire functionality in a single module. These SCS are embedded within a highly adaptable skateboard chassis architecture, enabling scalable deployment across diverse vehicle platforms. The central approach of this paper is the utilization of artificial intelligence and machine learning to implement multi-layer, data-driven control strategies, facilitating real-time actuation, fault mitigation, and a user-centric vehicle architecture. The SmartCorners project targets to demonstrate significant advancements, including improvement in real-world driving range, reduction of component and system costs, and development time drop of the EV systems enabled by digital
Ratz, Florian, Armengaud, Eric, Formento, Cecilia, Moscone, Giulia, Sorrentino, Gennaro, Bisciaio, Giorgio, Sorniotti, Aldo, Amati, Nicola, Braun, Daniel, Deibler, Bernd, Boxberger, Valerius, Sottile, Salvatore, Ivanov, Valentin, Fuse, Hiroyuki, Kompara, Tomaž
Analyzing Fastened Joints in Hydraulic Dampers using Simulation and Experimental Methods2026-01-0585To be published on 04/07/2026
The main purpose of this study is to develop and validate an accurate calculation model for an unorthodox hydraulic damper piston joint, enabling reliable torque specification and clamp behavior without full prototype iteration. The joint features a bolted interface with a laminated shim stack of many thin disks with varying outer diameters. Analysis of such unorthodox joints are uncommon in literature, making the effects of load distribution truncation in the member stack due to varying outer diameters and surface contact effects between thin members during compression and torquing difficult to quantify. The model discussed in this paper is based on frustum load distribution combined with annular-plate bending and elastic-foundation effects to capture the effects of washer cupping. Concrete outputs of the calculator include member load distribution, bolt and member stiffnesses, torque-to-preload relationships, including friction factors and a variable effective-bearing-diameter, and
Dresen, Gabriel S., Vollmar, Race, Roy Chowdhury, Sourav
Data-driven Study on Chassis Suspension Performance Degradation2026-01-0582To be published on 04/07/2026
The performance of chassis suspension mechanisms critically affects vehicle handling, ride comfort, and safety. Under severe operating conditions, health monitoring of chassis suspension mechanisms can detect potential problems in time, thereby reducing safety risks and optimizing maintenance costs. With the rapid development of sensing and data analytics technologies, data-driven approaches are increasingly used in health monitoring. This study aims to achieve real-time monitoring of chassis suspension performance degradation using a deep neural network (DNN). First, a semi-vehicle suspension model is constructed to simulate the vehicle's degraded state under bumpy road conditions, generating a dataset of key suspension parameters. Subsequently, a DNN model comprising three hidden layers is developed to assess suspension performance degradation. To optimize model performance, the effects of different numbers of neurons and hidden layers on model accuracy are explored. Experimental
Liao, Yinsheng, Lei, Yisong, Su, Ailin, Wang, Zhenfeng
Optimizing Ride Comfort and Stability in In-Wheel Motor Drive Electric Vehicles: A Correlated Semi-Active Suspension System with Kalman Filter and Spring-Type Analysis10-10-04-00303/25/2026
This research provides a unique contribution to the field of in-wheel motor drive electric vehicles (EVs) by addressing the challenges associated with the use of permanent magnet synchronous motors (PMSMs) for traction. These motors, integrated into the unsprung masses, increase the rotational inertia of the wheels, reducing ride smoothness on uneven roads. To mitigate this issue, we present an optimal Kalman filter for a magnetorheological (MR) control suspension system that correlates road inputs between the front and rear wheels. This filter significantly improves the estimation accuracy of state variables by incorporating the vertical motion of the motor, along with potential enhancements from wheelbase preview. To determine the most suitable coil spring types for use with MR dampers, we used the WDW-600 computer-controlled electronic universal testing machine to evaluate three coil spring types: constant pitch (model A), variable pitch (model B), and conical spring (model C). To
Gad, Ahmed Shehata, Darakhshan Jabeen, Syeda, El-Zomor, Haytham M., Tolba, Mohamed, Elamy, Mamdouh I.
Design and Performance Analysis of a Modular Transporter Based on Reconfigurable Wheel-Legged Corner Module10-10-04-00313/25/2026
Performing transportation and exploration tasks on rugged terrain requires both high load-bearing capacity and large suspension stroke. However, the corner module configurations applied to challenging terrain have rarely been explored. This article proposes an integrated framework that combines bionic principles with topology graph–based type synthesis. This framework leads to the creation of a reconfigurable wheel-legged mechanism capable of switching between wheeled locomotion and legged gait modes, which is then implemented as a corner module system. First, inspired by the skeletal–muscular system of the equine leg, a structure–function mapping relationship between the biological system and the mechanical system is established. Second, a multi-loop closed-chain mechanism with biomimetic morphology is represented in the form of graph theory. A configuration atlas of the wheel-legged hybrid mechanism is generated based on the contracted graph and open-loop kinematic chains, and
Gao, Zhenhai, Zhang, Hanying, Chen, Guoying, Zhang, Sumin, Han, Zongzhi
Anti-Rollover Strategy for Six-Axis Semi-Trailer Based on Lateral Force Balance02-19-04-00242/24/2026
To address the rollover risk of six-axle semi-trailers due to their large mass, high center of gravity, and multi-axle articulation, a lateral force balance anti-rollover strategy based on the Ackermann steering principle is proposed. By establishing the wheel angle constraint equations for the full-wheel steering system of the six-axle semi-trailer, a rigid-body dynamic model considering the articulation characteristics is developed. The key control and observation parameters are included in the wheel angles, center of gravity lateral offset, yaw angular velocity, sideslip angle, and lateral load transfer rate. An SMC-PID joint controller is designed, in which the third axle steering angle of the tractor is optimized by the SMC controller, and the trailer’s three-axle steering angle tracking control is achieved by the PID controller. The nonlinear accumulation of centrifugal force and dynamic load transfer under high-speed emergency lane change conditions is suppressed by a
Zhang, Qiyuan, Zhang, Lei, Liao, Shengkun, Sun, Jinxu, He, Jing
Prediction of Dynamic Stiffness of Automotive Components Using Support Vector Methods2026-01-50162/23/2026
In the current scenario of EV revolution in the automotive industry, NVH performance of the vehicles is one of the major points of sale to the customers. Auxiliary components play one of the predominant roles in the contribution of noise to overall vehicle interior or exterior sound pressure levels, which impact customer vehicle comfort. CAE prediction of NVH performance of automotive components involves a lot of design iterative processes, large server space utilization, and time-consuming. To reduce cost and time, data-driven technologies like AI algorithms can help CAE engineers because of their high efficiency and high precision. In the current research, a wiper motor mount stiffness prediction algorithm was designed based on the historical data using CAE analysis and AI algorithms, and improved prediction accuracy by tuning the parameters of AI algorithms using grid search methodology. High prediction accuracy of wiper motor mount stiffness has been achieved with the method of
Paturi, Yuva Venkata Sekhar
Sensitivity Analysis toward Differential Braking as Backup Steering Functionality2026-01-50132/20/2026
This paper presents a novel sensitivity analysis framework for differential braking as a backup steering solution in fail-operational Steer-by-Wire systems. The fault-tolerant design approach of Steer-by-Wire and steering systems for highly automated driving relies on the availability of road wheel actuators (RWA). Redundancies are therefore commonly used to ensure fail-operationality. Since its widespread implementation in production vehicles through electronic stability control, the use of differential braking as a cost-effective measure is desirable to increase functional diversity. However, feasible lateral accelerations through this backup solution are limited compared to conventional steering systems and lie close to ordinary driving scenarios. To address this limitation, this work investigates the influence of chassis parameters on differential braking performance. After defining characteristic values and a simulation test plan, a preliminary analysis using a linear single-track
Salzwedel, Leon, Iatropoulos, Jannes, Heise, Cedric, Frohn, Christian, Henze, Roman
Design Evolution of a Novel LCA for a Multi-Link Rear Suspension System in a Born Electric Vehicle2026-28-00092/12/2026
The spring link or the lower control arm (LCA) is a critical structural component in a multi-link rear suspension system especially in a sports utility vehicle (SUV). The design of the rear LCA is thus challenging due to higher loads owing to higher suspension articulation typical of a SUV and further complicated in a born electric vehicle (BEV) due to increased vehicle weight contributed by a large battery. In the present work, a novel LCA was designed for the rear suspension system of one such born electric SUV application. The unique link was designed to withstand 20% higher rear axle weight compared to the conventional LCA used in a typical SUV. The LCA housed the spring with increased stiffness and a semi-active damper with varying and higher damping forces which complicated the design. The link design was further complicated with stab link mounting provision and mass damper mounting for improved NVH performance. Furthermore, the link was designed to withstand significantly higher
Selvaraj, Saravanan, Nayak, Bhargav, J, Ramkumar, M, Sudhan, Chaudhari, Varun
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-00012/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
Selvendiran, P, J, Ramkumar, Nayak, Bhargav, M, Sudhan, Patnala, Avinash
Design evolution of Novel Subframe for a Multilink Rear Suspension of an e-SUV2026-28-00072/12/2026
As there is a major shift in customer demand for energy efficient transportation, electric vehicle development has taken prominence worldwide as they provide pollution free and noise free mobility. The subframe being an important structural component of the chassis system, the designers always find it challenging to provide best-in-class rear subframe (RSF) optimized in terms of cost and weight within the available packaging space especially in an electric sport vehicular boundary. The main function of rear subframe is to transmit forces to BIW without deflections hence for this it should be very stiff. At the same time, it should be light in weight and simpler to industrialize. In the present work, the design evolution of a novel sub-frame assembly for a multilink rear suspension of a born electric sports utility vehicle (e-SUV) platform is detailed. With increased rear axle weight contributed by the battery weight and rear mounted motor, the design evolution of the rear subframe (RSF
Nidasosi, Basavraj Maruti, J, Ramkumar, Nayak, Bhargav, Mani, Arun, M, Sudhan
Dynamic Stiffness Prediction in Cracked Cantilever Beams Using Enhanced ANN Techniques2026-28-00502/12/2026
This research paper provides a comprehensive study on how Artificial Neural Networks (ANNs) can be deployed to predict the stiffness characteristics of a cantilever beam with a crack of various depths and positions. The most destructive source of failure is considered to be vibration, so the major focus of this paper will be on how the cracks affect the modal stiffness. This study has various applications, such as airplane wings, bridges, stadiums, and arenas. A common research gap was noticed amongst the existing studies; the position of the cracks in the cantilever wasn’t considered, but this paper discusses how the location of cracks severely affects the dynamic behaviour of the cantilever. This study was done by carrying out modal analysis on a cantilever of the same dimensions with different crack configurations. Various crack dimensions and orientations were analysed to understand the effects of the crack on the dynamic behaviour of the cantilever. From the modal analysis results
SB, Harshini, Rajkumar, Manjari, R, Krithika, K, Anusha, K, Divya, Bhaskara Rao, Lokavarapu
Vibration Dynamics of a Half-Car Model Considering Tire–Road Separation02-19-04-00212/9/2026
The vibrating half-car model is used to represent the dynamic behavior of a truck’s dependent suspension system, capturing four degrees of freedom. This research investigates time and frequency responses of vibration behavior of half-car model with possible tire–road separation. This investigation is significant because all previously reported analyses based on the tire-road attachment were incorrect, particularly regarding the tire-road separation phenomenon. The differential equations are extended to enhance the accuracy of the model, incorporating tire–road separation conditions for both wheels. A numerical approach is applied to simulate the vertical and roll dynamics of the system under the separation assumption. The simulation results are validated through experiments conducted using ADAMS View software. Integrating the tire–road separation into the model results in dynamic responses that closely reflect real-world behavior. These findings provide valuable guidance for designing
Nguyen, Quy Dang, Jazar, Reza
PRODUCT BRIEFS26AUTP02_172/1/2026
SBD-YOLO: An Efficient Speed Bump Detector for Active Suspension Preview Control12-09-03-00181/28/2026
Speed bump detection through computer vision and deep learning is essential for advancing active suspension preview control and intelligent driving. Although substantial progress has been made in this field, there remains a need to enhance detection accuracy while reducing computational demands. This article introduces a novel single-stage speed bump detector, the Speed Bump Detector Based on You Only Look Once (SBD-YOLO), which utilizes the YOLOv9 architecture for speed bump identification. To better capture the deep global features of speed bumps, we propose an innovative convolutional module—specifically, a lightweight building block designed for efficient feature extraction—named the Aggregated-MBConv. Furthermore, we design a new YOLO backbone by stacking Mobile Inverted Bottleneck Convolution (MBConv) and Aggregated-MBConv modules, which reduces computational cost while enhancing detection accuracy. Additionally, we introduce a Squeeze-aggregated Excitation (SaE) attention
Mao, Ruichi, Wu, Jian, Wu, Yukai, Wang, Huiliang, Li, Jun, Wu, Guangqiang
Evaluation of Driveline NVH Performance Using Linear Dynamic Finite Element Simulation2026-26-03221/16/2026
Automotive driveline design plays an important role in defining a vehicle’s Noise, Vibration and Harshness (NVH) characteristics. Driveline system, responsible for torque transfer from the engine/transmission to the wheels, is exposed to a wide spectrum of vibrational excitations. The industry’s shift toward turbocharged engines with fewer cylinders while maintaining the equivalent torque and power has led to increased low-frequency torsional vibrations. This paper presents some key design considerations to drive the NVH design of a driveline system using linear dynamic FE simulations. Using an E-W All-Wheel Drive driveline architecture with independent suspension as a case study, the influence of various subsystem modes on driveline NVH performance is examined. The paper further explores the strategies for vibration isolation, motion control, and mode management to identify the optimal bushing rates and its location. Furthermore, it examines the ideal bushing specifications for
Joshi, Atul Kamalakarrao, Subramanian, MANOJ
Comprehensive Evaluation of Bolster Behaviour: Field Data Insights for Design Modifications2026-26-04971/16/2026
Bogie suspension systems are becoming increasingly popular in tipper vehicles to enhance their performance and durability, especially in demanding environments like construction and mining areas [1]. Bolsters contribute significantly to the overall performance and durability of the bogie suspension systems of tipper vehicles by evenly distributing the loads across the whole suspension system. They act as shock absorbers and negate the impact caused by the rough terrains and heavy loads, thereby reducing stress on individual components and maintaining the structural integrity of the vehicle. Bolsters also help in improving the ride comfort and to maintain the position of the suspension system [2]. This study focuses on the comprehensive testing and evaluation of bolsters to understand their modes and displacement data derived from field data. The primary objective is to analyse the performance and behaviour of bolsters under various operational conditions. Critical manners of
V Dhage, Yogesh, Kolage, Vikas
Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System2026-26-04871/16/2026
In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints
Patale Jr, Reshma, Pinjari, Jayant Namdev, Bali, Shirish
Optimizing Suspension Joint Reliability: Overcoming Bolt Loosening and Torque Variability in Automotive Production2026-26-04921/16/2026
In modern automotive manufacturing, ensuring the integrity of suspension joints under real-world driving conditions is a critical aspect of vehicle safety and performance. These joints endure substantial transverse loads and large vibrations due to irregular road surfaces, dynamic maneuvers, and varying environmental factors. As a result, bolt loosening becomes a significant concern, compromising joint integrity and overall vehicle reliability. This paper delves into the challenges associated with maintaining joint integrity, specifically focusing on pre-load determination, torque application, and production-related issues. The pre-load generated during torquing is the primary factor that ensures a suspension joint remains securely fastened under dynamic road conditions. This pre-load is derived using road load data acquisition (RLDA) inputs, which capture the forces acting on the joint during actual driving scenarios. RLDA inputs provide critical insights into the forces experienced
Kumar, Sabeesh, Vasant Kumar, Jesse Daniel, Mishra, Harshit, Senthil Raja, T, Nayak, Bhargav, M, Sudhan, Namani, Prasad, Vibhute, Shekhar
Boosting the Development of a BEV Rear Twist Beam Suspension Through a Pioneering Approach: ADAMS Real Time on Driving Simulator2026-26-03971/16/2026
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 Applus+ IDIADA & Mahindra, quick identification and optimisation of key tuneable items is achieved by employing a hybrid solution that combines full flexible and FE elements in Hexagon
Osorio, Alejandro García, Prabhakara Rao, Vageesh, Asthana, Shivam, Rasal, Shraddhesh
Fatigue Life Prediction Methodology for Vehicle Suspension Systems and Correlation with Physical Test2026-26-04591/16/2026
Fatigue analysis is a vital aspect of suspension design, especially for load bearing components such as the Rear Twist Beam, where durability under cyclic loading is essential for long-term vehicle performance. Among the various durability tests, the roll fatigue test is a key procedure for validating suspension strength and reliability. However, conducting physical roll fatigue tests can be both expensive and time consuming, particularly when multiple design iterations are required. This not only increases cost but also extends the development timeline. This study presents a virtual simulation methodology that replicates roll fatigue test conditions within a finite element analysis environment, enabling early fatigue assessment and design optimization. Developed to support the early design phase, the roll fatigue test simulation process ensures robust designs that meet targeted fatigue life requirements. The approach begins with a detailed understanding of the physical roll fatigue
Kokare, Sanjay, Nagapurkar, Tejas, Iqbal, Shoaib
Refinement of Road Induced Steering Wheel Vibration in Electric Vehicle2026-26-03371/16/2026
Nowadays, customers expect excellent cabin insulation and superior ride comfort in electric vehicles. OEMs focus on fine tuning the suspension system in electric vehicle to isolate the road induced shocks which finally offers superior ride quality. This paper focuses on enhancing the ride comfort by reducing the road excitation which originates mainly due to road inputs. Higher steering wheel vibration is perceived on the test vehicle on rough road surfaces. To determine the predominant force transfer path, Multi reference Transfer Path Analysis (MTPA) is performed on the front and rear suspension. Based on the finding from MTPA, various recommendations are explored and the effect of each modification is discussed. Apart from this, Operational Deflection Shape (ODS) analysis is used to determine the deflection shape on the entire steering system . Based on ODS findings, recommendations like dynamic stiffness improvements on the steering column and steering wheel are explored and the
S, Nataraja Moorthy, Rao, Manchi, Selvam, Ebinezer, Raghavendran, Prasath
Influence of Bushing Stiffness Measurement Methodology on Axle Elasto-Kinematics2026-26-00941/16/2026
The handling of a vehicle is crucial to the perception of its dynamic characteristics, such as comfort, stability, composure, sportiness, and precision. Kinematics and Elasto-kinematics, also known as Kinematics and Compliance (K&C), form the basis of an automobile's handling characteristics. Kinematics focuses on the movement of suspension components, including wheels, axles, and linkages, and how these movements relate to the vehicle's body motion. Compliance refers to the suspension's ability to deform under load, primarily due to the flexibility of springs, bushings, and other elastic components. Elastomer bushings, as flexible elements in the kinematic chain, significantly impact K&C and require a detailed study. Suspension bush stiffness is typically measured through static and dynamic tests, in various directions – radial, axial, torsional, etc. Tests involve applying a force or torque and measuring the resulting deflection and/or rotation. These measurements are used to
Avhad, Anish
Experimental Evaluation of Tyre Vertical Dynamic Stiffness and Damping for Ride Model Applications Using Flat Trac2026-26-06071/16/2026
The vertical dynamic stiffness and damping of a tyre are critical to ride comfort and overall dynamics, particularly for low-frequency excitations in urban and highway driving. As the tyres are the primary interface between the vehicle and the road, absorbing surface irregularities before the suspension engagement, precise tyre parametrization is essential for accurate ride models. This study investigates an experimental methodology characterizing the vertical dynamic behavior of pneumatic tyres using a Flat Trac test machine. Contrary to the conventional approaches that depend on intricate shaker rigs or frequency dependence function models, the proposed technique uses a realistic force displacement loop-based methodology which is appropriate for ride models. Dynamic stiffness is computed from slope of a linear regression fitted to force and displacements during vertical sinusoidal excitation. Damping is derived from hysteresis energy loss per cycle. The tests were conducted under
Duryodhana, Dasari, Sethumadhavan, Arjun, Tomer, Avinash, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Novel Approach on Material Characterization Testing of Various Wiring Harness2026-26-05481/16/2026
The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material property has a crucial role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs during product development. This study explains the novel method of Testing the Cables and Bundles
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, Shah, Dipam, Tas, Onur, Krogmann, Stephan
Artificial Intelligence in Passenger Cars: Unlocking Intelligent Mobility and Human-Centric Vehicle Innovation2026-26-06721/16/2026
Artificial Intelligence (AI) is radically transforming the automotive industry, particularly in the domain of passenger vehicles where personalization, safety, diagnostics, and efficiency. This paper presents an exploration of AI/ML applications through quadrant of the key pillars: Customer Experience (CX), Vehicle Diagnostics, Lifecycle Management, and Connected Technologies. Through detailed use cases, including AI-powered active suspension systems, intelligent fault code prioritization, and eco-routing strategies, we demonstrate how AI models such as machine learning, deep learning, and computer vision are reshaping both the user experience and engineering workflow of modern electric vehicles (EVs). This paper combines simulations, pseudo-algorithms and data-centric examples of the combined depth of functionality and deployment readiness of these technologies. In addition to technical effectiveness, the paper also discusses the challenges at field level in adopting AI at scale i.e
Hazra, Sandip, Tangadpalliwar, Sonali, Khan, Arkadip
Novel Approach for Predicting Steering Rack Load Using Multi-Body Simulation2026-26-03781/16/2026
In the initial stages of a vehicle development program, the sizing of various components is a critical deliverable. The steering system, in particular, requires a precise estimation of the rack load for the appropriate sizing of the rack and assists units. Accurately predicting the load on the system during the early stages of development is challenging, especially in the absence of benchmark or legacy data. Commonly used processes for estimating parking steering effort often employ simplistic approaches that may fail to account for parameters such as tire size, vertical stiffness, and steering geometry, leading to reduced accuracy. This paper introduces an advanced methodology for predicting steering rack loads, which incorporates considerations such as contact patch size and pressure variation, as well as the tire jacking effect. The methodology involves mathematical modeling of the contact patch using mesh-grids, utilizing common inputs available in the early stages of vehicle
Shirke, Umesh, Dabholkar, Aniruddh, Bardia, Vivek, Srivastava, Harshit, Prasad, Tej Pratap
Design & Optimization of CV Shaft System to Address Powertrain Induced NVH Issues2026-26-03361/16/2026
The automotive industry is a crucial sector that plays a significant role globally. Government policies have a profound impact on this automotive industry in defining the regulatory standards and emission controls. Such regulations incentivized automakers to invest in research and development complying those standards towards reduction of vehicle emission which intern result in higher torsional vibrations and excitations amplitudes. To address the rising NVH related concerns in driveline system. Drive shafts (CV shafts) is an important component in power-train system in vehicle. Drive shaft’s main purpose to transfer torque from engines to wheels at multiple speeds with different articulation angles. The roughness generated by the engine follows a transfer path from engine to transaxle and transaxle to half shafts in monocoque vehicles which generates discomfort to the drivers whenever the vehicle is driven. The roughness can also be addressed by proper design of CV Shaft stiffness and
M A, Abdul Azarrudin, Jayachandran, Suresh kumar, Kumar, Shivani, Bhardwaj, Kinshuk, M, Devamanalan, Kanagaraj, Pothiraj, Ahire, Manoj
Design Optimization of Jounce Bumper Support Ring Based on RWUP Loading2026-26-05141/16/2026
Designing and manufacturing a support ring (POM ring -Polyoxymethylene ring) for a MacPherson strut suspension system brings unique set of challenges due to the high-performance and durability demands for Indian road application. Support ring along with the jounce bumper used in the shock absorber is designed to absorb the strong shock coming from the road inputs when suspension travel reached to the maximum limit. thereby absorbing the impact energy and preventing it from transferring it to the body. A bump stopper for a suspension of a vehicle is made of poly urethane (PU) material and is surrounded by a support ring or POM ring made up of Polyoxymethylene material. The bump stopper deflects into bellow shape during the absorption of impact energy. In the present paper, the authors have demonstrated the key challenges experienced in successfully designing the support ring post initial failure experienced in the validation phase which was unprecedented. The authors detail the failure
Koritala, Ashok Kumar, Malekar, Amit, Kulkarni, Purushottam, S, Sivashankar, Mishra, Harshit, Ganesh, Mohan Selvakumar, Patnala, Avinash, J, Ramkumar, Nayak, Bhargav, M, Sudhan
New Generation Natural Rubber-Based Bump Stopper with Improved NVH Characteristics2026-26-02921/16/2026
In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria. Traditionally, Natural rubber (NR) has traditionally been favored for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. This study revisits NR with the goal of re-establishing its viability by enhancing its performance to match or surpass that of PU. Through compound optimization and advanced material processing techniques, significant improvements have been achieved in NR’s mechanical strength, compression set
Murugesan, Annarajan, Hingalaje, Abhijeet, Perumal, Mathavan, Pawar, Rohit
A Robustness Approach to Reducing Variability in Suspension System Performance2026-26-03811/16/2026
Determination of part tolerances for reduced variation in suspension level performance by using Multi-objective Robust Design Optimization (MORDO) The car industry is very competitive, and companies need to satisfy their customers to keep or grow their market share. It’s important for car makers to build affordable cars that provide a good driving experience, comfort for passengers, and safety for everyone. Suspension systems are very important for how a vehicle rides, handles, and stays stable, and they directly affect how driving feels. If parts are not positioned correctly, it can really impact how well a vehicle works. As a result, suggested limits for where suspension parts are placed are given to prevent issues with Kinematics and Compliance (K&C) properties. So, designing parts with the right tolerances is very important in making vehicles. It helps lower production costs and keeps the vehicle's performance consistent. This paper shows a step-by-step method to find the strongest
Pathak, Jugal, Ganesh, Lingadalu
Sound Quality Refinement and Vibration Reduction During Horn Application in Electric Vehicles2026-26-03381/16/2026
This paper focuses on the cabin sound quality refinement and the tactile vibration reduction during horn application in the electric vehicle. A loud cracking sound inside the cabin and higher accelerator pedal vibration are perceived while operating the horn. Sound diagnosis is carried out to find out the frequencies causing the cracking noise. Transfer path analysis is conducted to identify the nature of noise and the predominant path through which forces transfer. Based on finding from TPA, various recommendations are evaluated which reduced the noise to a certain extent. Operational Deflection Shape (ODS) is conducted on the horn mounting bracket and on the body to identify the component having higher deflection at the identified frequencies. Recommendations like DPDS improvement on the horn bracket and the body is assessed and the effect of each outcome is discussed. With all the recommendations proposed, the cabin noise levels are reduced by ~ 8 dB (A) and the accelerator pedal
S, Nataraja Moorthy, Rao, Manchi, R, Ashwin sathya, S, THARAKESWARULU, Raghavendran, Prasath
Investigation and Reduction of Road Noise due to Transient Road Inputs in Electric Vehicle2026-26-03581/16/2026
Higher road noise is perceived in the cabin when the test vehicle encounters road irregularities like bump or pothole in the public roads. The transfer of transient road inputs inside the body caused objectionable cabin noise. Measurements are conducted at different road surfaces to identify the patch where the objective data well correlated with the noise measured at the public road. Wavelet analysis is carried out to identify the frequency zones since the events are transient in nature. TPA is carried out in time domain to identify the nature of the noise and the dominant path through which the transient road forces are transferring inside the body. Based on the outcome of TPA, various countermeasures like reduction of dynamic stiffness of suspension bushes, TMDs on the path are proposed to reduce the structure borne noise. Criteria which need to be considered for reduction of cabin noise due to transient road inputs is also discussed.
S, Nataraja Moorthy, Rao, Manchi, Selvam, Ebinezer, Raghavendran, Prasath
Systematic Study to Understand and Resolve Brake Pull in Commercial Vehicles Using Simulation and Proving Ground Tests2026-26-00831/16/2026
In traditional commercial vehicles with leaf spring suspension and Recirculating Ball Joint (RCBT) steering systems often experience undesirable pulling due to unsymmetrical steering mechanism during braking, especially when the suspension and steering hardpoints are not properly tuned. This work analyzes the mechanisms responsible for pulling tendencies, primarily addressing brake steer and bump steer, which occur due to misalignments in the suspension and steering geometries. Brake steer occurs when braking forces create an imbalance in torque, resulting in the vehicle deviating to one side. On the other hand, bump steer refers to the unwanted changes in the wheel alignment when the suspension undergoes travel, leading to instability or unintended steering input. These two phenomena, if not controlled, can result in undesirable vehicle handling, especially under heavy braking conditions. This work focuses on evaluating these mechanisms and suggests strategies for minimizing their
Pandhare, Vinay Ramakant, M, Anantha Padmnabhan, Nizampatnam, Balaramakrishna, Londhe, Abhijit, Doundkar, Vikas
Analysis of Door Seal Compression and its Influence on NVH Performance in Heavy-Duty Vehicle2026-26-03391/16/2026
This study focuses on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Customer perception of vibrations are envisaged as quality criteria. It is necessary to determine the contribution of seal stiffness due to seal compression under closed condition of the door rather than considering stiffness of the door seal under uncompressed conditions. The dynamic stiffness of door seal is determined from analysis of non-linear type. The simulations are built using the Mooney - Rivlin model. The parameters influencing the compression of door seals in both two – dimension and three – dimension, are identified from the analysis. This involves contemplating the appropriate seal mounted boundary condition on the body and the door of the vehicle. The stiffness after compression of seal is extracted from this non-linear analysis which is further used to obtain the vibration modes for the doors in the truck cabin. As a part of next step, the compressed
L, Kavya, Ramanathan, Vijay
Experimental Evaluation of High Energy Impact Test of Wheel Rim2026-26-05041/16/2026
High energy impact testing using free fall mass is a crucial method for evaluating the structural integrity, and safety performance of automotive components subjected to sudden impact forces. This study focuses on assessing critical parts such as wheel rims, suspension knuckles, commonly exposed to unintentional impacts during vehicle operation, maintenance, or collisions. The test involves dropping a standardized mass from predetermined heights onto the component to simulate real-world impact scenarios. Key performance indicators include deformation, crack propagation, fracture resistance, and energy absorption capacity. Wheel rims and knuckles are evaluated for their ability to maintain structural integrity under localized impact without compromising vehicle handling or safety. Seats and related interior structures are tested to ensure occupant protection during crash-like events. Other components, such as brackets, mounts, or housings, are included based on functional criticality
Roham, Prasad, Bagade, Mohan, Sinnarkar, Nitin, Pawar, Prashant R, Shinde, Vikram
Simulation-Driven Load Spectrum Prediction: Virtual RLDA for Chassis and Suspension System2026-26-00951/16/2026
In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing. This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high
Goli, Naga Aswani Kumar, Prasad, Tej Pratap
Methodology for Optimizing the Bench Testing of Steering I-Shaft Using Vehicle Level Data to Reduce Overall Product Development Time and Cost2026-26-05601/16/2026
Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame (BOF) vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW (Body in white) of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development of I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at
Kabdal, Amit
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