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    10 Vijay Kumar PDF

    Uploaded by

    Karthi Keyan
    This document describes the suspension system for a semi-low floor bus developed by Ashok Leyland. The front uses a rubber-ended leaf spring suspension while the rear uses an air suspension system. The rear suspension includes air springs, shock absorbers, anti-roll bars, and radius rods to manage vertical, braking and cornering loads. Rig testing of the rear air suspension subjected it to various vertical, braking and cornering load cycles to validate the design. The semi-low floor bus suspension concept pioneered by Ashok Leyland uses a combination of leaf springs in front and air suspension in rear for a cost-effective solution.

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    © All Rights Reserved
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    10 Vijay Kumar PDF

    Uploaded by

    Karthi Keyan
    142 views19 pages
    This document describes the suspension system for a semi-low floor bus developed by Ashok Leyland. The front uses a rubber-ended leaf spring suspension while the rear uses an air suspension system. The rear suspension includes air springs, shock absorbers, anti-roll bars, and radius rods to manage vertical, braking and cornering loads. Rig testing of the rear air suspension subjected it to various vertical, braking and cornering load cycles to validate the design. The semi-low floor bus suspension concept pioneered by Ashok Leyland uses a combination of leaf springs in front and air suspension in rear for a cost-effective solution.

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    This document describes the suspension system for a semi-low floor bus developed by Ashok Leyland. The front uses a rubber-ended leaf spring suspension while the rear uses an air suspension system. The rear suspension includes air springs, shock absorbers, anti-roll bars, and radius rods to manage vertical, braking and cornering loads. Rig testing of the rear air suspension subjected it to various vertical, braking and cornering load cycles to validate the design. The semi-low floor bus suspension concept pioneered by Ashok Leyland uses a combination of leaf springs in front and air suspension in rear for a cost-effective solution.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    142 views19 pages

    10 Vijay Kumar PDF

    Uploaded by

    Karthi Keyan
    This document describes the suspension system for a semi-low floor bus developed by Ashok Leyland. The front uses a rubber-ended leaf spring suspension while the rear uses an air suspension system. The rear suspension includes air springs, shock absorbers, anti-roll bars, and radius rods to manage vertical, braking and cornering loads. Rig testing of the rear air suspension subjected it to various vertical, braking and cornering load cycles to validate the design. The semi-low floor bus suspension concept pioneered by Ashok Leyland uses a combination of leaf springs in front and air suspension in rear for a cost-effective solution.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 19

    Suspension System for Semi Low Floor Bus

    V. VijayKumar
    Manager- Product Development

    Page1 of 19

    CITY BUS
    Semi Low Floor - Entry + Two Steps
    Cost effective unique solution pioneered by Ashok Leyland
    860mm
    Floor
    Height

    Page2 of 19

    Frame Assembly

    Notch (78mm) is given in


    frame at Front axle region
    for Ride clearance

    Hump (120mm) is given in


    frame at Rear axle region
    for Ride clearance

    Page3 of 19

    Front & Rear Suspension

    Front - Rubber ended spring suspension


    Rear- Air Suspension ( Cowhorn type Suspension)

    Front Suspension

    Rear Suspension

    Page4 of 19

    Suspension Characteristics

    Suspension Characteristics
    Sl.No

    Description

    FAW-Kg

    5460

    RAW-Kg

    10200

    Front Leaf Spring Stiffness-Kg/mm

    Rear Air Spring Stiffness-Kg/mm

    Front Suspension Natural Frequency - Hz

    1.7

    Rear Suspension Natural Frequency - Hz

    1.3

    Front Suspension (Leaf Spring) Roll Stiffness-Nm/deg

    10

    Rear Air spring Roll Stiffness-Nm/deg

    7415.6

    11

    Rear ARB Roll Stiffness-Nm/deg

    5554.7

    12

    Rear Suspension Roll Stiffness-Nm/deg

    34.7
    15.42

    1960

    12970.3

    Page5 of 19

    Front Suspension
    Shock absorber
    Dampens Suspension travel

    Rubber ended spring


    1.Takes Vertical load and offers Stiffness
    2.Takes driving, braking and cornering load
    Advantages
    Leaf spring ends are connected to Frame
    brackets through Rubber pads. Rubber
    pads absorb vibrations.
    Weweller Spring helps the Axle to travel
    in Straight line path during Suspension
    travel articulation, which improves tyre life.

    Page6 of 19

    Front Spring
    Load Vs Deflection
    4500
    4000
    3500

    Load- Kg

    3000
    2500
    2000
    1500
    1000
    500
    0
    0

    20

    40

    60

    80

    100

    Deflection-mm

    Rated Load- 2400 kg


    Stiffness- 34.7 Kg/mm
    Stress @ Rated load- 50 Kg/mm2

    Page7 of 19

    120

    Rear Air suspension


    Bushes- to
    control low
    amplitude high
    frequency
    vibrations

    Air spring- to

    Radius rod
    (Top link)- to
    take driving,
    braking &
    Cornering forces

    Shock
    absorbers- to
    damp
    Suspension
    travel

    offer Variable
    stiffness for
    constant Natural
    frequency

    Radius rod
    (Bottom link)to take driving &
    braking force.

    Levelling
    valve- to
    maintain
    constant Chassis
    height

    Anti roll bar- to


    offer Suspension
    Roll Stiffness

    Page8 of 19

    Rear Air suspension

    840 mm

    Frame is modified at Rear axle to have Ride clearance. Hump(124mm) is


    given in Frame.
    Vehicle Frame height from Ground- 840 mm

    Page9 of 19

    Rear Air suspension Kinematics Analysis

    Kinematic analysis is done for the following conditions to


    arrive forces at Suspension Frame Reaction points.
    Vertical- 3g
    Braking- 0.8g
    Cornering- 0.6g

    Page10 of 19

    Vertical loading
    6750 Kg (3g)

    6750 Kg (3g)

    6750 Kg (3g)

    6750 Kg (3g)

    Page11 of 19

    Braking loading

    3727 Kg (0.8g)

    7485 Kg (0.8g)

    3727 Kg (0.8g)

    7485 Kg (0.8g)

    Top & bottom link will take


    Brake force.
    Top link will be in compression
    and bottom link will be in tension
    during Braking.

    Page12 of 19

    Cornering loading

    7524 Kg (0.6g)

    7524 Kg (0.6g)

    Cornering load acting on Top


    links. One link will be Tension and
    other link will be compression..

    Page13 of 19

    Rear Spring Variable Stiffness graph

    Air Spring Data


    6000

    5000

    Load in Kg

    4000

    3000

    2000

    1000

    0
    +70

    +60

    +40

    +20

    Static
    height

    -20

    -40

    -60

    -70

    Series1 1521.9164 1633.0275 1800.2039 2009.1743 2246.6871 2624.8726 3119.2661 3778.7971 5369.0112
    Displacement in mm

    Page14 of 19

    Rear Air suspension Brackets FEA


    Cowhorn- Stress Analysis

    Radius Rod Frame bracketStress Analysis

    Page15 of 19

    Rear Air suspension Axle Bracket Analysis

    Page16 of 19

    Rear Air suspension Rig testing

    Air Suspension System Rig testing is done for the following


    conditions:
    Case-1: 0.5g-2g Vertical load for 1 Lac Cycles
    Case-2: 1g Vertical & 0.8g (+/-) Braking for 1 Lac Cycles
    Case-3: 1g Vertical & 0.6g (+/-) Cornering for 1 Lac Cycles
    Page17 of 19

    Rear Air suspension Rig testing

    Page18 of 19

    Summary
    Front engine SLF is the Cost effective solution offered by
    Ahokleylend for City bus application.
    Rubber ended Leaf spring suspension at Front and Air suspension at
    Rear is new concept driven by Ashokleyland.

    Thank you

    Page19of 19

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